Method of making a combination speaker grill and automotive interior trim panel

Abstract

A method of manufacturing a rear shelf trim and speaker grill panel ( 12 ) for an automotive vehicle ( 10 ) includes steps of punching a substrate layer ( 16 ) of a polypropylene and flax material with a punch set ( 46 ) to form a grill section ( 60 ) and placing a decorative carpet layer ( 18 ) over the substrate layer ( 16 ) and molding the two layers into a combined speaker grill and rear shelf trim panel ( 12 ).

I claim:  
     
         1 . A process for forming a combined speaker grill and automotive interior trim panel characterized by the steps of: 
 providing a substrate layer of a heated mat material having a content of thermoplastic material such that it is moldable under heated conditions;    punching a plurality of apertures in said heated substrate to form a grill section;    providing a decorative layer onto said substrate;    molding said substrate and said decorative layer into said automotive interior trim panel of a desired shape such that said apertures form an integral speaker grill with said panel.    
     
     
         2 . A process as defined in  claim 1  further characterized by: 
 said punching of said apertures is simultaneous with said molding step such that said apertures are formed through both said substrate and said decorative layer as said substrate and decorative layer are shaped into said panel.  
 
     
     
         3 . A process as defined in  claim 2  further characterized by: 
 a first mold die having apertures therein and a second mold die having a punch set that fits in said apertures to punch said apertures through both of said decorative layer and said substrate as said mold dies are closed to shape said substrate and said decorative layer into said panel.  
 
     
     
         4 . A process as defined in  claim 3  further characterized by: 
 said decorative layer being a carpet which has a thermal plastic back surface that is adhered to said substrate during the molding process.  
 
     
     
         5 . A process as defined in  claim 1  further characterized by the steps of: 
 forming said apertures in said substrate before said substrate is molded into its final shape;  
 positioning pins in said apertures after said apertures are formed;  
 positioning said decorative layer over said substrate and said pins in a mold;  
 closing the mold and molding the substrate layer and decorative layer into a shape of an automotive interior panel under pressure; and  
 removing the substrate from said pins such that said molded panel has the decorative layer spanning over the apertures in said substrate.  
 
     
     
         6 . A process as defined in  claim 5  further characterized by the steps of: 
 extending said pins through a first mold die and positioning said pins to align with the interior surface of the mold;  
 punching said apertures by a first punch set aligned with said pins to push through said substrate and recess said pins;  
 raising said punch set to remove said punched scraps of substrate and lifting said pins to intrude into said apertures in said substrate;  
 providing a second mold die that complements said first mold die and closing said first and second mold dies for molding said panel into shape with said pins extending through said first mold die and remaining in said apertures in said substrate during molding of said panel.  
 
     
     
         7 . A process as defined in  claim 5  further characterized by: 
 said decorative layer being a carpet with a thermal plastic back surface that is adhered to said substrate during the molding process.  
 
     
     
         8 . A process as defined in  claim 1  further characterized by: 
 positioning a formed grill section over an opening through said substrate with a periphery of said grill section overlapping a peripheral edge of said opening in said substrate with pins extending through said apertures;  
 positioning said decorative layer over said substrate, said grill section, and said pins in a mold.  
 closing the mold and molding under pressure the substrate layer and decorative layer in a shape of an automotive interior panel;  
 demolding the substrate from said pins such that the molded panel has the decorative layer spanning over the aperture in the grill section.  
 
     
     
         9 . A process as defined in  claim 8  further characterized by: 
 punching out two additional grill sections upon said closing said mold at an end section of said substrate.  
 
     
     
         10 . A process as defined in  claim 9  further characterized by: 
 placing hot melt on top of the grill section for enhanced bonding with the decorative layer before said decoration layer is placed over said substrate and said grill section.  
 
     
     
         11 . A process for forming a combined speaker grill and automotive interior trim panel characterized by the steps of: 
 providing a decorative layer that is capable of being bonded to said substrate layer;    placing the heated substrate layer and decorative layer into an open mold;    closing the mold and molding said substrate layer and said decorative layer into a formed automotive interior panel under pressure between two closed mold dies with a first mold die section of said mold having a section with a plurality of holes therein and a complementary mold die section having a plurality of punches that mate with said plurality of holes to punch a plurality of apertures in the formed panel to form an integral speaker grill with said panel;    opening said mold dies and cooling said panel to be resolidified with the substrate and decorative layers being bonded together and removing the molded formed combined speaker grill and automotive interior trim panel from said mold.    
     
     
         12 . A process as defined in  claim 11  further characterized by: 
 applying said decorative layer on said substrate layer before said substrate is compression molded into shape such that said decorative layer is compression molded with said substrate layer into the shape of the combined speaker grill and automotive interior trim panel.  
 
     
     
         13 . A process as defined in  claim 12  further characterized by: 
 said plurality of punches punched through both the lower and decorative layer simultaneously with the compression molding of said substrate layer.  
 
     
     
         14 . A process as defined in  claim 13  further characterized by: 
 said decorative layer being a carpet layer with a back surface bonded onto the substrate during the molding process.  
 
     
     
         15 . A process as defined in  claim 14  further characterized by: 
 said combined speaker grill and automotive interior trim panel being in the form of an automotive rear shelf trim panel.  
 
     
     
         16 . A process as defined in  claim 12  further characterized by: 
 said plurality of punches punching through both the lower and decorative layer simultaneously with the compression molding of said speaker grill and automotive interior trim panel.  
 
     
     
         17 . A process as defined in  claim 11  further characterized by: 
 said decorative layer being a carpet layer with a back surface bonded onto the substrate during the molding process.  
 
     
     
         18 . A process for forming a combined speaker grill and automotive interior trim panel characterized by the steps of: 
 providing a grill section and a substrate layer of a heated mat material having a content of thermoplastic material such that it is moldable under heated conditions;    punching out a plurality of aperture in said grill section of said substrate layer;    positioning said grill section such that a pin is received in each respective aperture with an end of the pin substantially coplanar with one side of the grill section;    providing a decorative layer that is capable of being bonded to said substrate layer and said grill section;    molding said substrate layer, grill section and said decorative upper layer into a formed automotive interior panel under pressure between two closed mold dies with said decorative layer spanning over said pins in said holes in said substrate to form an integrated speaker grill with said panel;    removing the molded formed panel and speaker grill after said thermoplastic material in said panel is, cooled to allow said panel to be resolidified and said substrate, grill section and decorative upper layers are bonded together.    
     
     
         19 . A process as defined in  claim 18  further characterized by: 
 said pins being in a first mold die and being spring biased such that said heated mat is positioned over said spring biased pins;  
 said punching of said holes being done by a punch set aligned over said pins and pushing through said mat and pushing down on said pins;  
 said punch set withdrawn and said pins being biased to rise into said apertures formed in said grill section.  
 
     
     
         20 . A molded interior automotive panel and speaker grill combination characterized by: 
 a molded substrate layer having thermal plastic content and a flax fiber content;    a plurality of apertures through said substrate to be aligned with a speaker mounted therebehind;    a decorative layer on top of the substrate material and molded thereto.    
     
     
         21 . A molded interior automotive panel and speaker grill combination as defined in  claim 20  further characterized by: 
 said decorative layer being a porous carpet layer that spans over said plurality of apertures.  
 
     
     
         22 . A molded interior automotive panel and speaker grill combination as defined in  claim 20  further characterized by: 
 said decorative layer also having apertures therethrough that align with the apertures in said substrate.  
 
     
     
         23 . A molded interior automotive panel and speaker grill combination as defined in  claim 22  further characterized by: 
 said decorative layer being a porous carpet layer.