Method and apparatus for nonwoven trim panels

Abstract

A method of forming a trim panel is provided. The method including the steps of: placing a non-woven mat of material in a heating press; heating the material to a predetermined temperature; applying a decorative film to a first surface of the heated material to create a bilaminate; placing the bilaminate layer into a cavity of a tool such that the decorative film is facing the cavity; heating the cavity; and injecting a thermoplastic resin into the tool such that the thermoplastic resin is adhered to a second surface of the material, the second surface being opposite to the first surface. Also disclosed is the trip panel formed by the foregoing method.

What is claimed is: 
     
         1 . An automotive interior trim panel comprising a thermoplastic decorative film disposed on a first side of a non-woven mat and injection molded features disposed on a second side of the non-woven mat, wherein the second side of the non-woven mat is opposite the first side and the decorative film has a thickness of 0.1 to 0.5 millimeters. 
     
     
         2 . The automotive interior trim panel of  claim 1 , wherein the thermoplastic decorative film comprises a thermoplastic olefin. 
     
     
         3 . The automotive interior trim panel of  claim 1 , wherein the non-woven mat comprises natural fibers and manmade fibers. 
     
     
         4 . The automotive interior trim panel of  claim 1 , wherein the non-woven mat comprises a combination of flax and polypropylene. 
     
     
         5 . The automotive interior trim panel of  claim 1 , wherein the thermoplastic decorative film comprises a layer of foam. 
     
     
         6 . The automotive interior trim panel of  claim 1 , wherein the combination of the non-woven mat and decorative film has a thickness of 0.5 to 1.5 millimeters. 
     
     
         7 . An automotive interior comprising a thermoplastic decorative film disposed on a first side of a non-woven mat and injection molded features disposed on a second side of the non-woven mat, wherein the second side of the non-woven mat is opposite the first side and the non-woven mat, prior to forming the automotive interior trim panel, has an areal weight of 600 to 2500 grams per square meter. 
     
     
         8 . The automotive interior trim panel of  claim 7 , wherein the thermoplastic decorative film comprises a thermoplastic olefin. 
     
     
         9 . The automotive interior trim panel of  claim 7 , wherein the non-woven mat comprises natural fibers. 
     
     
         10 . The automotive interior trim panel of  claim 7 , wherein the non-woven mat comprises a combination of flax and polypropylene. 
     
     
         11 . The automotive interior trim panel of  claim 7 , wherein the thermoplastic decorative film comprises a layer of foam. 
     
     
         12 . The automotive interior trim panel of  claim 7 , wherein the combination of the non-woven mat and decorative film has a thickness of 0.5 to 1.5 millimeters. 
     
     
         13 . An automotive interior trim panel consisting of a thermoplastic decorative film disposed on a first side of a non-woven mat and injection molded features disposed on a second side of the non-woven mat. 
     
     
         14 . The automotive interior trim panel of  claim 13 , wherein the thermoplastic decorative film comprises a thermoplastic olefin. 
     
     
         15 . The automotive interior trim panel of  claim 13 , wherein the non-woven mat comprises natural fibers and manmade fibers. 
     
     
         16 . The automotive interior trim panel of  claim 13 , wherein the non-woven mat comprises a combination of flax and polypropylene. 
     
     
         17 . The automotive interior trim panel of  claim 13 , wherein the combination of the non-woven mat and decorative film has a thickness of 0.5 to 1.5 millimeters. 
     
     
         18 . The automotive interior trim panel of  claim 13 , wherein the decorative film has a thickness of 0.1 to 0.5 millimeters. 
     
     
         19 . The automotive interior trim panel of  claim 13 , wherein the non-woven mat, prior to forming the automotive interior trim panel, has an areal weight of 600 to 2500 grams per square meter. 
     
     
         20 . The automotive interior trim panel of  claim 13 , wherein the non-woven mat comprises natural fibers and the combination of the non-woven mat and decorative film has a thickness of 0.5 to 1.5 millimeters.