Apparatus and method for positioning reinforcement material within an interior trim panel

Abstract

A cassette comprising a frame member having at least two sides interconnected by a cross member, and a reinforcement material partially encapsulated by and suspended by the at least two sides of said frame member such that the reinforcement material is positioned at a predetermined location when placed in a mold tool.

1 .- 10 . (canceled)  
     
     
         11 . A cassette, comprising: 
 a frame member having at least two sides interconnected by a cross member; and    a reinforcement material partially encapsulated by and suspended by the at least two sides of said frame member such that the reinforcement material is positioned at a predetermined location when placed in a mold tool.    
     
     
         12 . The cassette of  claim 11 , wherein said frame member includes a spacer lug for positioning said reinforcement material at the predetermined location within the mold tool.  
     
     
         13 . The cassette of  claim 11 , wherein the at least two sides are two opposing sides, and wherein the reinforcement material is secured to the two opposite sides of the frame member.  
     
     
         14 . An interior trim panel, comprising: 
 a layer of material, and    a cassette disposed within the layer of material, the cassette including a frame member having at least two sides interconnected by a cross member, and a reinforcement material partially encapsulated by and suspended by the at least two sides of said frame member, wherein the reinforcement material is positioned at a predetermined location within the layer of material.    
     
     
         15 . The interior trim panel of  claim 14 , further comprising a shear plane located at an intersection of the frame member and the layer of material.  
     
     
         16 . The interior trim panel of  claim 15 , wherein the frame member comprises material having a first mold characteristic and the layer of material has a second mold characteristic that is at least partially incompatible with the first mold characteristic of the frame member such that the incompatibility substantially defines the shear plane.  
     
     
         17 . The interior trim panel of  claim 16 , wherein the first mold characteristic and the second mold characteristic are fully incompatible.  
     
     
         18 . The interior trim panel of  claim 14 , wherein the frame member and the layer of material are bondably attached.  
     
     
         19 . The interior trim panel of  claim 15 , further comprising a knife edge on the frame member substantially aligned with the shear plane  
     
     
         20 . The interior trim panel of  claim 18  wherein the frame member and the layer of material is are not fully bondably attached and define the shear plane.  
     
     
         21 . The interior trim panel of  claim 14 , further comprising an outer cassette member for positioning the reinforcement material outside a tear seam of the trim panel.  
     
     
         22 . The interior trim panel of  claim 14 , wherein the cassette further comprises at least one spacer lug for positioning the reinforcement material.  
     
     
         23 . The interior trim panel of  claim 14 , wherein the frame member includes two opposing sides, and wherein the reinforcement material is secured to the two opposite sides of the frame member.  
     
     
         24 . An interior trim panel, comprising: 
 a layer of material;    a reinforcement material; and    means for partially encapsulating and suspending said reinforcement material to define a cassette such that said reinforcement material is positioned at a predetermined location when placed in a mold tool.    
     
     
         25 . The interior trim panel of  claim 24 , wherein the partially encapsulating and suspending means is selected from the group consisting of a frame member and a spine having ribs.  
     
     
         26 . The interior trim panel of  claim 24 , wherein the partially encapsulating and suspending means is a frame member comprising at least two sides interconnected by a cross member, and wherein said reinforcement material is partially encapsulated by and suspended by the at least two sides of said frame member.  
     
     
         27 . The interior trim panel of  claim 24 , further comprising a shear plane defined at an interface between the partially encapsulating and suspending means and the layer of material.  
     
     
         28 . The interior trim panel of  claim 27 , wherein the partially encapsulating and suspending means has a first mold characteristic and the layer of material has a second mold characteristic that is incompatible with the first mold characteristic such that the incompatibility therebetween defines the shear plane.  
     
     
         29 . The interior trim panel of  claim 27 , further comprising a knife edge on the partially encapsulating and suspending means substantially aligned with the shear plane  
     
     
         30 . The interior trim panel of  claim 24 , further comprising an outer cassette member for positioning the reinforcement material outside a tear seam of the trim panel.