Method of forming multi-component instrument panel skin using negative vacuum forming

1 . A method of forming a multi-component skin for an instrument panel assembly comprising:

providing a negative vacuum forming tool adapted to form an instrument panel skin into a predetermined shape;

providing at least one skin element, being formed from a first material, and placing the at least one skin element within the negative vacuum forming tool;

securing the at least one skin element within the negative vacuum forming tool;

providing an instrument panel skin, being formed from a second material, heating the instrument panel skin, and placing the instrument panel skin within the negative vacuum forming tool, on top of the at least one skin element;

activating the negative vacuum forming tool to suck the instrument panel skin against the negative vacuum forming tool, wherein the instrument panel skin molds to the shape of the negative vacuum forming tool and around the skin element; and

allowing the instrument panel skin and the skin element to cool and removing the multi-component instrument panel skin from the negative vacuum forming tool.

2 . The method of claim 1 wherein providing at least one skin element, made from a first material, comprises:

thermoforming at least one skin element that is made from a first material; and

cutting the skin element to a predetermined shape.

3 . The method of claim 2 , further including applying an adhesive to a rear side of the skin element prior to cutting the skin element to a predetermine shape.

4 . The method of claim 3 wherein thermoforming at least one skin element, comprises thermoforming at least one skin element, by one of a negative vacuum forming process and a positive vacuum forming process.

5 . The method of claim 3 wherein the adhesive, comprises a heat activated adhesive.

6 . The method of claim 5 wherein the heat activated adhesive activates at a temperature greater than forty degrees Celsius.

7 . The method of claim 3 wherein cutting the skin element to a predetermine shape, comprises cutting the skin element to a predetermine shape using one of a knife, a drill, a lazer, a water jet, and an integrated feature within the skin tool.

8 . The method of claim 3 wherein activating the negative vacuum forming tool to suck the instrument panel skin against the negative vacuum forming tool, wherein the instrument panel skin molds to the shape of the negative vacuum forming tool and around the skin element, includes regulating the temperature of the negative vacuum forming tool, the instrument panel skin, and the skin element at a temperature greater than forty degrees Celsius for a predetermined amount of time to insure that the heat activated adhesive on the rear side of the skin element is activated.

9 . The method of claim 8 further including pre-heating the adhesive prior to placing the skin element within the negative vacuum forming tool.

10 . The method of claim 9 further including exposing the rear side of the skin element

11 . The method of claim 1 wherein securing the at least one skin element within the negative vacuum forming tool comprises securing the at least one skin element within the negative vacuum forming tool with one of mechanical features and vacuum effect from the negative vacuum forming tool.

12 . The method of claim 1 wherein providing an instrument panel skin, made from a second material, heating the instrument panel skin, and placing the instrument panel skin within the negative vacuum forming tool, on top of the at least one skin element comprises providing an instrument panel skin, made from a second material, heating the instrument panel skin to a temperature between about one-hundred and sixty degrees Celsius and about two-hundred and forty degrees Celsius, and placing the instrument panel skin within the negative vacuum forming tool, on top of the at least one skin element, such that the instrument panel skin forms to the shape of the negative vacuum forming tool and around the skin element.

13 . The method of claim 1 wherein providing an instrument panel skin, made from a first material, heating the instrument panel skin, and placing the instrument panel skin within the negative vacuum forming tool, on top of the at least one skin element, comprises providing an instrument panel skin, made from a second material, heating the instrument panel skin, and placing the instrument panel skin within the negative vacuum forming tool such that the instrument panel skin extends partially on top of the at least one skin element.

14 . The method of claim 13 , wherein when the instrument panel skin is placed on top of the skin element, the edge of the instrument panel skin overlaps the edge of the skin element, thereby defining a gluing ring.

15 . The method of claim 14 , wherein the edge of the instrument panel skin overlaps the edge of the skin element by approximately twenty millimeters.