Method of making a door panel with integrated bolster

Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor

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156 79, 156212, 156214, 156228, 156245, 156285, 156321, 264 464, 264511, B32B 3106, B32B 3120

Patent

active

055713556

ABSTRACT:
A method of making an interior panel of an automotive vehicle door having an exterior surface which is to face toward the interior of the automotive vehicle when installed therein which comprises the steps of forming a bolster laminate including a textile outer layer, a flexible imperforate layer and an inner surface layer of a material which becomes tacky when heated, mounting the bolster laminate in a vacuum mold part, heating a sheet of predetermined material content presenting a vinyl surface, vacuum forming the heated sheet in the vacuum mold part so that the vinyl surface bondingly interengages the tacky material of the film inner layer of the bolster laminate, molding material between the vacuum mold part with the bolster laminate and the sheet therein and a cooperating opposed mold part to form an integrally molded panel having a content between an exterior bolster and vinyl surface and an opposed surface which includes a relatively hard substrate defining the opposed surface, a layer of sheet vinyl presenting the vinyl surface and a layer of relatively soft foamed material adjacent the layer of sheet vinyl.

REFERENCES:
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patent: 4740417 (1988-04-01), Tornero
patent: 4766025 (1988-08-01), Sanok et al.
patent: 4923539 (1990-05-01), Spengler et al.
patent: 5053179 (1991-10-01), Masui et al.
patent: 5091031 (1992-02-01), Strapazzini
patent: 5236534 (1993-08-01), Noguti et al.
Patent Abstracts of Japan, vol. 10, No. 66 (M-461-2123) Mar. 1986 re JP-A 60 212313.
Patent Abstracts of Japan, vol. 10, No. 81 (M-465) (2138) Mar. 1986 re JP-A 60 222319.
Patent Abstracts of Japan, vol. 10, No. 33 (M-452) Aug. 1986 re JP-A 60 189432.

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