# US 7,744,983 B2 · Laminated structure and method for manufacturing the same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,744,983 B2 - Document ID: US7744983B2 - Status: Granted - Kind: B2 - Application number: 10/229,211 - Filed: 2002-08-28 - Published: 2004-03-04 - Granted: 2010-06-29 - Earliest claimed: 2002-08-28 - Assignees: Kasai Kogyo Co., Ltd. - Inventors: Tetsuyuki Ota; Masahiko Hara; Tatsushi Ohno; Hiroyuki Aizawa; Kiyohiko Obara - Web page: https://patentgrep.com/patent/US7744983B2 ## CPC - B32B 5/18: characterised by features of a layer {of} foamed material - B29C 45/14336: {Coating a portion of the article, e.g. the edge of the article (B29C45/14573 and B29C45/14598 take precedence)} - B29C 45/1671: {with an insert} - B32B 1/00: Layered products having a non-planar shape - B32B 3/26: characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids {(foam layer B32B5/18; layer of synthetic resin characterised by fillers that create voids or cavities B32B27/205); characterised by an apertured layer} - B32B 27/00: Layered products comprising {a layer of} synthetic resin {(fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18)} - B32B 27/283: {comprising polysiloxanes} - 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 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)} - B29C 51/10: Forming by pressure difference, e.g. vacuum - B29K 2105/043: {Skinned foam} - B29L 2031/3014: {Door linings} - B32B 2250/05: 5 or more layers - B32B 2250/24: All layers being polymeric - B32B 2250/44: Number of layers variable across the laminate - B32B 2255/26: Polymeric coating - B32B 2255/28: Multiple coating on one surface - B32B 2307/402: Coloured - B32B 2323/04: Polyethylene - B32B 2323/10: Polypropylene - B32B 2325/00: Polymers of vinyl-aromatic compounds, e.g. polystyrene - B32B 2327/06: PVC, i.e. polyvinylchloride - B32B 2355/02: ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers - B32B 2398/20: Thermoplastics - B32B 2439/00: Containers; Receptacles - B32B 2451/00: Decorative or ornamental articles - B32B 2605/08: Cars - Y10T 428/24174: including sheet or component perpendicular to plane of web or sheet - Y10T 428/24612: Composite web or sheet - Y10T 428/24777: Edge feature - Y10T 428/249989: Integrally formed skin - B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM - 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) - 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 - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract The laminated structure includes a lightweight and shape-retaining foamed resin base member, an outer circumference frame integrally laminated on the reverse side of the foamed resin base member along the outer circumference of an article, and bridging ribs connecting between respective points on the outer circumference frame. Accordingly, the present invention provides a lightweight laminated structure with low cost by reducing the amount of the resin used, since the molded synthetic resin outer circumference frame and bridging ribs have small projection areas. ## Claims ### Claim 1 A laminated structure for a vehicle interior component comprising: a vehicle interior component base member comprising a sheet of shape-retaining foamed resin molded into a predetermined shape having a continuous peripheral edge, a first side having a central area, and a second side suitable for use as an automobile interior; and an outer circumferential frame, said outer circumferential frame configured to reinforce rigidly and comprising a molded synthetic resin assembly, integrally laminated on the first side of the base member along only a portion of the continuous peripheral edge, wherein the peripheral edge is shaped and configured to connect without gaps to body panels and other adjacent components. ### Claim 2 (depends on 1) The laminated structure according to claim 1, further comprising bridging ribs integrally laminated to the first side of the base member and connecting between respective points on the outer circumferential frame across the central area of the base member. ### Claim 3 (depends on 2) The laminated structure according to claim 2, wherein the bridging ribs have a cross sectional shape configured to reinforce rigidly, the bridging ribs including a flat portion in flat contact with the first side of the base member. ### Claim 4 (depends on 2) The laminated structure according to claim 2, wherein a thickness of the bridging ribs corresponds respectively to the strength of the external force expected to be applied to an article formed using the laminated structure. ### Claim 5 (depends on 2) The laminated structure according to claim 2, wherein at least one mounting seat for mounting a functional member to the laminated structure is integrally molded with the outer circumferential frame or with the bridging ribs. ### Claim 6 (depends on 1, 2) The laminated structure according to claim 1 or claim 2, wherein a surface skin is integrally laminated on a second surface of the base member. ### Claim 7 (depends on 1, 2) The laminated structure according to claim 1 or claim 2, further comprising a molded synthetic resin assembly attached to said laminated structure so as to be integrally molded with the outer circumferential frame of the laminated structure. ### Claim 8 (depends on 2) The laminated structure according to claim 2, further comprising mountings supported on the bridging ribs for attaching automobile interior features to the laminated structure. ### Claim 9 (depends on 1) The laminated structure according to claim 1, wherein said laminated structure comprises an automotive door panel. ### Claim 10 (depends on 1) The laminated structure according to claim 1, wherein said sheet of shape-retaining foamed resin comprises a thermoplastic resin and a foaming agent added therein. ### Claim 11 (depends on 1) The laminated structure according to claim 1, wherein said sheet of shape-retaining foamed resin comprises a polypropylene based resin and sodium bicarbonate added therein. ### Claim 12 (depends on 1) The laminated structure according to claim 1, wherein said outer circumferential frame comprises a polypropylene based resin. ### Claim 13 (depends on 1) The laminated structure according to claim 1, wherein said outer circumferential frame comprises a polypropylene based resin and said sheet of shape-retaining foamed resin comprises a polypropylene based resin and sodium bicarbonate added therein. ### Claim 14 A vehicle interior laminated structure comprising: a vehicle interior shape-retaining base member molded into a predetermined shape from a foamed resin sheet and having a continuous peripheral edge, a first side having a central area, and a mutually-complementary second side; and a circumferential frame configured to reinforce rigidly and comprising an injection-molded synthetic resin integrally laminated on the first side of the base member along only a portion of the continuous peripheral edge. ### Claim 15 A vehicle interior component, comprising: a vehicle interior component base member comprising a sheet of shape-retaining foamed resin molded into a predetermined shape having a peripheral edge and a first side having a central area; a frame configured to reinforce rigidly and comprising a molded synthetic resin assembly, integrally laminated on the first side of the base member along at least a portion of the peripheral edge, wherein said frame has an opening corresponding to said central area of said first side of said sheet of shape-retaining foamed resin; and at least one rib integrally laminated to the central area of said first side of the base member.