# US 5,705,003 A · Method for manufacturing a linear vibration welded carpeted panel

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- Number: US 5,705,003 A
- Document ID: US5705003A
- Status: Granted
- Kind: A
- Application number: 08/651,187
- Filed: 1996-05-17
- Granted: 1998-01-06
- Earliest claimed: 1992-12-21
- Assignees: Ford Motor Company
- Inventors: Samuel Farrow; Lee Avrial Walker; Paul E. Debbaudt; Aaron S. Wisniewski
- Web page: https://patentgrep.com/patent/US5705003A

## CPC

- B29C 66/5326: {said single elements being substantially flat}
- B29C 65/0618: {Linear}
- B29C 66/1122: {Single lap to lap joints, i.e. overlap joints (B29C66/45, B29C66/472, B29C66/52272 take precedence)}
- B29C 66/80: {General aspects of machine operations or constructions and parts thereof}
- B29C 66/81429: {comprising a single tooth}
- B29C 66/81433: {being toothed, i.e. comprising several teeth or pins (comprising a single tooth B29C66/81429), or being patterned}
- B29C 66/81461: {being multi-lamellar or segmented, i.e. comprising a plurality of strips, plates or stacked elements}
- B32B 37/04: characterised by the partial melting of at least one layer
- B29C 66/4724: {said single elements being appliques, e.g. in the form of a text or drawing}
- B29C 66/71: {characterised by the composition of the plastics material of the parts to be joined (welding bar compositions B29C65/125)}
- B29C 66/712: {the composition of one of the parts to be joined being different from the composition of the other part}
- B29L 2031/3005: {Body finishings}
- B29L 2031/732: {Floor coverings (piles carpets B29L2031/7652; for vehicles B29L2031/3017)}
- B32B 2310/028: using vibration, e.g. sonic or ultrasonic
- 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
- B29L: INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES

## Abstract

The present invention relates to a method of producing a carpeted vehicle interior panel. A rigid backing having a carpeted surface and a mating surface is molded such that the backing mating surface is 3-dimensional and self-supporting after molding. The backing is overlaid atop the panel with the mating surface juxtaposed a mating surface of the panel. The backing is secured to the panel by linear welding.

## Claims

### Claim 1

A method of producing a carpeted vehicle interior panel comprising the steps of:
providing a rigid backing having a carpeted surface and a mating surface;
molding said backing such that said backing mating surface is three-dimensionally contoured shaped, said backing being self-supporting after molding;
overlaying said backing atop a panel, said backing mating surface juxtaposed a three-dimensionally contoured shaped mating surface of said panel; and securing said backing to said panel by linear vibration welding, whereby said backing mating surface welds to said panel mating surface to form said carpeted vehicle interior panel.

### Claim 2 (depends on 1)

The method of claim 1, further comprising the step of:
rendering said backing mating surface permeable to said welded panel mating surface, said welding causing said panel mating surface to soften and permeate said backing mating surface.

### Claim 3 (depends on 2)

The method of claim 2, wherein said rendering step comprises:
securing a permeable layer to said backing, said permeable layer juxtaposed said panel mating surface, said welding causing said panel mating surface to soften and permeate said permeable layer.

### Claim 4 (depends on 1)

The method of claim 1, further comprising forming positioning means on said backing mating surface and said panel mating surface, and aligning said backing positioning means with said panel positioning means prior to said welding step.

### Claim 5

A method of producing a carpeted vehicle interior panel comprising the steps of:
providing a rigid backing having a carpeted surface and a permeable layer;
molding said backing such that said backing is three-dimensionally contoured shaped and self-supporting and forming positioning means in said backing;
overlaying said backing atop a panel, said backing positioning means aligning with positioning means on said panel, said permeable layer juxtaposed a three-dimensionally contoured shaped mating surface of said panel; and securing said backing to said panel by linear vibration welding, said welding causing said panel mating surface to soften and permeate said permeable layer to form said carpeted vehicle interior panel .