Panel, in particular for vehicle doors and relative method of manufacture

Abstract: The panel comprises a rigid insert (7) having a decorative lining (9) in fabric, edges (11) with undercuts and a series of oblong elements (12) with a swollen head (14). On the said insert (7) is placed a thermoformed sheet (16) in foam PVC onto which is vacuum injected a layer of foamed polyurethane (6), in such a way as to incorporate during polymerization, via the PVC sheet, the undercuts and oblong elements (12).

Description: The invention refers to lining panels, in particular for vehicle doors, and to the relative method of manufacture. Various types of panels are known which comprise an insert having a decorative lining on one side, which is connected to the supporting structure of the panel. Generally in these the insert is substantially flat and can be connected to the structure by glueing, or by compressing, or by cold riveting. The said inserts are therefore connected to the supporting structure only superficially and are not closely connected to it, nor do they serve as reinforcement for the supporting structure. Therefore, when the panel is subjected to stress from vibrations or tensions, which in the case of vehicle doors are very intense, the insert is not obliged to follow the sudden deformation. The sliding which occurs between the insert described and the structure therefore generates, in the interior of the vehicle, irritating creaks which are difficult to eliminate. The technical problem of the invention consists in creating a panel which is highly robust and free of the noise. It is also known from the document EP-A-0 226 105 a foamed polyurethane molding useful for interior parts of a motor vehicle, i.e. head rests, sunvisors, arm rests, crash pads and bumpers of the vehicle. In order to obviate the use of parting agents for protection of the mold and for ensuring release of the molding, an expansible film, preferably of polyurethane with high tensile stretchability, in the form of a flat sheet or a bag, is interposed between the the mold and the foamed resin. In some embodiments disclosed in this document, i.e. the crash pads, an insert of a hard material is placed between one molding surface and the expansible film, for the purpose of a secure attachment to the vehicle body, whereby the insert is not a decorative lining, and is not provided on the outer surface of the panel. The insert is provided with anchorage areas in from of tapered sectional or stepped areas, which cause enfolding portions of the resin to securely grip the insert in position. The foamed resin molding is also provided with a film-like cover member on the opposite side of the expansible film, which will represent the visible outer surface of the molded part. According to the invention it is now provided a panel for interior parts of a vehicle, in particular vehicle doors, comprising a support of foamed polyurethane, a rigid insert formed on a first side with means of anchorage, and a sheet fitted onto said first side of said insert and compressed by said foamed polyurethane during its expansion and polymerization to shape said support in such a way as to adhere intimately to said means of anchorage through said sheet, said panel being characterized in that said insert includes a layer of plastic and a decorative lining provided on a side thereof opposite to said first side, said insert being hot-molded to assume a three dimensional shape with at least two curved edges, said means of anchorage including a perimeter sections of said edges in form of an undercut, and a plurality of oblong elements in form of undercut protruding perpendicularly from said first side. The properties of the invention will be more clearly shown by the following description of a preferred embodiment, made as an example not restrictive, in conjunction of the attached drawings, in which: Fig. 1 is a section of a panel for vehicle doors, in accordance with the invention; Fig. 2 is a section on an enlarged scale of a portion of Fig. 1; Fig. 3 is a partial section of a mold for the manufacture of the panel as in Fig. 1 in an intermediate stage of processing; Fig. 4 is the section of the mould as in Fig. 3 in the final stage of processing. With reference to Figures 1 and 2, by 5 is generally indicated a decorative lining panel for a vehicle door. Panel 5 comprises essentially a support 6 consisting of a layer of polymerized foamed polyurethane appropriately formed in three dimensions. Panel 5 comprises a rigid insert 7 connected on a first side, or surface 8, with the support 6. The insert 7 has a decorative lining 9 on the other side. In particular, the support 6 is obtained by vacuum injecting the polyurethane into a mould, by means of the known technology of foaming. In its turn the insert 7 is formed from a layer of plastic 10 whilst the lining 9 is in fabric. It can be made from the material known commercially as "Woodstock". The insert 7 is hot-moulded so that it assumes a three dimensional shape, with two or more curved edges. These edges 11 can include perimeter sections in the form of an undercut, which constitute means of anchorage of the insert 7 to the support 6. Furthermore, in layer 10 are placed a multiplicity of oblong elements, which shall henceforth be referred to as "pine-nut shapes" 12 and they also have the function of acting as means of anchorage. Each pine-nut 12 (Fig. 2) is arranged substantially perpendicular to the surface of the side 8 and has a body 13 which is slightly conical. Each pine-nut is, moreover, fitted with a base flange 14 fixed to the layer 10 and a swelling or head 15 at its free extremity, which thus forms other undercuts. Between the insert 7 and the support 6 is placed a thermoformed sheet 16, in foam PVC. It is compressed by the foamed polyurethane of the support 6 in the stage of expansion and polymerization, particularly in the undercuts of the edges 11 and of the heads 15. In this way the support 6 and the insert 7 are intimately connected, forming a single entity. Therefore, on the one hand the insert 7 contributes to the robustness and the mechanical stability of the panel 5, and on the other hand any tension or vibration of the support 6 is followed by the insert 7, avoiding any sliding between the two parts and therefore any noise or creaking of the panel. The incorporating into a single entity of the means of anchorage also allows greater flexibility in the design and in the distribution of the decorative effect of the fabric 9 on the surface of the panel 5. For the manufacture of the panel 5 an injection mould is used, generically indicated as 17 (Figures 3 and 4), which includes a fixed part 18 and an opening part 19 hinged on a fulcrum 20 to the fixed part 18. Firstly with the mould 17 open, the insert 7, formed and fitted with pine-nuts 12, is placed with the decorative lining 9 in contact with a housing 21 of the fixed part 18. The housing 21 also has a centring function for the insert 7. Afterwards on the insert 7 and on the part 18 of the mould 17, is placed the thermoformed sheet 16 in foam PVC, with a slight dimensional excess in relation to panel 5. The sheet 16 is placed on the insert 7 leaving spaces 22 between the edges 11 and the layer 10 and spaces 23 between the pine-nuts and the layer 10 itself. The gap between the two parts 18 and 19 is made and the mould 17 is now closed in the usual fashion. Finally, the polyurethane is vacuum injected into the mould 17, via a head 24 of the feed pipe. The polyurethane is thus foamed and the polymerization stage commences. During this stage, when the foamed polyurethane is created, the thermoformed sheet 16 is compressed onto the layer 10 and therefore also onto the edges 11 and onto the pine-nuts 12. When the reaction has taken place, the foamed polyurethane of the support 6 has incorporated intimately both the edges 11 and the pine-nuts 12, eliminating the spaces 22 and 23, enabling the insert 7 and the sheet 16 to form a single entity with the support 7. Now the mould 17 can be opened and eliminate the riser 25 from the panel 5. Naturally, various modifications and improvements can be made to the panel 5 and to the relative method of manufacture without leaving the ambit of the invention. For example, the insert 7 need not have the undercuts on the edges 11, or the pine-nuts 12. Moreover, the lining 9 can consist of other than fabric.

Claims: A panel for interior parts of a vehicle, in particular vehicle doors, comprising a support (6) of foamed polyurethane, a rigid insert (7) formed on a first side (8) with means of anchorage (11, 12), and a sheet (16) fitted onto said first side (8) of said insert (7) and compressed by said foamed polyurethane during its stage of expansion and polymerization to shape said support (6) as to adhere intimately to said means of anchorage (11, 12) through said sheet (16), characterized in that said insert (7) includes a layer of plastic (10) and a decorative lining (9) provided on a side thereof opposite to said first side (8), said insert (7) being hot-molded to assume a three dimensional shape with at least two curved edges (11), said means of anchorage (11, 12) including a perimeter sections of said edges (11) in form of an undercut, and a plurality of oblong elements (12) in form of undercut protruding perpendicularly from said first side (8). A panel according to claim 1, characterized in that said sheet (16) is thermoformed in foam PVC, the exposed surface of the panel being formed by said decorative lining (9) and by said thermoformed sheet (16). A panel according to claim 1 or 2, characterized in that each one of said oblong elements (12) includes a frusto-conical body (13) having a swelling (15) at its free extremity, and a base flange (14) fixed to said layer of plastic (10). A panel according to any previous claim, characterized in that said decorative lining (9) is fabric. A method of manufacture of a panel for interior parts of a vehicle, in particular vehicle doors, comprising the following stages: prepare a rigid insert (7) having a layer of plastic (10) and a decorative lining (9) as to assume a three dimensional shape with at least two curved edges (11) having perimeter undercut sections; prepare a plurality of oblong elements (12), each one having a swelling (15) at its free extremity; secure said plurality of elements (12) to said layer of plastic (10) as to protrude each one substantially perpendicularly from the side (8) opposite to said decorative lining (9); place said insert (7) into a housing (20) of a part (18) of a mold (17) for the injection of foam plastic materials; cover said opposite side (8) and said elements (12) with a thermoformed sheet (16) in foamed PVC, with a slight dimensional excess in relation to the panel; close said mold (17), and vacuum inject a layer of foamed polymerizable polyurethane (6) in said closed mold (17) above said sheet (16); open said mold (17), and remove the panel; and remove a molding riser (25) from the panel.

Inventors: MARGIARIA GIORGIO, MARGIARIA, GIORGIO
Applicants: FIAT AUTO SPA, FIAT AUTO S.P.A.
Application year: 1990
Main classification: B60R13
IPC codes: B29C51, B29C44, B60R13