Granted Patent B1

US 7,045,206 · App. 09/612,869 · Granted May 16, 2006

Abstract

Claims (42)

1. An automobile interior molded panel comprising:

a rigid substrate having a first substrate surface and a second substrate surface generally opposed to the first substrate surface;

a composite pad supported by the substrate, the pad comprising a non-impregnable layer of an elastomeric material and an impregnable layer adjacent the non-impregnable layer, the impregnable layer including a reticulated foam resin material such that at least a portion of the substrate extends into the impregnable layer and extends adjacent to sides of the impregnable layer, the non-impregnable layer being disposed adjacent the first substrate surface and the non-impregnable layer having a first non-impregnable layer surface facing away from the impregnable layer and the substrate, and a second non-impregnable layer surface generally opposite the first non-impregnable layer surface, the first substrate surface and the first non-impregnable layer surface facing in the same general direction; and

a cover skin disposed over and directly bonded to the first substrate surface and the first non-impregnable layer surface of the pad.

2. The panel of claim 1 the reticulated material having an amount of pores per inch of about 1 to 100 and a foam density of about 1.5 to 2.5 pcf.

3. The panel of claim 2 wherein the non-impregnable layer is made of an elastomeric foam material.

4. The panel of claim 3 wherein at least a portion of the rigid substrate is present throughout the impregnable layer.

5. The panel of claim 4 wherein the composite pad has a Shore A hardness of about 35–70 when measured according to ASTM No. D2240.

6. The panel of claim 5 wherein the molded panel has a Shore A hardness of about 45–70 when measured according to ASTM No. D2240 while measuring along a line that intersects the composite pad.

7. The panel of claim 1 wherein the non-impregnable layer and the impregnable layer of the composite pad are connected.

8. The panel of claim 1 wherein the pad extends along only a portion of the substrate.

9. The panel of claim 1 wherein the cover skin is a polymeric layer.

10. The panel of claim 1 wherein the composite pad is preformed.

11. An automobile interior molded panel comprising:

a rigid substrate;

a preformed composite pad including a non-impregnable layer and an impregnable layer;

a cover skin disposed over and bonded to the substrate and the pad, wherein the cover skin is directly bonded to at least a portion of the non-impregnable layer of the pad and a portion of the substrate;

wherein the impregnable layer is made of reticulated resin material having an amount of pores per inch of about 1 to 100 and a foam density of about 1.5 to 2.5 pcf;

wherein the non-impregnable layer is made of elastomeric foam material;

wherein at least a portion of the rigid substate is present substantially throughout the impregnable layer; and

wherein at least a portion of the rigid substrate is adjacent to sides of the impregnable layer.

12. An automobile interior molded panel comprising:

a rigid substrate;

a composite pad comprising a non-impregnable layer of an elastomeric material and an impregnable layer including a reticulated foam resin material defining a network within the reticulated material;

a cover skin disposed over and directly bonded to at least a portion of the substrate and at least a portion of the non-impregnable layer of the pad;

wherein at least a portion of the rigid substrate is present substantially throughout the network of the impregnable layer.

13. The panel of claim 12 , the reticulated material having an amount of pores per inch of about 1 to 100 and a foam density of about 1.5 to 2.5 pcf.

14. The panel of claim 12 wherein the non-impregnable layer is made of an elastomeric foam material.

15. The panel of claim 12 , the reticulated material having an amount of pores per inch of about 1 to 100 and a foam density of about 1.5 to 2.5 pcf and the non-impregnable layer including an elastomeric foam material.

16. The panel of claim 15 wherein the composite pad has a Shore A hardness of about 35–70 when measured according to ASTM No. D2240.

17. The panel of claim 15 wherein the molded panel has a Shore A hardness of about 45–70 when measured according to ASTM NO. D2240 while measuring along a line that intersects the composite pad.

18. The panel of claim 12 , wherein the impregnable layer comprises a porous material and the non-impregnable layer comprises an elastomeric foam material.

19. An automobile interior molded panel comprising:

a rigid substrate;

a composite pad comprising a non-impregnable layer of an elastomeric material and an impregnable layer including a reticulated foam resin material defining a network within the reticulated material; and

a cover skin disposed over and directly bonded to at least a portion of the substrate and at least a portion of the non-impregnable layer of the pad; wherein at least a portion of the rigid substrate is adjacent to sides of the impregnable layer and wherein at least a portion of the rigid substrate is present substantially throughout the network of the impregnable layer.

20. The panel of claim 19 , the reticulated material having an amount of pores per inch of 1 to 100 and a foam density of about 1.5 to 2.5 pcf.

21. The panel of claim 20 wherein the non-impregnable layer is made of an elastomeric foam material.

22. The panel of claim 21 wherein the composite pad has a Shore A hardness of about 35–70 when measured according to ASTM No. D2240.

23. The panel of claim 22 wherein the molded panel has a Shore A hardness of about 45–70 when measured according to ASTM No. D2240 while measuring along a line that intersects the composite pad.

24. The panel of claim 19 , wherein the non-impregnable layer comprises an elastomeric foam material.

25. The panel of claim 19 , wherein the impregnable layer comprises a porous material the non-impregnable layer comprises an elastomeric foam-material.

Assignments (8)