Abstract:
A vehicle trim panel for use in a vehicle having an interior portion includes a first substrate panel. A first cover is coupled to the first substrate panel. A second substrate panel is coupled to the first substrate panel. A second cover is coupled to the second substrate panel, wherein the first and second substrate panels are aligned in the vehicle with the first and second covers exposed to the interior portion of the vehicle.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to U.S. Provisional Application No. 60/796,793, filed May 02, 2006, which is incorporated herein by reference. 
     
     BACKGROUND 
       [0002]    The present application relates generally to the field of vehicle interior panels. In particular, the present application relates to a vehicle trim panel, such as a headliner, having multiple materials and different colors. 
         [0003]    Vehicle headliners generally include a substrate and a cover. The substrate provides structural strength for the headliner. The cover, which may be a fabric or other material, may be laminated onto the substrate by use of an adhesive. The cover is usually selected to have color and/or texture that matches or coordinates with other trim panels or the upholstery in the vehicle. Headliners typically are produced having a single color and comprise a single cover. Such headliners do not allow for a headliner having multiple colors and/or materials that may better coordinate with the rest of a vehicle interior. 
         [0004]    Trim panels, including headliners, also are incorporating more and more accessories. These accessories may include sunroofs, in-vehicle entertainment systems, telematics devices, side curtain air bags, and a variety of other accessories. Many headliner materials are rigid and can be difficult to manipulate around accessories during manufacture or installation. Further, to accommodate a variety of trim levels within a single vehicle model, a number of completely different headliners may be required. 
         [0005]    Accordingly, it would be desirable to provide a trim panel capable of accommodating a plurality of cover materials. It would be desirable to provide a trim panel system that may be used to accommodate a variety of trim levels for the same vehicle model. 
       SUMMARY 
       [0006]    According to an exemplary embodiment, a vehicle trim panel for use in a vehicle having an interior portion includes a first substrate panel. A first cover is coupled to the first substrate panel. A second substrate panel is coupled to the first substrate panel. A second cover is coupled to the second substrate panel, wherein the first and second substrate panels are aligned in the vehicle with the first and second covers exposed to the interior portion of the vehicle. 
         [0007]    According to another exemplary embodiment, a method of making a vehicle trim panel includes coupling a first cover to a first substrate panel and coupling a second cover to a second substrate panel. An arcuate portion is formed along an edge of the first substrate panel. An arcuate portion is formed along an edge of the second substrate panel. The arcuate portions of each of the first and seconds substrate panels are joined to each other to form the vehicle trim panel. 
         [0008]    According to another exemplary embodiment, a vehicle trim panel for use in a vehicle interior includes a substrate panel defining a channel. A first cover is coupled to the substrate panel, wherein a portion of the cover is disposed in the channel. Another embodiment includes a second cover, and both the first and second channels are disposed in the channel. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a perspective view of an exemplary embodiment of a trim panel, for example, a headliner for a vehicle. 
           [0010]      FIG. 2  is a schematic perspective view of an exemplary embodiment of a process for producing the headliner of  FIG. 1 . 
           [0011]      FIG. 3  is an elevation view of an exemplary embodiment of a trim panel composed of two different materials. 
           [0012]      FIG. 4  is a cross-sectional view of the trim panel illustrated in  FIG. 3  taken along seam line  4 - 4  which is parallel to the longitudinal axis of a vehicle headliner. 
           [0013]      FIG. 5  is an elevation view of an exemplary embodiment of a trim panel composed of multiple, co-extruded materials. 
           [0014]      FIG. 6  is a cross-sectional view of the trim panel illustrated in  FIG. 5  illustrating a “false stitch” feature, taken along line  6 - 6  which is perpendicular to the longitudinal axis of a vehicle headliner. 
       
    
    
     DETAILED DESCRIPTION 
       [0015]      FIGS. 1-6  illustrate exemplary embodiments of a trim panel for use in a vehicle (e.g., an automobile such as a car, truck, sport utility vehicle, minivan bus, and the like; airplanes; and/or boats). In one embodiment, the trim panel is configured as a headliner for use in an automobile. 
         [0016]    Referring to  FIG. 1 , headliner  10  includes middle portion  12 , side portion  14 , and side portion  16 . Middle portion  12 , side portion  14 , and/or side portion  16  may be provided with detents  18 , openings  20 , ridges  22 , and/or other structural elements to accommodate various vehicle accessories or structural elements. Each of portions  12 ,  14 , and  16  may be formed separately and then joined together to form headliner  10 . 
         [0017]    Alternatively, portions  12 ,  14 , and  16 , may be formed as a single unitary body. In some embodiments, it may be desirable to provide a headliner having a substrate and a cover formed as a laminate or other composite. In other embodiments, the headliner, or one or more portions thereof, may comprise a single layer assembly. Portions  12 ,  14 , and  16  are shown as configured to extend along a longitudinal axis of the vehicle in the direction of vehicle travel. Alternatively, the portions may be arranged laterally or non-orthogonally to the longitudinal axis of the vehicle. 
         [0018]    Referring to  FIG. 2 , an exemplary embodiment of a process for producing headliner  10  is illustrated. Material rolls  24 ,  26 , and  28  provide material for covering a substrate  23  at middle portion  12 , side portion  14 , and side portion  16  of headliner  10 , respectively. The materials from rolls  24 ,  26 , and  28  are combined longitudinally to cover a substrate material. The coverings of middle portion  12  and side portions  14  and  16  may be coupled in a variety of manners. For example, seams  30  may be provided to join the covering of middle portion  12  and the coverings of side portions  14  and  16 . Alternatively, the coverings of side portion  14  and/or side portion  16  may overlap an edge of the cover of middle portion  12  to form a joint  32  where side portions  14  and/or  16  may be joined to middle portion  12 . 
         [0019]    The material used to form the cover of the middle portion  12  and side portion  14  and/or  16  of the trim panel may be any one of a number of thermal setting or thermal forming materials. Such materials include polymers selected from the group consisting of polyethylene teraphthalate (“PET”), polypropylene, and derivatives and mixtures thereof. Alternatively, other suitable materials may be used as well. For example, any of a variety of biodegradable and/or recyclable materials may be used. The materials may be provided with a variety of surface finishes. For example, the material may have a brushed appearance. Alternatively, the material may have a flat or simulated finish or have some other textured finish. 
         [0020]    For reference purposes, the longitudinal axis  42  of headliner  10  is illustrated in  FIGS. 3 and 5 . Longitudinal axis  42  of headliner  10  is configured to align with the longitudinal axis of a vehicle along a direction of vehicle travel. 
         [0021]    Referring to  FIG. 3 , a trim panel shown as a headliner includes middle portion B and side portions A. Referring to  FIG. 4 , the joint between side portion A and middle portion B is illustrated. According to the embodiment shown, a seam is provided between side portion A and middle portion B. Side portion A includes an arcuate portion  34  that joins to arcuate portion  36  of middle portion B at an interface or a contact surface between side portion A and middle portion B. Side portion A and middle portion B may be coupled along this interface by a variety of means. For example, side portion A and middle portion B may be stitched together by stitching which passes through arcuate portion  34  and arcuate portion  36 . The stitching may be real, e.g., using a suitable thread, or simulation stitching, e.g. stitch feature formed in a mold. Alternatively, arcuate portion  34  and arcuate portion  36  may be joined by an adhesive along the interface. In yet another embodiment, side portion A and middle portion B may be coupled by ultrasonic welding, heat welding, and/or other applicable attachment methods. 
         [0022]    Portions A and B may be individually covered with a polymeric cover. Alternatively, portions A and B may be covered with another material such as a non-woven fabric, woven fabric, polyvinylchloride (“PVC”), leather, or other suitable material. When an uncovered substrate is used in the headliner, the surface of the uncovered substrate may be provided with a textured finish or a decorative pattern in the surface. 
         [0023]    Referring to  FIG. 5 , a trim panel shown as a headliner may include alternating panels A and B. Alternating panels A and B are joined along seams. 
         [0024]      FIG. 6  illustrates one embodiment of the seam for attaching alternating materials A and B. According to this embodiment, the headliner includes a single substrate, and a channel  38  is provided in substrate to receive a cover material. The cover material may comprise one or more materials. For example, cover portion  40  may comprise a material A and cover portion  42  may comprise a material B. Cover portions  40  and  42  provide an interface between material A and material B and may be joined together by any of the methods discussed above. Alternatively, cover portions  40  and  42  may be held in the channel by friction, by adhesive joining of each of materials A and B to the substrate, or by co-lamination of materials A and B to the substrate. 
         [0025]    In another embodiment, a single cover portion may be used (i.e., a co-extruded material having two color portions A and B). Such a co-extruded material may include a boundary region between portion A and portion B where the colors bleed and/or otherwise mix together. In order to provide a clean boundary between the two color regions for a headliner type trim panel, the boundary region may be disposed within the channel, ditch joint, or other structure in the substrate. This allows for concealment of the boundary region which may include an area where colors have bled together. The channel may be formed during the extrusion process, i.e., by selecting a die having a cross-section configured to provide the channel. Alternatively, the channel may be formed by bending or warping a flat panel such that the boundary region is disposed within a channel or ditch. Headliner  10  may also be manufactured by injection molding processes to form portions  12 ,  14 , and  16 . In other embodiments, the trim panel may be formed by compression molding. 
         [0026]    Headliner  10  may be configured to accommodate a vehicle accessory, such as a power and/or communication system including lighting, compass systems, telematics systems, integrated transceivers, and other such devices and systems. Headliner  10  may also accommodate other devices including visors, air bags, grab handles, and other devices. Headliner  10  may be configured to receive such devices by use of any suitable attachment method, such as threaded fasteners and back brackets or clips, adhesive (e.g. hot-melt glue, etc.), Christmas tree type fasteners or any other suitable method. Appropriate sized and positioned openings  20  in the trim panel are provided to receive the various types of vehicle accessories. The openings  20  can be formed during the manufacturing process of the trim panel or cut out after the trim panel is formed. 
         [0027]    For purposes of this disclosure, the term “coupled” means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components, or the two components and any additional member being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature 
         [0028]    The construction and arrangement of the elements of the trim panel system and apparatus as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of trim panels have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. It should be noted that the elements and/or assemblies of the trim panel may be constructed from any of a wide variety of materials that provide sufficient strength or durability, including any of a wide variety of moldable plastic materials (such as high-impact plastic) in any of a wide variety of colors, textures and combinations. Further, the trim panel may be configured to interface with a wide variety of other vehicle accessories. Other substitutions, modifications, changes and omissions may be made in the design of the exemplary embodiments without departing from the scope of the claims.