Hidden lamp manufacture process

• US 8,475,017 B2
• Filed: 10/12/2009
• Issued: 07/02/2013
• Est. Priority Date: 02/22/2009
• Status: Expired due to Fees

• Current Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Original Assignee: Ford Global Technologies, LLC (Ford Motor Company)
• Inventors: Salter, Stuart C., Li, Chi, Igoe, Denis Patrick, Singer, Jeffrey, Gardner, Cornel Lewis
• Primary Examiner(s): Lee, Y My Quach
• Application Number:
  US12/577,294
• Publication Number:
  US 20100212819A1
• Time in Patent Office: 1,359 Days
• Field of Search: 362/147, 362/364, 362/365, 362/471, 362/488, 362/489, 362/490, 362/493, 294/262, 298/972, 156/221
• US Class Current: 362/490
• CPC Class Codes: B60Q 3/54 Lighting devices embedded in interior trim, e.g. in roof liners
• CPC Class Codes: B60Q 3/74 for overall compartment lighting; for overall compartment lighting in combination with specific lighting, e.g. room lamps with reading lamps general lighting mounted on specific fittings B60Q3/20; general lighting for mass transit vehicles B60Q3/43
• CPC Class Codes: B60Q 3/82 Switches specially adapted for vehicle interior lighting, e.g. switching by tilting the lens
• CPC Class Codes: B60R 13/02 Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners B60R13/01 takes precedence ; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18
• CPC Class Codes: B60R 13/0212 Roof or head liners movable head-liners B60J7/0007
• CPC Class Codes: B60R 13/0243 Doors
• CPC Class Codes: B60R 2013/0287 integrating other functions or accessories
• CPC Class Codes: Y10T 156/1043 Subsequent to assembly
• CPC Class Codes: Y10T 29/49622 Vehicular structural member making
• CPC Class Codes: Y10T 29/49817 with other than ancillary treating or assembling

Abstract

A method for making a vehicle interior panel including positioning a slipsheet on a film or fabric liner. The liner is placed on a substrate board. The liner and substrate board are formed into an interior panel. A cavity is formed by removing a portion of the substrate board from the interior panel adjacent to the slipsheet position. A lamp is positioned in the cavity.

Claims

1. A method for making a vehicle interior panel comprising:

positioning a slipsheet on a liner;

placing the liner on a substrate board;

forming the liner and substrate board into an interior panel;

forming a cavity by removing a portion of the substrate board from the interior panel adjacent to the slipsheet position; and

positioning a lamp in the cavity.

2. The method of claim 1, further comprising:

adhering the lamp onto the interior panel.

3. The method of claim 1, wherein the step of forming the liner further comprises:

heating the liner and substrate board and molding the substrate board to form the vehicle interior panel.

4. The method of claim 1, wherein the step of positioning a slipsheet further comprises:

positioning a mylar slipsheet on the liner.

5. The method of claim 1, further comprising:

removing excess liner material and substrate material on an outer edge of the interior panel.

6. The method of claim 1, wherein the step of forming a cavity further comprises:

using a water jet to cut away substrate material.

7. The method of claim 1, further comprising:

positioning a proximity sensor adjacent to the cavity.

8. A method for making a vehicle interior panel comprising:

forming an interior panel with a liner, a substrate, and a removable slipsheet disposed therebetween;

removing a portion of the substrate adjacent to the slipsheet to form a cavity;

positioning a lamp in the cavity; and

displaying a visual indicator on an interior side of the interior panel that denotes the position of the lamp behind the liner.

9. The method of claim 8, further comprising:

positioning a proximity sensor adjacent to the cavity.

10. The method of claim 9, wherein the step of positioning a lamp in the cavity further comprises:

installing a light source in the cavity that emits light through the liner.

11. The method of claim 10, wherein the step of positioning a lamp in the cavity further comprises:

installing at least one light emitting diode in the lamp.

12. The method of claim 11, wherein the step of positioning a lamp in the cavity further comprises:

installing a light diffuser between the liner and the lamp.

13. The method of claim 8, further comprising:

operably connecting a lens on the lamp that is visible through the liner.

14. The method of claim 8, further comprising:

printing indicia on the liner below the lamp.

15. A method of positioning a vehicle lamp comprising:

forming an interior panel from a liner and a substrate board;

forming a cavity in the interior panel by removing a portion of the substrate board from the liner;

positioning a lamp in the cavity; and

displaying a visual indicator on an interior side of the interior panel that denotes the position of the lamp behind the liner.

16. The method of claim 15, wherein the step of positioning a lamp in the cavity further comprises:

installing a light source in the cavity that emits light through the liner.

17. The method of claim 16, wherein the step of installing a light source further comprises:

installing a light emitting diode in the cavity that emits light visible on the interior side of the interior panel.

18. The method of claim 15, further comprising:

operably connecting a lens on the lamp that is visible through the liner.

19. The method of claim 15, further comprising:

printing indicia on the liner below the lamp.

20. The method of claim 15, wherein the step of forming an interior panel from a liner and a substrate board further comprises:

forming the liner to include a first textured material adjacent to the substrate board and a second textured material adjacent to the cavity.