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  Vehicle component and method for making a vehicle componentUSPTO Application #: 20080107889Title: Vehicle component and method for making a vehicle component Abstract: A process for providing a cushioned region (14) on a substrate (12) is disclosed. The substrate (12) is at least partially covered by a sheet (18) of preferably textured material. A skin (22) is coupled to the substrate (12) and a compressible material (24) (such as foam) is injected between the sheet (22) and skin (24). The sheet (18) is intended to promote adhesion to the compressible material (24) (e.g., mechanical and/or chemical joining or bonding). If portions of the coversheet (18) are exposed on a visible surface, the coversheet may also be configured to provide a decorative or ornamental appearances. (end of abstract) Agent: Foley And Lardner LLP Suite 500 - Washington, DC, US Inventor: Bart W. Fox USPTO Applicaton #: 20080107889 - Class: 428319700 (USPTO) Related Patent Categories: Stock Material Or Miscellaneous Articles, Web Or Sheet Containing Structurally Defined Element Or Component, Composite Having Voids In A Component (e.g., Porous, Cellular, Etc.), With Nonvoid Component Of Specified Composition, Synthetic Resin Or Natural Rubbers, Linear Or Thermoplastic The Patent Description & Claims data below is from USPTO Patent Application 20080107889. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS [0001] The present application claims priority under 35 U.S.C. .sctn. 119 to U.S. Provisional Application No. 60/662,568, filed on Mar. 17, 2005, titled "VEHICLE COMPONENT AND METHOD FOR MAKING A VEHICLE COMPONENT" (Attorney Docket No. 026032-4876) which is hereby incorporated herein by reference in its entirety. BACKGROUND OF THE INVENTION [0002] The present invention relates generally to the field of providing cushioned regions to a substrate for use in a vehicle, such as a vehicle panel. [0003] It is known to foam in place and to partially foam in place vehicle trim panels. Such known panels include a substrate, a skin coupled to the substrate, and a foam injected between the substrate and skin. However, obtaining a bond between the substrate (typically plastic) and the foam sometimes requires treating the surface of the substrate (e.g., flame, primer, or abrading), to promote adhesion between the substrate and foam. Such treatments cost materials and labor. [0004] Accordingly, it would be advantageous to couple a sheet to the substrate base to provide a desired ornamental appearance on one portion of the panel and provide a surface that promotes adhesion to the foam at the cushioned region. It would also be advantageous to couple the sheet to the substrate so that the sheet provides at least a portion of the visible surface (e.g., the "A" surface or side). To provide an inexpensive, reliable, and widely adaptable component for a vehicle interior that avoids the above-referenced and other problems would represent a significant advance in the art. SUMMARY OF THE INVENTION [0005] The present invention relates to a process for providing a cushioned region on a substrate. The substrate comprises a base that is covered by a sheet of material. The sheet of material may be coupled to the substrate base by molding the substrate against the sheet of material. A skin is coupled to the substrate and a filler material such as foam is injected between the substrate and skin. The coversheet is intended to promote adhesion to the filler material (e.g., mechanical and/or chemical joining or bonding). If portions of the coversheet are exposed on the "A" surface, the coversheet may also be configured to provide a decorative or ornamental appearance. [0006] The present invention also relates to a method of making a cushioned region on a substrate. The method comprises coupling a sheet to at least a portion of the substrate; coupling a cover layer to the substrate; and introducing a compressible material between the sheet and the cover layer. [0007] The present invention further relates to a panel comprising a substrate; a sheet coupled to the substrate; a cover layer coupled to the substrate; and a compressible material disposed between at least a portion of the textured layer and at least a portion of the cover layer. [0008] Various arrangements of the substrate and cushioned region may be used. For example, the coversheet may cover the entire side or face of the substrate base (e.g., by a mold behind process) and the cushioned region is disposed over a portion of the substrate (e.g., by a partial foam in place or PFIP process). Alternatively, the coversheet may cover an entire side or face of the substrate (e.g., by a mold behind process) and the cushioned region is disposed over the entire substrate (e.g., by a foam in place or FIP process) such that the filler material is enclosed by the skin and by the coversheet coupled to the substrate. Alternatively, the coversheet covers a local area or a side or face of the substrate (e.g., by a partial mold behind or PMB process) and the cushioned region is disposed over a portion of the substrate local area (e.g., by a partial foam in place or PFIP process). Alternatively, the coversheet covers a local area of a side or face of the substrate (e.g., by a partial mold behind or PMB process) and the cushioned region is disposed over the entire local areas of the sheet/substrate laminate. [0009] The present invention further relates to various features and combinations of features shown and described in the disclosed embodiments. Other ways in which the objects and features of the disclosed embodiments are accomplished will be described in the following specification or will become apparent to those skilled in the art after they have read this specification. Such other ways are deemed to fall within the scope of the disclosed embodiments if they fall within the scope of the claims which follow. BRIEF DESCRIPTION OF THE DRAWINGS [0010] FIG. 1 is a perspective view of a vehicle door trim panel having a cushioned region coupled to a substrate base covered by a sheet of material. [0011] FIG. 2 is a front view of a vehicle door trim panel (the "A" surface) having a cushioned region coupled to a substrate base covered by a sheet of material along with sections molded by separate injections of plastic resin. [0012] FIG. 3 is a fragmentary perspective view of the cushioned region, coversheet, and multiple plastic injected substrate of FIG. 2 substrate. [0013] FIG. 4 is a rear view of the panel (the "B" surface) of FIG. 2. [0014] FIG. 5 is a fragmentary view of the panel of FIG. 4 with an aperture for injecting a filler material between the skin and substrate. [0015] FIG. 6 is a front view of the panel of FIG. 2 before the coversheet and skin are coupled to the substrate base. [0016] FIG. 7 is a front view of the panel of FIG. 6 after the coversheet has been coupled to the substrate base. [0017] FIG. 8 is a fragmentary view of the coversheet coupled to the substrate base of FIG. 7, illustrating the coversheet in the recesses of the substrate base. [0018] FIGS. 9-12 are schematic section views of exemplary embodiments of vehicle interior components. [0019] FIG. 13 is a section view of a substrate secured against a skin by closed mold sections. [0020] FIG. 14 is a section view of a substrate secured against a skin by a vacuum pressure. Continue reading... Full patent description for Vehicle component and method for making a vehicle component Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Vehicle component and method for making a vehicle component patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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