Method of producing a vehicle interior lining and vehicle interior lining

• US 6,977,019 B2
• Filed: 08/19/2003
• Issued: 12/20/2005
• Est. Priority Date: 08/19/2002
• Status: Expired due to Fees

• Current Assignee: Arvinmeritor Light Vehicle Systems FRA (Meritor, Inc. (Nevada))
• Original Assignee: Arvinmeritor Light Vehicle Systems FRA (Meritor, Inc. (Nevada))
• Inventors: Schonebeck, Horst
• Primary Examiner(s): YAO, SAMCHUAN CUA
• Application Number:
  US10/643,782
• Publication Number:
  US 20040076814A1
• Time in Patent Office: 854 Days
• Field of Search: 156/78, 156/79
• US Class Current: 156/79
• CPC Class Codes: B29C 44/145 the lining being a laminate
• CPC Class Codes: B32B 2375/00 Polyureas; Polyurethanes
• CPC Class Codes: B32B 2605/00 Vehicles
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: B32B 5/245 another layer next to it being a foam layer
• CPC Class Codes: B32B 5/32 at least two layers being foamed and next to each other
• CPC Class Codes: Y10T 428/249981 Plural void-containing components

Abstract

A vehicle interior lining having good sound absorbing properties and that is permeable to air is formed from an intermediate product comprising an inside decorative layer and a barrier layer made of open-cell foam. The barrier layer adjoins the rear side of the decorative layer. A foam backing is disposed on the rear side of the intermediate product is provided with a foam backing. The barrier layer prevents the foam backing material from penetrating through toward the decorative layer, eliminating the need for a barrier film and improving sound absorption. The interior lining can be used as a roof lining.

Claims

1. A method of producing a vehicle interior lining comprising:

forming an intermediate product having a decorative layer and an open-cell foam barrier layer, the open-cell foam barrier layer adjoining a rear side of the decorative layer; and

providing a foam backing to a rear side of the intermediate product by a back foaming process that includes applying a liquid plastic to the open-cell foam barrier layer, wherein the open-cell foam barrier layer blocks the liquid plastic to prevent the liquid plastic from penetrating the open-cell foam barrier layer toward the decorative layer wherein the vehicle interior lining is permeable to air.

2. The method according to claim 1, wherein forming the intermediate product comprises gluing the open-cell foam barrier layer and the decorative layer to each other.

3. The method according to claim 1, wherein forming the intermediate product comprises laminating the open-cell foam barrier and the decorative layer together.

4. The method according to claim 1, wherein a fiber mat is applied to a rear side of the foam backing produced during the back foaming process.

5. The method according to claim 1, wherein a fiber mat is embedded in the liquid plastic during the back foaming process.

6. The method according to claim 1, wherein the liquid plastic is directly applied to the open-cell foam barrier layer and comes into contact with the open-cell foam barrier layer during the back foaming process.

7. The method according to claim 1, further comprising introducing fibers into the liquid plastic during the back foaming process, wherein the fibers are distributed in the foam backing formed by the back foaming process.

8. The method according to claim 7, wherein the fibers are glass fibers introduced into the liquid plastic via a Long Fiber Injection process.

9. The method according to claim 1, further comprising embedding at least one of a fastener and a spacer in the liquid plastic during the back foaming process.

10. The method according to claim 1, wherein the liquid plastic is polyurethane.

11. The method according to claim 1, wherein the decorative layer is one selected from a group consisting of a textile material, a leather material, and an imitation leather material.

12. The method according to claim 1, wherein the open-cell foam barrier layer is permeable to air.

13. The method according to claim 1 wherein the open-cell foam barrier layer comprises a soft layer such that the intermediate product of the decorative layer and open-cell foam barrier layer cooperate to provide the vehicle interior lining with a soft touch exterior surface.

14. A method of producing a vehicle interior lining comprising:

joining a decorative layer and a barrier layer together to form an intermediate product wherein the decorative layer comprises an air-permeable material and the barrier layer comprises an open-cell foam that is air-permeable;

back foaming a foam layer onto one side of the intermediate product by applying a liquid plastic to the barrier layer;

blocking the liquid plastic with the barrier layer to prevent the liquid plastic from penetrating the barrier layer and contacting the decorative; and

wherein the barrier layer of the open-cell foam comprises a soft layer such that the intermediate product of the decorative layer and barrier layer cooperate to provide the vehicle interior lining with a soft touch exterior surface with the vehicle interior lining being permeable to air.

15. The method according to claim 14 including positioning the barrier layer intermediate the decorative layer and the foam layer such that the barrier layer directly contacts both the decorative layer and the foam layer.

16. The method according to claim 14 including attaching a fiber mat directly to the foam layer.

17. The method according to claim 16 including embedding a spacer within the foam layer to maintain a predetermined distance between the fiber mat and the barrier layer during back foaming.

18. The method according to claim 14 including injecting a plurality of fibers into the foam layer during back foaming and blocking the plurality of fibers with the barrier layer to prevent the plurality of fibers from penetrating the decorative layer.

19. The method according to claim 14 wherein the decorative layer forms a vehicle interior surface with the barrier layer being positioned between the vehicle interior surface and a vehicle roof component.