Liner apparatus and method of making a liner

Abstract

A liner for a cargo area of a vehicle, such as a car, truck, trailer, or the like, includes at least three layers, a base layer, an intermediate patterned layer, and a clear or transparent top layer so that the patterned layer may be viewed. The patterned layer may be monochromatic, where only a single color is used, or it may be polychromatic, where several colors are used. The patterned layer may be a color scape, a design or logo, a message, or any decorative item, etc. Three embodiments of methods for making a liner are disclosed. The methods include the use of a female mold, a male mold, or a combination of male and female molds where the male mold is a ram applying pressure and heat to the several layers on the female mold.

What I claim is:  
     
         1 . A method of making a liner for the cargo area of a vehicle comprising the steps of: 
 providing a mold;    spraying a base coat on the mold;    spraying a patterned coat on the first coating; and    spraying a clear coat on the patterned coat.    
     
     
         2 . The method of  claim 1  in which the provided mold is a female mold.  
     
     
         3 . The method of  claim 1  in which the provided mold is a male mold.  
     
     
         4 . The method of  claim 1  which further includes the step of spraying a release agent on the mold before spraying the base coat.  
     
     
         5 . The method of  claim 1  which further includes the steps of curing each coat after a coat is sprayed.  
     
     
         6 . A method of making a liner comprising the steps of: 
 providing a mold;    spraying a first coat on the mold;    spraying a patterned coat in the first coat; and    spraying a third coat on the patterned coat.    
     
     
         7 . The method of  claim 6  in which the provided mold is a female mold, and the first coat is a base coat, and the third coat is a clear coat.  
     
     
         8 . The method of  claim 6  in which the provided mold is a male mold, and the first coat is a clear coat, and the third coat is a base coat.  
     
     
         9 . The method of  claim 6  in which the spraying the first coat includes the step of applying a release agent to the mold prior to spraying the first coat.  
     
     
         10 . The method of  claim 9  which further includes the step of curing each coat after spraying a coat.  
     
     
         11 . A method of making a multilayer element having a patterned layer and a clear layer over the patterned layer comprising the steps of: 
 providing a first mold;    providing a first coat on the mold;    providing a patterned second coat on the first coat;    providing a third coat on the patterned second coat; and    curing each coat prior to providing the next coat.    
     
     
         12 . The method of  claim 11  in which the first mold is a male mold, and the first coat is a clear coat.  
     
     
         13 . The method of  claim 11  in which the first mold is a female mold, and the third coat is a clear coat.  
     
     
         14 . The method of  claim 11  in which the first coat is sprayed on the mold.  
     
     
         15 . The method of  claim 14  in which the first coat is a base coat.  
     
     
         16 . The method of  claim 11  in which the step of providing a third coat comprises providing a film coat.  
     
     
         17 . The method of  claim 16  which further includes the step of providing a second mold, and the first mold is a lower, female, mold, and the second mold is an upper mold.  
     
     
         18 . The method of  claim 17  which further includes the step of providing heat to heat the film coat to allow the film coat to stretch.  
     
     
         19 . The method of  claim 18  which further includes the step of providing a ram in the upper mold to provide pressure on the film coat to move the film coat against the second coat.  
     
     
         20 . The method of  claim 18  which further includes the step of providing pressure in the upper mold to provide pressure on the film coat to move the film coat against the second coat.  
     
     
         21 . A liner for the cargo area of a vehicle comprising in combination: 
 a first base layer;    a patterned second layer; and    a clear third layer on the patterned layer for permitting the patterned layer to be viewed.    
     
     
         22 . The liner of  claim 21  in which the base layer is a foam layer.  
     
     
         23 . The liner of  claim 21  in which the patterned layer is polychromatic.  
     
     
         24 . The liner of  claim 21  in which the patterned layer is monochromatic.  
     
     
         25 . The liner of  claim 21  in which the liner is relatively flexible.  
     
     
         26 . The liner of  claim 21  in which the liner is relatively inflexible.  
     
     
         27 . The liner of  claim 21  which includes a clear fourth layer on the clear third layer.