Method of manufacturing a padded panel

A padded panel for a vehicle dashboard, console box or the like has an opening for mounting a desired article, such as an instrument, a switch, etc. The panel includes a base plate which is formed with a closed loop groove. A portion of a surface layer, which covers the base plate, is adhered to the surface of the groove to define a completely closed space therebetween. Foamable material is injected into the closed space and caused to foam and harden to form the pad. After completion of hardening of the pad, the base plate and the surface layer are cut along the inner periphery of the groove to form the opening. The bottom surface of the groove affords a seat to accurately position and positively mount the desired article.

BACKGROUND OF THE INVENTION 
The present invention relates to a padded panel of a vehicle dashboard, 
console box or the like, which is formed with an opening for mounting a 
desired article, such as an instrument, a switch, etc. The present 
invention relates also to a method of manufacturing such a panel. 
Conventionally, as shown in FIG. 1, such a panel includes a base plate 11 
having an opening 13 whose contour conforms with that of the article to be 
mounted. A surface layer 12 is prepared by vacuum molding plastics 
material, e.g. polyvinyl chloride, and covers the base plate 11 with a 
space therebetween. The surface layer 12 on its outer periphery is adhered 
to, or in close contact with the surface of the base plate. Subsequently, 
a seal member 14 is superimposed on the periphery of the opening 13 at the 
opposite side of the surface layer 12, and substantially seals the space 
between the base plate 11 and the surface layer 12. Foamable material 15, 
such as urethane, is injected into the space and foamed therein. After 
completion of hardening of thus foamed material 15, the seal member 14 is 
removed, and the surface layer 12 and the foamed material 15 are cut away 
along the periphery of the opening 13. Thus a panel having a resilient pad 
is manufactured, which is formed with a complete opening 16 for mounting 
the desired article. 
The above described process is disadvantageous in that, as the base plate 
11 is not rigid enough against the foaming pressure, the base plate 11 is 
liable to deform during the foaming period. Thus, gaps are formed between 
the base plate 11 and the seal member 14, so that a substantial amount of 
foamable material (about 200 to 300 grams per one foaming operation) leaks 
away through the gaps. Such a loss of the material cannot be considered 
negligible, and makes it difficult to reduce the manufacturing cost. 
Furthermore, with the padded panel thus manufactured, the connection 
between the foamed material and the surface layer is exposed on the 
peripheral wall of the opening 16 so that the surface layer 12 might be 
relatively easily separated from the pad without a careful mounting 
operation. 
SUMMARY OF THE INVENTION 
Therefore, it is an object of the present invention to provide an improved 
padded panel which can be manufactured without accompanying unnecessary 
material loss, and in which the separation of the surface layer is 
effectively prevented. 
Another object of the present invention is to provide an improved method of 
manufacturing such a padded panel, which can be easily carried out and 
which prevents undesirable leakage of the foamable material without using 
a separate seal member. 
Briefly stated, according to the present invention, the base plate is 
formed with a groove in the form of a closed loop. A surface layer is 
adhered on the surface of the groove and defines a completely closed space 
between the surface layer and the base plate. Foamable material is 
injected into the closed space and foamed therein. After hardening of the 
foamed material is completed, the surface layer and the base plate are cut 
along the inner periphery of the closed loop groove. Since the opening in 
the base plate is formed only after the molding of the pad, leakage of the 
foamable material can be completely eliminated without using a separate 
seal member. 
The present invention will now be explained more in detail by referring to 
one preferred embodiment shown in the accompanying drawings.

DESCRIPTION OF THE PREFERRED EMBODIMENT 
Referring now to FIG. 2, there is shown a padded panel according to one 
preferred embodiment of the present invention, which comprises a base 
plate 1 consisting of suitable plastics material, for example. The base 
plate 1 has an opening 10 surrounded by a thin-walled peripheral portion 6 
which is connected through a stepped portion 5 with the general surface 7 
of the base plate 1. A resilient pad 2 made of foamed plastics material, 
such as urethane, covers the surface 7 of the base plate 1, leaving an 
opening 8 which is contiguous with the opening 10 in the base plate 1. The 
edge of the opening 8 is aligned with the stepped portion 5. A surface 
layer 3 covers the outer surface of the pad 2 and the inner peripheral 
wall of the opening 8, and is adhered to the thin-walled peripheral 
portion 6 of the base plate 1. The openings 8 and 10 permit a desired 
article, such as a switch SW, to be mounted on the panel. 
According to the present invention, the padded panel as shown in FIG. 2 is 
manufactured in the following manner. Referring to FIGS. 3 and 4, the base 
plate 1 on its outer side surface 7 is formed with a groove 9 in the form 
of a closed loop. Thus at the location of the groove 9, the base plate has 
a reduced thickness or the thin-walled portion 6. After the thin-walled 
portion 6 is processed by a flame treatment, or is applied with adhesive 
agent, a portion of the surface layer 3 is pressed against the surface of 
the groove 9 and adhered thereto. The outer periphery of the surface layer 
3 is also adhered to the surface 7 of the base plate 1. By this, a 
completely closed space is formed between the base plate 1 and the surface 
layer 3. Subsequently, foamable urethane material is injected into the 
closed space between the base plate 1 and the surface layer 3, and is 
foamed to provide the pad 2. After completion of the foaming and hardening 
of the pad 2, the base plate 1 and the surface layer 3 are cut along the 
inner periphery 9a of the groove 9, as shown in FIG. 4, also, to form the 
opening 10. 
As mentioned above, when the surface layer 3 is adhered to the base plate 1 
but the pad 2 is not yet formed, the space between the base plate 1 and 
the surface layer 3 is completely closed and sealed by them. Thus, leakage 
of the foamable material can be completely eliminated without using 
unsatisfactory sealing members during the foaming. Consequently, the 
padded panel can be manufactured in a very simple and facilitated manner, 
and the material cost is minimized. 
With the padded panel thus manufactured, the thin-walled portion 6 serves 
to accurately position and positively mount the desired article. 
Otherwise, such an article is positioned with respect to the base plate 1 
with the resilient pad 2 therebetween so that a positive and accurate 
positioning can never be achieved. Furthermore, according to the present 
invention, the inner peripheral wall of the opening 8 is completely 
covered by the surface layer 3 so that the connection between the pad 2 
and the surface layer 3 is not exposed. Thus, separation of the surface 
layer 3 from the pad 2 is positively prevented and the refined appearance 
is effectively maintained. In order to obtain an accurate dimension of the 
opening 10, it may be formed by a press operation.