Patent Application
20060008609
1. Field of the Invention
The present invention relates to a sandwich panel and method of manufacturing a sandwich panel and, more particularly, to a sandwich panel and method of manufacturing a sandwich panel for use as a structural member.
2. Description of the Related Art
Load panels are used for covering storage areas and supporting weight in applications such as automotive interiors and storage spaces. Common uses include load floors, bay covers, flipper panels, seat backs, and cargo cabinets. Solid material panels are used for typical load panels in addition to blow molded panels.
A known prior art load panel is shown in
However, typical load panels have undue flex when supporting large weights. Additionally, typical panels do not maintain their desired shape under changes in atmospheric conditions such as temperature and humidity. The typical solid or single layer panels do not have the rigidity or atmospheric stability required for the harsh automotive environment. Additionally, typical panels do not include finished edges or edges that trap covering material at the edges to reduce peeling or separation of covering material.
Accordingly, a panel and method of manufacturing a panel is required that has improved strength, stiffness, dimensionally stability under various atmospheric conditions, provides expanded covering solutions, reduces costs for attachment devices installed during manufacture, and provides the option of trapping carpet fibers used as covering. More particularly, a panel is needed that provides for an improved panel for use as a structural member in, among other applications, automotive interior components, such as cargo trays, load floors, bay covers, flipper panels, seat backs, cargo cabinets and the like.
The present invention provides a structural panel and a method of manufacturing a structural panel. An embodiment comprises two skins attached to each other forming a structural panel. Another embodiment comprises two skins attached to an intermediate substrate forming a structural panel. Each skin may be made of a pressboard material. The skins may be attached to the intermediate substrate using adhesives or other attachment methods. Further, a covering material may be selectively applied to the skins.
Another embodiment comprises two skins attached to an intermediate substrate forming a structural panel further including an edge member. The edge member may include an engaging member that mechanically engages the intermediate substrate. The engaging member may also have anti-reverse fins that prevent the engaging member from backing out of the intermediate substrate. Further, a covering material may be selectively applied to the skins for improved reliability or for cosmetic appearance. The edge member may also trap a portion of the covering material to improve reliability and improve fit and finish of the panel.
The present invention also provides a method for manufacturing the sandwich panel for an automobile where two skins of predetermined size and shape are provided and attached to each other forming a structural panel. An intermediate substrate may also be provided and attached between the skins. The skins and intermediate substrate may be attached using adhesives or other fasteners. Further, additional hardware such as handles, connectors or the like, may be installed onto the panel. Another method of manufacturing the sandwich panel includes an edge member applied to the periphery of the structural panel.
Embodiments of the invention will now be described, by way of example, with reference to the accompanying drawings, wherein:
Referring now to the drawings, the preferred illustrative embodiments of the present invention are shown in detail. Although the drawings represent some preferred embodiments of the present invention, the drawings are not necessarily to scale and certain features may be exaggerated to better illustrate and explain the present invention. Further, the embodiments set forth herein are not intended to be exhaustive or otherwise limit or restrict the invention to the precise forms and configurations shown in the drawings and disclosed in the following detailed description.
When panel 40 is received in an automotive interior, for example, skins 42, 44 may be formed to match not only the peripheral shape of the area into which panel 40 may be received, but also the contour thereof. The contours may include a complex shape of an interior wall, or, for example, a bulge, pocket, or recess in an otherwise flat panel. Because skins 42, 44 may be made of a pressboard-type material, such as SUPERWOOD®, panel 40 may be molded in a heated press to conform to the shape of the receiving environment or to provide additional structural rigidity through predetermined structural formations, such as folds, bends and pockets. Among other benefits, panel 40 is dimensionally stable under various atmospheric conditions.
Panel 40 may also be aesthetically configured to provide an attractive outward appearance to complement the décor of the automobile interior. For example, skins 42, 44 may be covered with an upholstery material or painted to match the décor of a vehicle interior. Panel 40 allows for unique covering solutions, particularly when compared to similar non-sandwich products. Depending upon predetermined design considerations, one or both sides of panel 40 may be covered with a covering material 50, such as upholstery, carpet, leather, rubber or the like. If applied, covering material 50 then forms an exterior surface 52 of panel 40.
As illustrated in
In the embodiment shown in
In a particular implementation, edge member 54 includes an extruded plastic or vinyl cap having an engaging member 57 with anti-reverse fins 58. Fins 58 extend outwardly from engaging member 57 to grip center layer 48. Fins 58 may be configured to allow for easy insertion of the engaging member 57 with center layer 48, and may also be configured to prevent extraction of engaging member 57 from center layer 48 once installed. Once engaged in panel 40, fins 58 prevent the edge member 54 from releasing from the engaging substrate. Thus, anti-reverse fins 58 firmly hold edge member 54 to the panel 40. Other ways of securing edge member 54 to panel 40, such as adhering edge member 54 to panel 40, are also within the scope of the invention.
Edge member 54 may also include edge(s) 60 that trap covering material 50 and allow the panel to meet or exceed standards for fit, finish and safety, among other things. Among other benefits, edge member 54 allows for a professionally finished edge with less labor and/or material than typical pinch trimmed or edge folded panels. Edge member 54 may also trap the covering material 50 under its edge preventing the covering material 50 from delaminating from the skin(s) 42, 44.
Panel 40 may also be fitted with various devices such as handles, connectors or the like, which may be used with the panel 40 in its installed environment. The devices may be secured or attached to panel 40 in a number of ways, including, without limitation, adhering, screwing, riveting, and using an engaging member with anti-reverse fins 58 similar to that shown in
It will be appreciated that panel 40 is not limited to use as a load-floor in a vehicle. Among other applications, panel 40 may be used in a number of automotive interior components, such as cargo trays, load floors, bay covers, flipper panels, seat backs, cargo cabinets or the like. Further, panel 40 may be used in a number of non-automotive applications, particularly where a recyclable, formable structural member is desired.
A method for manufacturing panels according to embodiments of the present invention will now be described. Skins 42, 44 are cut to the appropriate dimension and, optionally, molded or formed under heat and/or pressure to create the desired shape of the panel. The optional intermediate substrate or center layer 48 is secured between skins 42, 44 prior to or after the covering material 50 is applied to skins 42, 44 (if required). An edge member 54 may then be secured to the panel by engaging anti-reverse fins 58 with the panel or adhering the edge member to the panel. If required, additional hardware, such as handles, connectors or the like, may be installed onto the panel.
The present invention has been particularly shown and described with reference to the foregoing embodiments, which are merely illustrative of the best modes for carrying out the invention. It should be understood by those skilled in the art that various alternatives to the embodiments of the invention described herein may be employed in practicing the invention without departing from the spirit and scope of the invention as defined in the following claims. It is intended that the following claims define the scope of the invention and that the method and apparatus within the scope of these claims and their equivalents be covered thereby. This description of the invention should be understood to include all novel and non-obvious combinations of elements described herein, and claims may be presented in this or a later application to any novel and non-obvious combination of these elements. Moreover, the foregoing embodiments are illustrative, and no single feature or element is essential to all possible combinations that may be claimed in this or a later application.
This application claims the benefit of U.S. Provisional Application No. 60/539,517 filed Jan. 26, 2004, the entire contents of which are herein incorporated by reference.
| Number | Date | Country | |
|---|---|---|---|
| 60539517 | Jan 2004 | US |
