Method and apparatus for nonwoven trim panels

Patent metadata

Field	Value
Publication number	US-2021237323-A1
Application number	US-202117239865-A
Country	US
Kind code	A1
Filing date	Apr 26, 2021
Priority date	Sep 23, 2015
Publication date	Aug 5, 2021
Grant date	—

Abstract

A method of forming a trim panel is provided. The method including the steps of: placing a non-woven mat of material in a heating press; heating the material to a predetermined temperature; applying a decorative film to a first surface of the heated material to create a bilaminate; placing the bilaminate layer into a cavity of a tool such that the decorative film is facing the cavity; heating the cavity; and injecting a thermoplastic resin into the tool such that the thermoplastic resin is adhered to a second surface of the material, the second surface being opposite to the first surface. Also disclosed is the trip panel formed by the foregoing method.

First claim

What is claimed is:

1 . An automotive interior trim panel comprising a thermoplastic decorative film disposed on a first side of a non-woven mat and injection molded features disposed on a second side of the non-woven mat, wherein the second side of the non-woven mat is opposite the first side and the decorative film has a thickness of 0.1 to 0.5 millimeters.

2 . The automotive interior trim panel of claim 1 , wherein the thermoplastic decorative film comprises a thermoplastic olefin.

3 . The automotive interior trim panel of claim 1 , wherein the non-woven mat comprises natural fibers and manmade fibers.

4 . The automotive interior trim panel of claim 1 , wherein the non-woven mat comprises a combination of flax and polypropylene.

5 . The automotive interior trim panel of claim 1 , wherein the thermoplastic decorative film comprises a layer of foam.

6 . The automotive interior trim panel of claim 1 , wherein the combination of the non-woven mat and decorative film has a thickness of 0.5 to 1.5 millimeters.

7 . An automotive interior comprising a thermoplastic decorative film disposed on a first side of a non-woven mat and injection molded features disposed on a second side of the non-woven mat, wherein the second side of the non-woven mat is opposite the first side and the non-woven mat, prior to forming the automotive interior trim panel, has an areal weight of 600 to 2500 grams per square meter.

8 . The automotive interior trim panel of claim 7 , wherein the thermoplastic decorative film comprises a thermoplastic olefin.

9 . The automotive interior trim panel of claim 7 , wherein the non-woven mat comprises natural fibers.

10 . The automotive interior trim panel of claim 7 , wherein the non-woven mat comprises a combination of flax and polypropylene.

11 . The automotive interior trim panel of claim 7 , wherein the thermoplastic decorative film comprises a layer of foam.

12 . The automotive interior trim panel of claim 7 , wherein the combination of the non-woven mat and decorative film has a thickness of 0.5 to 1.5 millimeters.

13 . An automotive interior trim panel consisting of a thermoplastic decorative film disposed on a first side of a non-woven mat and injection molded features disposed on a second side of the non-woven mat.

14 . The automotive interior trim panel of claim 13 , wherein the thermoplastic decorative film comprises a thermoplastic olefin.

15 . The automotive interior trim panel of claim 13 , wherein the non-woven mat comprises natural fibers and manmade fibers.

16 . The automotive interior trim panel of claim 13 , wherein the non-woven mat comprises a combination of flax and polypropylene.

17 . The automotive interior trim panel of claim 13 , wherein the combination of the non-woven mat and decorative film has a thickness of 0.5 to 1.5 millimeters.

18 . The automotive interior trim panel of claim 13 , wherein the decorative film has a thickness of 0.1 to 0.5 millimeters.

19 . The automotive interior trim panel of claim 13 , wherein the non-woven mat, prior to forming the automotive interior trim panel, has an areal weight of 600 to 2500 grams per square meter.

20 . The automotive interior trim panel of claim 13 , wherein the non-woven mat comprises natural fibers and the combination of the non-woven mat and decorative film has a thickness of 0.5 to 1.5 millimeters.

Assignees

• Inteva Products Llc

Inventors

• Gassman Kenneth
• Wenzel Edward J

Classifications

• B29C45/14221 Primary

  by tools, e.g. cutting means · CPC title

• B60R13/04

  External} Ornamental or guard strips; Ornamental inscriptive devices {thereon (fastening strips or bars to sheets or plates by means of clips F16B5/12) · CPC title

• B60J5/0481

  plastic · CPC title

• B29C2045/14245

  using deforming or preforming means outside the mould cavity · CPC title

• B32B27/32 Primary

  comprising polyolefins {(comprising vinyl (co)polymers or acrylic (co)polymers B32B27/30)} · CPC title