US2021237323A1PendingUtilityA1

Method and apparatus for nonwoven trim panels

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Assignee: INTEVA PRODUCTS LLCPriority: Sep 23, 2015Filed: Apr 26, 2021Published: Aug 5, 2021
Est. expirySep 23, 2035(~9.2 yrs left)· nominal 20-yr term from priority
Inventors:Kenneth GassmanEdward J. Wenzel
B29C 45/14221B60R 13/04B60J 5/0481B29C 2045/14245B32B 27/32B60R 13/0256B29C 2045/0032B60R 13/0262B32B 7/08B32B 38/00B32B 33/00B29C 45/14786B32B 27/12B29L 2031/302B32B 37/10B32B 3/266B29C 2045/14729B32B 37/06B29C 45/14688B29K 2995/007B29C 45/1418B32B 43/003B29C 45/14811B29C 2045/14188B32B 2605/08B32B 2605/003B29C 45/14631B29C 45/14336B60R 13/02
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Claims

Abstract

A method of forming a trim panel is provided. The method including the steps of: placing a non-woven mat of material in a heating press; heating the material to a predetermined temperature; applying a decorative film to a first surface of the heated material to create a bilaminate; placing the bilaminate layer into a cavity of a tool such that the decorative film is facing the cavity; heating the cavity; and injecting a thermoplastic resin into the tool such that the thermoplastic resin is adhered to a second surface of the material, the second surface being opposite to the first surface. Also disclosed is the trip panel formed by the foregoing method.

Claims

exact text as granted — not AI-modified
What is claimed is: 
     
         1 . An automotive interior trim panel comprising a thermoplastic decorative film disposed on a first side of a non-woven mat and injection molded features disposed on a second side of the non-woven mat, wherein the second side of the non-woven mat is opposite the first side and the decorative film has a thickness of 0.1 to 0.5 millimeters. 
     
     
         2 . The automotive interior trim panel of  claim 1 , wherein the thermoplastic decorative film comprises a thermoplastic olefin. 
     
     
         3 . The automotive interior trim panel of  claim 1 , wherein the non-woven mat comprises natural fibers and manmade fibers. 
     
     
         4 . The automotive interior trim panel of  claim 1 , wherein the non-woven mat comprises a combination of flax and polypropylene. 
     
     
         5 . The automotive interior trim panel of  claim 1 , wherein the thermoplastic decorative film comprises a layer of foam. 
     
     
         6 . The automotive interior trim panel of  claim 1 , wherein the combination of the non-woven mat and decorative film has a thickness of 0.5 to 1.5 millimeters. 
     
     
         7 . An automotive interior comprising a thermoplastic decorative film disposed on a first side of a non-woven mat and injection molded features disposed on a second side of the non-woven mat, wherein the second side of the non-woven mat is opposite the first side and the non-woven mat, prior to forming the automotive interior trim panel, has an areal weight of 600 to 2500 grams per square meter. 
     
     
         8 . The automotive interior trim panel of  claim 7 , wherein the thermoplastic decorative film comprises a thermoplastic olefin. 
     
     
         9 . The automotive interior trim panel of  claim 7 , wherein the non-woven mat comprises natural fibers. 
     
     
         10 . The automotive interior trim panel of  claim 7 , wherein the non-woven mat comprises a combination of flax and polypropylene. 
     
     
         11 . The automotive interior trim panel of  claim 7 , wherein the thermoplastic decorative film comprises a layer of foam. 
     
     
         12 . The automotive interior trim panel of  claim 7 , wherein the combination of the non-woven mat and decorative film has a thickness of 0.5 to 1.5 millimeters. 
     
     
         13 . An automotive interior trim panel consisting of a thermoplastic decorative film disposed on a first side of a non-woven mat and injection molded features disposed on a second side of the non-woven mat. 
     
     
         14 . The automotive interior trim panel of  claim 13 , wherein the thermoplastic decorative film comprises a thermoplastic olefin. 
     
     
         15 . The automotive interior trim panel of  claim 13 , wherein the non-woven mat comprises natural fibers and manmade fibers. 
     
     
         16 . The automotive interior trim panel of  claim 13 , wherein the non-woven mat comprises a combination of flax and polypropylene. 
     
     
         17 . The automotive interior trim panel of  claim 13 , wherein the combination of the non-woven mat and decorative film has a thickness of 0.5 to 1.5 millimeters. 
     
     
         18 . The automotive interior trim panel of  claim 13 , wherein the decorative film has a thickness of 0.1 to 0.5 millimeters. 
     
     
         19 . The automotive interior trim panel of  claim 13 , wherein the non-woven mat, prior to forming the automotive interior trim panel, has an areal weight of 600 to 2500 grams per square meter. 
     
     
         20 . The automotive interior trim panel of  claim 13 , wherein the non-woven mat comprises natural fibers and the combination of the non-woven mat and decorative film has a thickness of 0.5 to 1.5 millimeters.

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