Interior trim component and method of forming same

Abstract

An interior trim component is formed utilizing an injection molding apparatus having first and second molds. The component includes a laminate and a polymer. The laminate includes a face layer having a finished and unfinished side, an adhesive layer bonded to the unfinished side, and a barrier bonded to the adhesive layer. The barrier includes a non-woven textile weighing at least 80 g/m 2 . The laminate is positioned in the first mold such that the barrier is exposed to face the second mold. The apparatus is moved into a closed position and a cavity is established between the barrier and the second mold. The polymer is injected into the cavity at a pressure of at least 500 psi. The polymer reacts with the barrier to bond the laminate to the polymer and to form the interior trim component without the polymer penetrating through the barrier and into the face layer.

1 - 13 . (canceled)  
   
   
       14 . An interior trim component comprising: 
 a laminate having a face layer with a finished and unfinished side, an adhesive layer bonded to said unfinished side of said face layer, and a barrier layer bonded to said adhesive layer, wherein said barrier layer comprises a non-woven textile weighing at least 140 g/m 2 ; and    a polymer reactive with said barrier layer such that said laminate is bonded to said polymer without said polymer penetrating through said barrier layer and into said face layer.    
   
   
       15 . (canceled)  
   
   
       16 . An interior trim component as set forth in  claim 14  wherein said non-woven textile weighs from 140 to 160 g/m 2 .  
   
   
       17 . An interior trim component as set forth in  claim 14  wherein said non-woven textile is further defined as needled fleece.  
   
   
       18 . An interior trim component as set forth in  claim 14  wherein said non-woven textile is selected from the group consisting of needled fleece, polyester fibers, polypropylene fibers, foam, and combinations thereof.  
   
   
       19 . An interior trim component as set forth in  claim 14  wherein said polymer is injection molded, to bond said laminate to said polymer via said barrier layer, at an injection pressure of at least 500 psi.  
   
   
       20 . An interior trim component as set forth in  claim 14  wherein said polymer is injection molded, to bond said laminate to said polymer via said barrier layer, at an injection temperature of from 350 to 575° F.  
   
   
       21 . An interior trim component as set forth in  claim 14  wherein said polymer is selected from the group consisting of ABS, polycarbonate, nylon, polypropylene, and combinations thereof.  
   
   
       22 . An interior trim component as set forth in  claim 14  further comprising a fiber disposed in said polymer for reinforcing said polymer.  
   
   
       23 . An interior trim component as set forth in  claim 14  wherein said face layer of said laminate is selected from the group consisting of polyester warp knits, circular knits, non-woven polyesters, non-woven polypropylenes, rashel fabrics, nylon, and combinations thereof.  
   
   
       24 . An interior trim component as set forth in  claim 14  further comprising a second laminate bonded to said polymer opposite said laminate, wherein said second laminate also has a barrier layer comprising a non-woven textile weighing at least 80 g/m 2  for preventing said polymer from penetrating through said barrier layer of said second laminate and into a face layer of said second laminate.