Decorative components for motor vehicle interiors

Abstract

A method of manufacturing a decorative components for vehicle interiors, comprises the steps of pre-forming a sheet of formable veneer material under pressure and heath, positioning the pre-formed sheet in a mold half of an injection mold comprising a cavity; holding the sheet in position on the mold half, closing said mold and injecting into the cavity one or more thermoplastic materials on the back of the veneer sheet to provide a support layer.

1 . A method of manufacturing a component for a vehicle interior comprising the steps of: 
 (a) preparing a laminate layer comprising a veneer layer and a formable and form-retaining layer selected from thermoplastic and thermosetting plastic materials;    (b) pre-forming said laminate layer in a mold having a cavity and a male portion, said male portion comprising a deformable element to shape said laminate layer according to said cavity;    (c) positioning said pre-formed laminate layer in an injection mold and injecting into said mold one or more thermoplastic materials on the back of the said pre-formed laminate to provide a laminate having a support and coupling layer.    
     
     
         2 . The method of manufacturing a component for a vehicle interior according to  claim 1 , wherein said laminate comprises a peripheral rim or step.  
     
     
         3 . The method of manufacturing a component for a vehicle interior according to  claim 1  or  2 , wherein said laminate comprises a veneer layer bonded to a transparent film material.  
     
     
         4 . The method of manufacturing a component for a vehicle interior according to  claim 1  or  2  wherein said laminate comprises a layer of resistive material.  
     
     
         5 . The method of manufacturing a component for a vehicle interior according to  claim 3  wherein said laminate comprises a layer of resistive material.  
     
     
         6 . The method of manufacturing a component for a vehicle interior according to  claim 1  or  2  wherein said veneer material comprises wood.  
     
     
         7 . The method of manufacturing a component for a vehicle interior according to  claim 3  wherein said veneer material comprises wood.  
     
     
         8 . The method of manufacturing a component for a vehicle interior according to  claim 4  wherein said veneer material comprises wood.  
     
     
         9 . The method of manufacturing a component for a vehicle interior according to  claim 1  wherein means of attachment of the decorative component are molded integral with said injected support layer.  
     
     
         10 . The method of manufacturing a component for a vehicle interior according to  claim 1  wherein said veneer material comprises at least one material selected from a group consisting of wood, fabrics, carbon fiber, and aramid fiber.  
     
     
         11 . The method of manufacturing a component for a vehicle interior according to  claim 1  further comprising an “In-Mold Paint” step.  
     
     
         12 . A component for a vehicle interior manufactured by the method of  claim 1  comprising a veneer material bonded to a first layer of formable and form retaining material selected from thermosetting or thermoplastic material, said thermoplastic film being bonded with one layer of thermoplastic material produced by injection molding.  
     
     
         13 . The component for a vehicle interior according to  claim 12  that is a shell for a steering wheel.  
     
     
         14 . The component for a vehicle interior according to  claim 12  wherein said veneer material comprises wood.  
     
     
         15 . The component for a vehicle interior according to  claim 13  wherein said veneer material comprises wood.  
     
     
         16 . A mold for pre-forming sheets of formable veneer material for a component for a vehicle interior comprising two mold halves defining a cavity, expandable means located on one of said mold halves and projecting into said cavity when the mold is closed, and means of expanding said expandable means and causing it to occupy substantially all said cavity.  
     
     
         17 . The mold according to  claim 16 , further comprising at least one insert for the production of undercuts, steps and locking rims.