# US 11,305,464 B2 · Vehicle interior board and method for manufacturing same

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- Number: US 11,305,464 B2
- Document ID: US11305464B2
- Status: Granted
- Kind: B2
- Application number: 16/338,180
- Filed: 2016-12-28
- Published: 2020-01-23
- Granted: 2022-04-19
- Earliest claimed: 2016-12-28
- Assignees: MORIDEN Co., Ltd.
- Applicants: MORIDEN Co. , Ltd.
- Inventors: Junichi Ishii; Yoshitaka Maehara; Takumi Ono
- Web page: https://patentgrep.com/patent/US11305464B2

## CPC

- B29C 39/10: incorporating preformed parts or layers, e.g. casting around inserts or for coating articles {(coating a surface by casting in general B05D1/30, B29C39/126 takes precedence)}
- B29C 45/14508: {Joining juxtaposed sheet-like articles, e.g. for making trim panels}
- B29C 44/1228: {Joining preformed parts by the expanding material}
- B29C 44/143: {Means for positioning the lining in the mould (in general B29C33/12)}
- B32B 3/04: characterised by {at least one} layer folded at the edge, e.g. over another layer {; characterised by at least one layer enveloping or enclosing a material}
- B32B 3/08: characterised by added members at particular parts {(layer formed of separate pieces of material which are juxtaposed side-by-side B32B3/14, B32B3/18)}
- 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}
- B32B 3/28: characterised by a layer comprising a deformed thin sheet {, i.e. the layer having its entire thickness deformed out of the plane}, e.g. corrugated, crumpled (B32B29/08 takes precedence)
- B32B 5/022: {Non-woven fabric}
- B32B 5/20: foamed in situ
- B32B 15/046: {of foam}
- B32B 15/095: comprising polyurethanes
- B32B 15/14: next to a fibrous or filamentary layer
- B32B 15/18: comprising iron or steel {(B32B15/011, B32B15/012 and B32B15/013 take precedence)}
- B32B 15/20: comprising aluminium or copper {(B32B15/016 and B32B15/017 take precedence)}
- B60R 13/02: {Internal} Trim mouldings {; Internal} Ledges; Wall liners {for passenger compartments}; Roof liners (B60R13/01 takes precedence {; padded linings for the vehicle interior B60R21/04; arrangements or adaptations of floor mats or carpets in vehicles B60N3/04; internal lining for trains B61D17/18})
- B29C 2045/14237: {the inserts being deformed or preformed outside the mould or mould cavity}
- B29C 2045/14319: {bonding by a fusion bond}
- B29C 2045/14532: {injecting between two sheets}
- B29K 2075/00: Use of {PU, i.e.} polyureas or polyurethanes {or derivatives thereof}, as moulding material
- B29K 2105/04: cellular or porous
- B29K 2705/00: Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
- B29L 2007/002: {Panels; Plates; Sheets}
- B29L 2009/003: {comprising a metal layer}
- B29L 2031/30: Vehicles, e.g. ships or aircraft, or body parts thereof {(vanes or blades B29L2031/08, air bags B29L2022/027)}
- B29L 2031/3005: {Body finishings}
- B29L 2031/3041: {Trim panels}
- B32B 27/40: comprising polyurethanes
- B32B 2250/44: Number of layers variable across the laminate
- B32B 2255/06: on metal layer
- B32B 2255/26: Polymeric coating
- B32B 2262/0284: Polyethylene terephthalate [PET] or polybutylene terephthalate [PBT]
- B32B 2266/0278: Polyurethane
- B32B 2307/208: Magnetic, paramagnetic
- B32B 2307/732: Dimensional properties
- B32B 2605/003: Interior finishings
- B60R 13/01: Liners for load platforms or load compartments
- F16B 5/0004: {Joining sheets, plates or panels in abutting relationship (F16B5/01 takes precedence)}
- F16B 37/048: {Non-releasable devices (F16B37/044, F16B37/045 and F16B37/06 take precedence)}
- 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)
- 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
- 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
- F16B: DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING (couplings for transmitting rotation F16D)

## Abstract

A vehicle interior board which has less deterioration and peeling near an end portion of a metal plate, has high quality, is thin, lightweight, and has high strength and excellent productivity. The vehicle interior board includes a pair of metal plates and a foamed polyurethane layer formed between the pair of metal plates. At the peripheral edge portion of the vehicle interior board, the foamed polyurethane layer covers peripheral end portions of the metal plates and is formed flush with outer surfaces of the metal plates. This makes it possible to suppress oxidation of the peripheral end portions which are cutting surfaces of the metal plates. Further, bonding is good between the metal plates and the foamed polyurethane layer. Further, it is possible to prevent peeling of the metal plates, chipping of the foamed polyurethane layer, and the like. Furthermore, it is easy to demold a vehicle interior board.

## Claims

### Claim 1

A method for manufacturing a vehicle interior board, comprising:
a step of molding a pair of metal plates respectively into predetermined shapes;
a step of applying an epoxy resin-based coating agent to main surfaces respectively corresponding to inner surfaces of the pair of metal plates with;
a step of forming a molding space between the pair of metal plates by sandwiching the pair of metal plates between a lower mold and an upper mold so that the main surfaces corresponding to the inner surfaces coated with the coating agent face each other; and
a step of forming a foamed polyurethane layer by reacting raw materials of foamed polyurethane injected into the molding space,
wherein a setting surface, which has a planar shape larger than that of the metal plate and on which the metal plate is set so that an outer surface of the metal plate abuts the setting surface, is formed in each of the lower mold and the upper mold,
lower mold protuberances protruding from the setting surface are formed in the lower mold,
in the step of molding the metal plates, positioning holes are formed in the metal plate, and
in the step of forming the molding space, the metal plate is set so that the positioning holes of the metal plate arranged on the lower mold side are fitted to the lower mold protuberances, and each of the pair of metal plates is disposed near a center of the setting surface,
wherein the foamed polyurethane layer covers peripheral end portions of the metal plates, and the foamed polyurethane layer is formed flush with outer surfaces of the metal plates,
wherein a chamfered portion is formed at a corner portion of the foamed polyurethane layer, and the chamfered portion is located outside the peripheral end portions of the metal plates, and
a step of forming a handle hole through a handle hole forming portion, wherein the handle hole forming portion is located in a recess of the lower mold, wherein a channel groove, through which the raw materials of foamed polyurethane flow, is located on an upper surface of the handle hole forming portion.

### Claim 2 (depends on 1)

The method for manufacturing the vehicle interior board according to claim 1, wherein
in the step of forming the foamed polyurethane layer, mounting holes for mounting other components on the vehicle interior board are formed at positions corresponding to the lower mold protuberances.

### Claim 3 (depends on 1)

The method for manufacturing the vehicle interior board according to claim 1, wherein
at least one of the lower mold protuberances abuts the main surface corresponding to the inner surface of the metal plate disposed on the upper mold side.

### Claim 4 (depends on 1)

The method for manufacturing the vehicle interior board according to claim 1, wherein
at least one of the lower mold protuberances is formed to reach the upper mold, and
in the step of molding the metal plates, the positioning hole is formed in the metal plate disposed on the upper mold side so as to correspond to a position of each of the at least one of the lower mold protuberances reaching the upper mold.

### Claim 5 (depends on 4)

The method for manufacturing the vehicle interior board according to claim 4, wherein
one or more upper mold protuberances protruding from the setting surface and abutting the lower mold protuberances are formed on the upper mold so as to correspond to each of the position of the at least one lower mold protuberances reaching the upper mold, and
in the step of forming the molding space, the metal plate is set so that the positioning holes of the metal plate arranged on the upper mold side are fitted to the upper mold protuberances.

### Claim 6 (depends on 4)

The method for manufacturing the vehicle interior board according to claim 4, wherein
at least one of the lower mold protuberances reaching the upper mold has a step portion abutting the main surface corresponding to the inner surface of the metal plate disposed on the upper mold side, and a protrusion protruding from the step portion, wherein the protrusion is fitted into the positioning hole formed in the metal plate disposed on the upper mold side.

### Claim 7 (depends on 1)

The method for manufacturing the vehicle interior board according to claim 1, wherein
the setting surface of at least one of the upper mold and the lower mold is provided with a vacuum hole opening to the setting surface and a sealing member surrounding a periphery of the vacuum hole, and
in the step of forming the molding space, an inside of the vacuum hole is depressurized, the metal plate is sucked in a region surrounded by the sealing member, and the metal plate set on the setting surface is held in the lower mold or the upper mold.

### Claim 8 (depends on 1)

The method for manufacturing the vehicle interior board according to claim 1, wherein
in the step of forming the molding space, a reinforcing member is disposed around the positioning hole fitted to the lower mold protuberance between the pair of metal plates,
in the step of forming the foamed polyurethane layer, the reinforcing member is fixed in the foamed polyurethane layer.

### Claim 9 (depends on 1)

The method for manufacturing the vehicle interior board according to claim 1, each metal plate is in a shape of a waveform.

### Claim 10 (depends on 1)

The method for manufacturing the vehicle interior board according to claim 1, the chamfered portion is in a rounded shape.