Vehicle Component and Method for Making a Vehicle Component

Abstract

A process for providing a cushioned region ( 14 ) on a substrate ( 12 ) is disclosed. The substrate ( 12 ) is at least partially covered by a sheet ( 18 ) of preferably textured material. A skin ( 22 ) is coupled to the substrate ( 12 ) and a compressible material ( 24 ) (such as foam) is injected between the sheet ( 22 ) and skin ( 24 ). The sheet ( 18 ) is intended to promote adhesion to the compressible material ( 24 ) (e.g., mechanical and/or chemical joining or bonding). If portions of the coversheet ( 18 ) are exposed on a visible surface, the coversheet may also be configured to provide a decorative or ornamental appearances.

1 . A method of making a cushioned region on a substrate comprising: 
 coupling a sheet to at least a portion of a base to form the substrate;    coupling a cover layer to the substrate; and    introducing a compressible material between the sheet and the cover layer.    
     
     
         2 . The method of  claim 1  wherein the step of coupling the cover layer to the substrate comprises providing a cavity between the sheet and the cover layer and the step of introducing the compressible material comprises injecting a foam material and expanding the foam material.  
     
     
         3 . The method of  claim 1  wherein the step of coupling the sheet to the base comprises molding the base against the sheet.  
     
     
         4 . The method of  claim 1  wherein the step of coupling the sheet to the base comprises applying an adhesive to one of the base and the sheet.  
     
     
         5 . The method of  claim 1  wherein the step of coupling the sheet to the base comprises heat staking the sheet to the base.  
     
     
         6 . The method of  claim 1  wherein the step of coupling the sheet to the base comprises welding the sheet to the base.  
     
     
         7 . The method of  claim 1  wherein the step of coupling the sheet to the base comprises using one or more mechanical fasteners to attach the sheet to the base.  
     
     
         8 . The method of  claim 1  further comprising the step of coupling the compressible layer to a textured surface of the sheet.  
     
     
         9 . The method of  claim 8  wherein the compressible material comprises a foam material.  
     
     
         10 . The method of  claim 9  wherein the foam material is coupled to the sheet with a mechanical bond as the foam material cures.  
     
     
         11 . The method of  claim 9  wherein the foam material is coupled to the sheet with a chemical bond.  
     
     
         12 . The method of  claim 9  wherein the cover layer and the foam material provide the cushioned region of an armrest on a vehicle trim panel.  
     
     
         13 . The method of  claim 1  wherein the step of coupling the cover layer to the substrate comprises retaining the cover layer by at least one of mold sections, vacuum pressure, fasteners, or interference fittings.  
     
     
         14 . A panel comprising: 
 a base;    a sheet coupled to the base to form a substrate;    a cover layer coupled to the substrate; and    a compressible material disposed between at least a portion of the sheet and at least a portion of the cover layer;    wherein the sheet comprises a textured surface so that the compressible material mechanically bonds to the textured surface of the sheet.    
     
     
         15 . (canceled)  
     
     
         16 . The panel of  claim 14  wherein the sheet comprises one of a textile, fabric, cloth, leather, thermoplastic material, or combinations thereof.  
     
     
         17 . The panel of  claim 14  wherein the compressible material comprises at least one of a foam material, elastomer, rubber, butyl, or combinations thereof.  
     
     
         18 . The panel of  claim 14  wherein the panel is a vehicle trim panel.  
     
     
         19 . The panel of  claim 18  wherein the vehicle trim panel is one of a door trim panel, an instrument panel, a visor, or a headliner.  
     
     
         20 . The panel of  claim 14  wherein perimeter portions of the cover layer are retained in a recess formed in the substrate.  
     
     
         21 . The panel of  claim 20  wherein perimeter portions of the sheet are retained in a recess formed in the base.  
     
     
         22 . The panel of  claim 14  wherein an “A” surface of the panel is provided by at least a portion of the base and at least a portion of the cover layer.  
     
     
         23 . The panel of  claim 14  wherein an “A” surface of the panel is provided by at least a portion of the base, a portion of the sheet, and at least a portion of the cover layer.  
     
     
         24 . A method of forming a panel comprising: 
 providing a sheet having a textured surface;    injection molding a base against a surface of the sheet opposite the textured surface;    coupling a cover layer to at least one of the sheet and the base; and    introducing a compressible material between at least a portion of the cover layer and at least a portion of the sheet.