Multi-piece vehicle interior trim panel

Abstract

The present invention provides a method for making a multi-piece vehicle interior trim panel. In at least one embodiment, the method comprises providing a major panel having a major substrate, a sprayed urethane major skin layer disposed over at least a portion of the major substrate, and a foam layer between the major substrate and the major skin layer. The method further includes forming a minor panel by spraying polyurethane material proximate a relatively small mold surface to form a sprayed urethane minor skin layer, spraying expandable polyurethane material onto the minor skin layer to form a first resilient layer, placing a mounting substrate onto the first resilient layer, and spraying expandable polyurethane material onto the first resilient layer and the mounting substrate to form a second resilient layer. The method further comprises removing the minor panel from the mold and securing the minor panel to the major panel portion.

1 . A method for making a multi-piece vehicle interior trim panel, said method comprising: 
 providing a major panel having a major substrate, a sprayed urethane major skin layer disposed over at least a portion of the major substrate, and a layer of foam between the major substrate and the major skin layer, the major panel having a mounting portion having at least one mounting opening;    forming a minor panel, said minor panel being formed by: 
 providing a spray mold having a mold surface smaller than the outer surface of the major skin layer;  
 spraying polyurethane material proximate the mold surface to form a sprayed urethane minor skin layer having a height (H), an exterior surface, and an interior surface;  
 spraying a first portion of expandable polyurethane material onto the minor skin layer to form a first resilient layer;  
 placing a mounting substrate onto the first resilient layer; and  
 spraying a second portion of expandable polyurethane material onto the first resilient layer and the mounting substrate to form a second resilient layer;  
   removing the minor panel from the mold; and    securing the minor panel to the mounting portion of the major panel, wherein a package space (X) is disposed between the interior surface of the minor skin layer and the mounting portion of the major substrate, with at least one of (i) the height (H) of the minor skin being less than 12 mm and (ii) the package space (X) being less than 5 mm.    
     
     
         2 . The method of  claim 1  wherein the mounting substrate is placed onto the first resilient layer before the first resilient layer has substantially cured.  
     
     
         3 . The method of  claim 1  wherein the mounting substrate has at least one projection and wherein securing the minor panel to the major panel comprises inserting the projection through the mounting opening of the major panel and securing the projection to the major panel.  
     
     
         4 . The method of  claim 3  wherein the mounting substrate comprises a plate, the projection extending from the plate, the plate having at least one plate opening therein.  
     
     
         5 . The method of  claim 4  wherein spraying a second portion of expandable polyurethane material onto the first resilient layer and the mounting substrate comprises spraying the second portion onto the plate and through the plate opening.  
     
     
         6 . The method of the  claim 3  wherein the projection is heat-staked to the major panel portion.  
     
     
         7 . The method of  claim 4  wherein the resilient layers each have a density of 0.1 to 0.75 g/cm 3 .  
     
     
         8 . The method of  claim 7  wherein the skin layer each have a density of 0.85 to 1.2 g/cm 3 .  
     
     
         9 . The method of  claim 7  wherein the first resilient layer has an average thickness of 0.3-4.5 mm.  
     
     
         10 . The method of  claim 9  wherein the second resilient layer has an average thickness of 0.3 to 3 mm.  
     
     
         11 . The method of  claim 10  wherein the minor skin layer has a n average thickness of 0.3 to 8 mm.  
     
     
         12 . The method of  claim 11  wherein the plate has a thickness of 0.2 to 3 mm.  
     
     
         13 . An automobile interior panel made by the method of  claim 1 .  
     
     
         14 . An automobile instrument panel made by the method of  claim 1 .  
     
     
         15 . A method for making a multi-piece vehicle interior trim panel, said method comprising: 
 providing a major panel having a major substrate and major skin layer disposed over at least a portion of the major substrate, the major substrate having a mounting portion;    forming a minor panel, said minor panel being formed by: 
 spraying polyurethane material proximate a mold surface to form a sprayed urethane minor skin layer having a height (H);  
 placing a mounting substrate proximate the minor skin layer; and  
 spraying expandable polyurethane material over the mounting substrate to form a resilient layer to secure the mounting substrate to the minor skin layer; and  
 securing the minor panel to the mounting portion of the major panel, wherein a package space (X) is present between the minor skin layer and the mounting portion, with at least one of the height (H) being less than 12 mm or the package space (X) being less than 5 mm.  
   
     
     
         16 . The method of  claim 15  wherein the mounting substrate has at least one projection and wherein securing the minor panel to the major panel comprises securing the projection to mounting portion of the major panel.  
     
     
         17 . The method of  claim 15  wherein the minor skin layer has an average thickness of 0.3 to 8 mm.  
     
     
         18 . The method of  claim 15  wherein the resilient layers each have a density of 0.1 to 0.75 g/cm 3 .  
     
     
         19 . The method of  claim 18  wherein the skin layer each have a density of 0.85 to 1.2 g/cm 3 .  
     
     
         20 . A method for making a multi-piece vehicle interior trim panel, said method comprising: 
 providing a major panel having a major substrate and sprayed urethane major skin layer disposed over at least a portion of the major substrate, the major panel having at least one mounting opening;    forming a minor panel, said minor panel being formed by: 
 providing a spray mold having a mold surface smaller than the outer surface of the major skin layer;  
 spraying polyurethane material proximate the mold surface to form a polyurethane skin layer;  
 spraying a first portion of expandable polyurethane material onto the skin layer to form a first resilient layer;  
 placing a mounting substrate proximate the first resilient layer; and  
 spraying a second portion of expandable polyurethane material onto the first resilient layer and the mounting substrate to form a second resilient layer; and  
   securing the minor panel to the major panel.