# US 10,246,023 B2 · Collapsible map pocket with thermoformed polyethylene/polypropylene fibers

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- Number: US 10,246,023 B2
- Document ID: US10246023B2
- Status: Granted
- Kind: B2
- Application number: 15/477,948
- Filed: 2017-04-03
- Published: 2018-10-04
- Granted: 2019-04-02
- Earliest claimed: 2017-04-03
- Assignees: GM Global Technology Operations LLC
- Applicants: GM Global Technology Operations LLC
- Inventors: Eduardo Gutierrez Guzman; Ivan Escutia Figueroa; Fernando Nava Ortiz
- Web page: https://patentgrep.com/patent/US10246023B2

## CPC

- B32B 3/266: {characterised by an apertured layer, the apertures going through the whole thickness of the layer, e.g. expanded metal, perforated layer, slit layer regular cells B32B3/12}
- B60R 7/046: {mounted on door}
- B29C 51/00: Shaping by thermoforming {, i.e. shaping sheets or sheet like preforms after heating}, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor {(blow moulding of tubular preforms B29C49/00, deforming of tubular or hollow preforms B29C67/0014)}
- B32B 3/02: characterised by features of form at particular places, e.g. in edge regions {(non-uniform thickness B32B3/263)}
- B32B 5/022: {Non-woven fabric}
- B32B 5/26: another layer {next to it} also being fibrous or filamentary {(relative arrangement of fibres or filaments of different layers B32B5/12)}
- B32B 7/12: using interposed adhesives or interposed materials with bonding properties
- B32B 37/06: characterised by the heating method
- B32B 37/12: characterised by using adhesives
- B60R 7/081: {for supporting maps}
- B60R 13/0243: {Doors}
- B29C 51/145: {having at least one layer of textile or fibrous material combined with at least one plastics layer}
- B29K 2023/06: {PE, i.e. polyethylene}
- B29K 2023/12: {PP, i.e. polypropylene}
- B29L 2031/3014: {Door linings}
- B29L 2031/3055: {Cars}
- B32B 2250/02: 2 layers
- B32B 2250/20: All layers being fibrous or filamentary
- B32B 2262/0253: Polyolefin fibres
- B32B 2307/72: Density
- B32B 2307/732: Dimensional properties
- B32B 2605/003: Interior finishings
- B60R 2013/0287: {integrating other functions or accessories}
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B60R: VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B29C: SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING (making preforms B29B11/00; making laminated products by combining previously unconnected layers which become one product whose layers will remain together B32B37/00 - B32B41/00)
- B29K: INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR {MOULDS, } REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

A map pocket usable as a trim component for a vehicle door assembly includes an inward-facing, substrate material layer including a polyethylene/polypropylene fibrous, thermoformed material and an outward-facing, A-side material layer including a non-woven, thermoformed material, disposed abuttingly against the substrate material layer.

## Claims

### Claim 1

A map pocket usable as a trim component for a vehicle door assembly, the map pocket comprising:
an inward-facing, substrate material layer comprising a polyethylene/polypropylene fibrous, thermoformed material, wherein the fibrous, thermoformed material comprises two material-types of fibers, polyethylene fibers and polypropylene fibers, that are neither woven nor knitted, but that are blended and laid into a matted form with the fibers randomly oriented in the mat; and
an outward-facing, A-side material layer comprising a non-woven, thermoformed material, disposed abuttingly against the substrate material layer.

### Claim 2 (depends on 1)

The map pocket of claim 1, wherein the map pocket has a shape and configuration that includes at least one substantially horizontal surface and at least one substantially vertical surface.

### Claim 3 (depends on 2)

The map pocket of claim 2, wherein the map pocket has a shape and configuration that includes at least one open end, and wherein objects are storable within the at least one open end against the at least one substantially horizontal surface and the at least one vertical surface.

### Claim 4 (depends on 3)

The map pocket of claim 3, further comprising a flange disposed about the at least one open end.

### Claim 5 (depends on 4)

The map pocket of claim 4, wherein the flange comprises a plurality of attachment point apertures for receiving a fastener.

### Claim 6 (depends on 1)

The map pocket of claim 1, wherein the A-side material layer comprises a Troubador material.

### Claim 7 (depends on 1)

The map pocket of claim 1, wherein the substrate material layer has a density of from about 500 grams per square meter to about 2000 grams per square meter.

### Claim 8 (depends on 1)

The map pocket of claim 1, wherein the substrate material layer has a thickness of about 3 to about 15 millimeters.

### Claim 9 (depends on 1)

The map pocket of claim 1, wherein the A-side material layer has a thickness of about 0.5 to about 5 millimeters.

### Claim 10 (depends on 1)

The map pocket of claim 1, wherein the substrate material layer excludes cut-out void portions, wherein a cut-out void portion is defined as a void within the periphery of the substrate layer that exceeds 5% of the total surface area of the substrate layer.

### Claim 11 (depends on 1)

The map pocket of claim 1, wherein the substrate material layer and the A-side material layer comprise a unitary, bi-layer, thermoformed structure.

### Claim 12 (depends on 1)

The map pocket of claim 1, wherein a ratio of polyethylene fibers to polypropylene fibers in the substrate material layer is from about 80:20 to about 20:80.

### Claim 13

A vehicle comprising:
at least one door assembly, wherein the at least one door assembly comprises a plurality of trim components, wherein at least one of the plurality of trim components comprises a map pocket, and wherein the map pocket comprises:
an inward-facing, substrate material layer comprising a polyethylene/polypropylene fibrous, thermoformed material, wherein the fibrous, thermoformed material comprises two material-types of fibers, polyethylene fibers and polypropylene fibers, that are neither woven nor knitted, but that are blended and laid into a matted form with the fibers randomly oriented in the mat; and
an outward-facing, A-side material layer comprising a non-woven, thermoformed material, disposed abuttingly against the substrate material layer.

### Claim 14 (depends on 13)

The vehicle of claim 13, wherein the substrate material layer is disposed against the at least one door assembly and wherein the A-side material layer faces an interior portion of the vehicle.

### Claim 15 (depends on 13)

The vehicle of claim 13, wherein the map pocket is collapsible and serves as a barrier for protecting passengers of the vehicle against the forces of a side-impact collision.

### Claim 16 (depends on 15)

The vehicle of claim 15, wherein the substrate material layer is tunable to provide the vehicle with varying levels of side impact protection without any change to the shape or configuration of the map pocket.

### Claim 17

A method for manufacturing a map pocket usable as a trim component for a vehicle, the method comprising the steps of:
providing or obtaining a substrate material layer comprising a polyethylene/polypropylene fibrous, thermoformable material, wherein the fibrous, thermoformed material comprises two material-types of fibers, polyethylene fibers and polypropylene fibers, that are neither woven nor knitted, but that are blended and laid into a matted form with the fibers randomly oriented in the mat;
providing or obtaining an A-side material layer comprising a non-woven, thermoformable material; and
disposing the substrate material layer adjacent to the A-side material layer in a thermoforming mold with adhesive between the A-side material layer and the substrate material layer, and thermoforming the substrate material layer with the A-side material layer to form the map pocket as a unitary, bi-layer structure.

### Claim 18 (depends on 17)

The method of claim 17, further comprising, subsequent to the step of thermoforming, performing post-processing steps comprising trimming the map pocket or forming attachment points in the map pocket.

### Claim 19 (depends on 17)

The method of claim 17, further comprising, subsequent to the step of thermoforming, attaching the map pocket to a vehicle door as a trim component of the vehicle door.

### Claim 20 (depends on 17)

The method of claim 17, wherein a ratio of polyethylene fibers to polypropylene fibers in the substrate material layer is from about 80:20 to about 20:80.