Sealing systems and related methods for automotive interior trim panels and the like

Abstract

A combined trim panel and water shield includes a water shield having opposite first and second surfaces, and is of a size and shape to generally conform to a door panel and a trim panel to be protected. The trim panel is configured to cover a vehicle door panel and has a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface. A first sealing layer, applied in a predetermined pattern, engages the first surface of the water shield and the second surface of the trim panel. A second sealing layer, applied in a predetermined pattern, engages the second surface of the water shield. In a further aspect, a sealing system is provided for application to a vehicle interior trim panel to prevent the entry of water or dust into an interior compartment of the vehicle. The system includes a trim panel configured for covering a vehicle door panel wherein the trim panel has a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface. At least one compressible sealing member engages the trim panel and provides a sealing interference between the vehicle door panel and the trim panel when the trim panel is installed on the door panel.

1 . A combined trim panel and water shield assembly for a vehicle comprising: 
 a trim panel configured for covering a vehicle door panel, the trim panel having a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface;    a generally flat water shield having opposite first and second surfaces and having a size and shape to generally conform to a surface of said trim panel and a surface of said door panel;    a first adhesive layer engaging the first surface of the flat sheet and the second surface of the trim panel, the first adhesive layer applied in a first predetermined pattern; and    a second adhesive layer engaging the second surface of the flat sheet and applied in a second predetermined pattern.    
     
     
         2 . The combined trim panel and water shield assembly of  claim 1 , wherein the water shield comprises a sheet of flexible plastic material.  
     
     
         3 . The combined trim panel and water shield assembly of  claim 1 , wherein the water shield comprises a sheet of foam material.  
     
     
         4 . The combined trim panel and water shield assembly of  claim 1 , wherein the first and second predetermined patterns are the same.  
     
     
         5 . The combined trim panel and water shield assembly of  claim 1 , further comprising: 
 a protective sheet removably engaging the second adhesive layer.    
     
     
         6 . The combined trim panel and water shield assembly of  claim 5 , wherein the protective sheet comprises a release-treated plastic sheet.  
     
     
         7 . The combined trim panel and water shield assembly of  claim 1 , wherein the first and second adhesive layers are the same or different, and are selected from the group consisting of removable pressure-sensitive adhesives, permanent pressure-sensitive adhesives, and a compressible seal.  
     
     
         8 . The combined trim panel and water shield assembly of  claim 7 , wherein the first adhesive material is a permanent pressure-sensitive adhesive and the second adhesive material is a compressible seal.  
     
     
         9 . The combined trim panel and water shield assembly of  claim 7 , wherein the first adhesive material is a temporary pressure-sensitive adhesive and the second adhesive material is a permanent pressure-sensitive adhesive.  
     
     
         10 . A method for the production of a combined water shield and trim panel structure, comprising: 
 providing a trim panel configured to cover a door panel, the trim panel having a first surface configured to face an interior compartment of a vehicle;    providing a generally flat sheet of material having opposite first and second surfaces and having a size and shape to generally conform to the trim panel and the door panel;    applying a first adhesive material to the first surface of the flat sheet in a first predetermined pattern;    applying a second adhesive material to the second surface of the flat sheet in a second predetermined pattern;    aligning the flat sheet and the trim panel so that the first surface of the flat sheet is in facing relation with a second surface of the trim panel, the second surface of the trim panel opposite the first surface thereof; and    contacting the trim panel with the first adhesive to attach the trim panel to the water shield.    
     
     
         11 . The method of  claim 10 , wherein the flat sheet comprises a sheet of flexible plastic material.  
     
     
         12 . The method of  claim 10 , wherein the flat sheet comprises a sheet of foam material.  
     
     
         13 . The method of  claim 10 , wherein the first and second predetermined patterns are the same.  
     
     
         14 . The method of  claim 10 , further comprising: 
 removably applying a protective sheet of material to the second adhesive layer.    
     
     
         15 . The method of  claim 14 , wherein the protective sheet comprises a release-treated plastic sheet.  
     
     
         16 . The method of  claim 10 , wherein the first and second adhesive layers are the same or different, and are selected from the group consisting of removable pressure-sensitive adhesives, permanent pressure-sensitive adhesives, and a compressible seal.  
     
     
         17 . The method of  claim 16 , wherein the first adhesive material is a permanent pressure-sensitive adhesive and the second adhesive material is a compressible seal.  
     
     
         18 . The method of  claim 16 , wherein the first adhesive material is a temporary pressure-sensitive adhesive and the second adhesive material is a permanent pressure-sensitive adhesive.  
     
     
         19 . A sealing system for application to a vehicle inner door panel for preventing the entry of water or dust from entering an interior compartment of the vehicle, comprising: 
 a trim panel configured for covering the vehicle door panel, the trim panel having a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface; and    a sealing member engaging at least one of the trim panel and the vehicle door panel and providing a sealing interference between the vehicle door panel and the trim panel when the trim panel is installed on the door panel.    
     
     
         20 . The sealing system of  claim 19 , wherein the sealing member comprises a compressible gasket engaging a peripheral edge of one of the vehicle door panel and the trim panel.  
     
     
         21 . The sealing system of  claim 20 , wherein said gasket does not completely circumscribe the peripheral edge.  
     
     
         22 . The sealing system of  claim 20 , wherein said gasket completely circumscribes the peripheral edge.  
     
     
         23 . The sealing system of  claim 20 , wherein the sealing member forms one or more bands and further comprising a second sealing member engaging one of the vehicle door panel and the trim panel within the one or more peripheral bands of the first sealing member.  
     
     
         24 . The sealing system of  claim 23 , wherein the second sealing member circumscribes one or both of an opening in the trim panel and an opening in the door panel.  
     
     
         25 . The sealing system of  claim 19 , wherein the sealing member is retained on the trim panel using one or more mechanical fasteners.  
     
     
         26 . The sealing system of  claim 19 , wherein the sealing member is attached to one of the vehicle door panel and the trim panel using an adhesive.  
     
     
         27 . The sealing system of  claim 19 , wherein the sealing member is attached to one of the vehicle door panel and the trim panel using a combination of adhesive and one or more mechanical fasteners.  
     
     
         28 . The sealing system of  claim 19 , further comprising: 
 a plurality of mechanical fasteners which engage the trim panel, the sealing member, and the door panel.    
     
     
         29 . The sealing system of  claim 19 , wherein the door panel comprises a generally flat portion which is aligned with and sealingly engages the sealing member when the trim panel is installed on the door panel.  
     
     
         30 . The sealing system of  claim 19 , wherein the trim panel comprises one or more pressure ribs engaging the sealing member.  
     
     
         31 . The sealing system of  claim 19 , wherein the sealing member comprises a compressible foam material.  
     
     
         32 . The sealing system of  claim 19 , wherein the sealing members is an adhesive.  
     
     
         33 . The sealing system of  claim 19 , wherein the sealing member is a removable pressure-sensitive adhesive.  
     
     
         34 . The sealing system of  claim 19 , wherein the sealing member is a generally permanent pressure-sensitive adhesive.  
     
     
         35 . The sealing system of  claim 19 , wherein the sealing member is compressible forming a compression-type gasket when the trim panel is attached to the vehicle door panel.  
     
     
         36 . The sealing system of  claim 19 , wherein the sealing member is a compressible formed-in-place gasket.  
     
     
         37 . The sealing system of  claim 19 , wherein the sealing member is a compressible water shield adapted to be disposed between the door panel and trim panel.  
     
     
         38 . The sealing system of  claim 19 , further comprising a water shield engaging the sealing member and adapted to be disposed between the door panel and trim panel.  
     
     
         39 . The sealing system of  claim 38 , wherein the water shield is compressible.  
     
     
         40 . The sealing system of  claim 39 , wherein the water shield is a foam material.  
     
     
         41 . The sealing system of  claim 40 , wherein the water shield is an open-cell foam material.  
     
     
         42 . The sealing system of  claim 40 , wherein the water shield is a closed-cell foam material.  
     
     
         43 . The sealing system of  claim 38 , wherein the water shield is non-compressible.  
     
     
         44 . The sealing system of  claim 43 , wherein the water shield is rigid.  
     
     
         45 . The sealing system of  claim 38 , wherein the water shield is a polymer film.  
     
     
         46 . The sealing system of  claim 19 , further comprising a release coated protective liner applied over the sealing member for removal prior to the installation of the trim panel to the vehicle door panel.  
     
     
         47 . The sealing system of  claim 19 , further comprising a second sealing member engaging the other of the trim panel and the vehicle door panel and providing a sealing interference between the vehicle door panel and the trim panel when the trim panel is installed on the door panel.  
     
     
         48 . The sealing system of  claim 47  wherein the first and second sealing members are formed of the same material.  
     
     
         49 . The sealing system of  claim 47  wherein the first and second sealing members are formed of different materials.  
     
     
         50 . A method for sealing a vehicle door interior trim panel against entry of water or dust, comprising: 
 attaching at least one compressible sealing member to a trim panel such that the at least one sealing member is positioned to provide a sealing interference between the door panel and the trim panel when the trim panel is installed on the door panel; and    installing the trim panel retaining the at least one compressible sealing member onto the door panel.    
     
     
         51 . The method of  claim 50 , wherein the sealing member is retained on the trim panel using one or more mechanical fasteners.  
     
     
         52 . The method of  claim 50 , wherein the sealing member is attached to the trim panel using an adhesive.  
     
     
         53 . The method of  claim 50 , wherein the sealing member is attached to the trim panel using a combination of adhesive and one or more mechanical fasteners.  
     
     
         54 . The method of  claim 50 , further comprising: 
 a plurality of mechanical fasteners which engage the trim panel, the one or more compressible sealing members, and the door panel.    
     
     
         55 . A stacked plurality of sealing systems, each adapted for application to a vehicle door panel, comprising: 
 a first sealing system including (i) a first trim panel adapted to cover a vehicle door panel, said first trim panel having a first surface configured to face an interior compartment of the vehicle and a second surface opposite said first surface, and (ii) a first sealing member engaging said first trim panel and providing a sealing interference between said vehicle door panel and said first trim panel when the first trim panel is installed on the vehicle door panel;    a second sealing system positioned adjacent said first sealing system, said second sealing system including (i) a second trim panel adapted to cover a vehicle door panel, said second trim panel having a first surface configured to face an interior compartment of the vehicle and a second surface opposite said first surface, and (ii) a second sealing member engaging said second trim panel and providing a sealing interference between said vehicle door is panel and said second trim panel when the second trim panel is installed on the vehicle door panel; and    a releasable protective liner disposed between said first and said second sealing systems.    
     
     
         56 . The stacked plurality of sealing systems of  claim 55  further comprising: 
 an adhesive disposed on at least one of said first sealing member and said second sealing member, said adhesive contacting said protective liner.    
     
     
         57 . A combined trim panel and water shield assembly for a vehicle comprising: 
 a trim panel adapted for covering a vehicle door panel, the trim panel having a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface;    a generally flat non-compressible water shield having opposite first and second surfaces and having a size and shape to generally conform to a surface of said trim panel and a surface of said vehicle door panel; and    an adhesive layer engaging the first surface of the flat sheet and the second surface of the trim panel, the first adhesive layer applied in a first predetermined pattern.    
     
     
         58 . A combined trim panel and water shield assembly for a vehicle comprising: 
 a trim panel configured for covering a vehicle door panel, the trim panel having a first surface configured to face an interior compartment of the vehicle and a second surface opposite the first surface;    a generally flat non-compressible water shield having opposite first and second surfaces and having a size and shape to generally conform to a surface of said trim panel and a surface of said vehicle door panel, said first surface of said flat sheet engaging said trim panel; and    an adhesive layer engaging the second surface of the flat sheet and applied in a predetermined pattern adapted to engage said vehicle door panel.