Method and apparatus for nonwoven trim panels

1. A method of forming a trim panel ( 38 ), comprising:

placing a non-woven mat of material ( 12 ) in a heating press ( 16 );

heating the material ( 12 ) to a predetermined temperature;

applying a decorative film ( 18 ) to a first surface of the heated material ( 12 ) to create a bilaminate ( 26 );

placing the bilaminate ( 26 ) into a cavity ( 32 ) of a forming mold ( 28 ) such that the decorative film ( 18 ) is facing the cavity ( 32 );

heating half of the cavity ( 32 );

closing the forming mold ( 28 ); and

injecting a thermoplastic resin ( 33 ) into the forming mold ( 28 ) having a heated cavity such that the thermoplastic resin is adhered to a second surface of the material ( 12 ) which is part of the bilaminate, the second surface being opposite to the first surface.

2. The method as in claim 1 , wherein the decorative film ( 18 ) is applied to the material via a contact roller ( 20 ) of a roller system ( 22 ).

3. The method as in claim 1 , wherein the decorative film ( 18 ) is perforated.

4. The method as in claim 1 , wherein the decorative film ( 18 ) consists of a layer of thermoplastic olefin laminated to a layer of foam.

5. The method as in claim 1 , wherein the decorative film ( 18 ) is a thermoplastic olefin.

6. The method as in claim 1 , wherein injection pressures of the thermoplastic resin ( 33 ) are limited using sequential valve gating, foaming agents, or flow enhancers in order to reduce injection pressure.

7. The method as in claim 1 , further comprising opening and closing the mold ( 28 ) prior to injecting the thermoplastic resin ( 33 ).

8. The method as in claim 1 , wherein the predetermined temperature is in the range of 200-210 degrees Celsius.

9. A method of forming a trim panel ( 38 ), comprising:

placing a non-woven mat of material ( 12 ) in a heating press ( 16 );

heating the non-woven mat ( 12 ) to a predetermined temperature;

heating half of a cavity ( 32 ) of a forming mold;

inserting a decorative film ( 18 ) in the cavity ( 32 ) of the forming mold ( 28 );

removing the heated non-woven mat from the heating press and inserting between a half of the forming mold and the decorative film such that a first surface of the non-woven mat contacts the decorative film, wherein inserting the decorative film occurs after heating the cavity;

closing the forming mold ( 28 ); and

injecting a thermoplastic resin into the forming mold such that the thermoplastic resin is adhered to a portion of a second surface of the material, the second surface being opposite to the first surface.

10. The trim panel as in claim 9 , wherein the decorative film ( 18 ) is perforated.

11. The method as in claim 9 , wherein the decorative film ( 18 ) consists of a layer of thermoplastic olefin laminated to a layer of foam.

12. The method as in claim 9 , wherein the decorative film ( 18 ) is a thermoplastic olefin.

13. The method as in claim 9 , further comprising heating the decorative film ( 18 ) prior to placement in the cavity ( 32 ) of the forming mold ( 28 ).

14. The method as in claim 9 , further comprising heating the decorative film ( 18 ) after placement in the cavity ( 32 ) of the forming mold ( 28 ) but prior to inserting the non-woven mat.

15. The method as in claim 9 , further comprising opening and closing the tool ( 28 ) prior to injecting the thermoplastic resin ( 33 ).

16. The method as in claim 9 , wherein the predetermined temperature is in the range of 200-210 degrees Celsius.

17. A method of forming a trim panel ( 38 ), comprising:

placing a non-woven mat of material ( 12 ) in a heating press ( 16 );

heating the material ( 12 ) to predetermined temperature;

applying a thermoplastic topcoat ( 44 ) into a cavity ( 32 ) of a tool ( 28 );

heating half of the cavity ( 32 );

placing the material ( 12 ) into the heated cavity ( 32 ) such that a first surface of the material is adhered to the thermoplastic topcoat ( 44 );

closing the tool ( 28 ); and

injecting a thermoplastic resin ( 33 ) into the tool ( 28 ) such that the thermoplastic resin is adhered to a second surface of the material ( 12 ), the second surface being opposite to the first surface.

18. The method as in claim 17 , wherein the topcoat ( 44 ) is sprayed into the cavity ( 32 ).

19. The method as in claim 17 , further comprising opening and closing the tool ( 28 ) prior to injecting the thermoplastic resin ( 33 ).

20. The method as in claim 17 , wherein the predetermined temperature is in the range of 200-210 degrees Celsius.