Automotive trim panel and method of making same

Abstract

A trim panel for use in automotive trim applications is made from a laminate of a thermoformable foam layer and an A-side layer made of vinyl or cloth or the like. The laminate is thermoformed to impart permanently the contour of a rigid substrate to which the panel will be attached. The foam layer retains the desired contour without the use of other materials. The A-side material and foam layer may be laminated by an adhesive layer may be a foam which is flame laminated to the foam layer and A-side layer. The foam layer may be encased by thin layers of polyethylene. Process controls are applied allowing thermoforming of parts to automotive precision.

1 . A panel for covering a substantially rigid substrate having a non-flat contour, the panel comprising an A-side layer and a foam layer laminated to one another, the A-side layer by itself having insufficient stiffness to retain a particular shape, and the foam layer having sufficient stiffness to impart to the panel a permanent, non-flat contour generally matching that of the substrate.  
     
     
         2 . The panel of  claim 1  wherein the foam layer is made from one of the group of urethane foam or polyethylene foam, either of which may be either closed or open cell, and any of which may be thermo or chemically cross-linked.  
     
     
         3 . The panel of  claim 1  wherein the A-side layer is vinyl.  
     
     
         4 . The panel of  claim 1  wherein the A-side layer is a textile material.  
     
     
         5 . The panel of  claim 1  wherein the foam layer and A-side layer are laminated together by an adhesive foam layer.  
     
     
         6 . The panel of  claim 1  further comprising a backing layer made of a thermoformable material and laminated to the foam layer such that the foam layer is between the A-side layer and the backing layer.  
     
     
         7 . The panel of  claim 1  further comprising a polyethylene film on at least one side of the foam layer.  
     
     
         8 . A panel for covering a substantially rigid substrate having a non-flat contour, the panel being made by the process of laminating together first and second sheets, the first sheet comprising an A-side layer which by itself has insufficient stiffness to retain a particular shape, the second sheet comprising a thermoformable foam layer, and thermoforming the laminated sheets into a non-flat contour generally matching that of the substrate with the foam layer having sufficient stiffness to permanently retain said contour.  
     
     
         9 . The panel of  claim 8  wherein the foam layer is made from one of the group of urethane foam or polyethylene foam, either of which may be either closed or open cell, and any of which may be thermo or chemically cross-linked.  
     
     
         10 . The panel of  claim 8  wherein the A-side layer is vinyl.  
     
     
         11 . The panel of  claim 8  wherein the A-side layer is a textile material.  
     
     
         12 . The panel of  claim 8  wherein the foam layer and A-side layer are laminated together by an adhesive foam layer.  
     
     
         13 . The panel of  claim 8  further comprising a backing layer made of thermoformable material and laminated to the foam layer such that the foam layer is between the A-side layer and the backing layer.  
     
     
         14 . The panel of  claim 8  further comprising a polyethylene film on at least one side of the foam layer.  
     
     
         15 . An automotive trim panel for covering a substantially rigid substrate having a non-flat contour, the panel comprising an A-side layer and a foam layer laminated to one another, the A-side layer by itself having insufficient stiffness to retain a particular shape, and the A-side and foam layers being thermoformed such that the foam layer will have sufficient stiffness to impart to the panel a permanent, non-flat contour generally matching that of the substrate.  
     
     
         16 . An automotive trim panel for covering a substantially rigid substrate having a non-flat contour, the panel comprising an A-side layer, a foam layer and a backing layer laminated to one another with the foam layer between the A-side layer and the backing layer, the A-side layer by itself having insufficient stiffness to retain a particular shape, and the A-side, foam and backing layers being thermoformed such that the backing layer will have sufficient stiffness to impart to the panel a permanent, non-flat contour generally matching that of the substrate.  
     
     
         17 . A method of making a panel for covering a substantially rigid substrate having a non-flat contour, the method comprising the steps of: 
 a) laminating together first and second sheets, the first sheet comprising an A-side layer which by itself has insufficient stiffness to retain a particular shape, the second sheet comprising a thermoformable foam layer; and    b) thermoforming the laminated sheets into a non-flat, contour generally matching that of the substrate with the foam layer having sufficient stiffness to permanently retain said contour.    
     
     
         18 . The method of  claim 17  wherein the laminating step is further characterized by the steps of: 
 a) heating a third sheet, the third sheet comprising an adhesive foam layer;  
 b) pressing the A-side layer and adhesive layer together;  
 c) reheating the adhesive layer; and  
 d) pressing the thermoformable foam layer and adhesive layer together.