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Патент USA US2131728

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Patented Oct. 4, 1938
Harry B. Denman, Birmingham, Mich., assignor
to Detroit Gasket & Manufacturing Company,
Detroit, Mich., a vcorporation ol' Michigan
Application January 7, 1935, Serial No. ‘782`1o claims. (Cl. 154-46)
The present invention relates to panels and
more particularly those associated with the in
teriors of motor vehicles where a permanent,
attractive appearance must be preserved under
5 relatively diilicult and widely varying condi
tions of temperature and moisture, as well as
shock and Vibration.
Thus an object of the invention is to produce
a panel substantially free of warping tendencies,
10 and which is not affected by moisture and heat
or cold.
Ordinarily, panels are made by indenting a
base material to produce a raised configuration,
over which. the trim cloth is adhered.> Fre
15 quently, it is diñicult to produce a uniform in
Figure 6 is a sectionalview of a further form
of panel material;
- Figure 7 is a sectional view similar to Figure 6
showing the panel provided with configurations
or raised portions;
Figure 8 is a sectional view of a modification;
this panel may also be used in connection with
Figures 2, 4, 5 and 6.
Figure 9 is a sectional view of a further modi
fication; this panel may also be used in connec- 10
tion with the structures shown in Figures 2; .4, 5
and 6.
Referring to the drawing, I have illustrated in
Figure 1 at I0 a panel in accordance with this f
dentation as where the conñguration -includes
invention, in position yon the door of an auto- 15
sharp outlines and moreover, the pressed-in por
tion or portions exert a normal tendency to re
of this application is not restricted to motor
cars but may be used with any-other structure.
Referring to Figures 2 and 3, this panel com
prises a base Il of any suitable stiff material, 20
turn or “fade” under conditions of usage. As a
20 result, a uniformly neat and attractive appear
ance for a given design is sometimes impossible
and when the indentations contract or “fade”,
the cloth becomes loose and saggy, i. e., it sep
arates from the panel body.
25 These obstacles are overcome by the present
invention wherein the sharpest configuration is
easily molded and, moreover, is solid or sub
stantially solid so that (l) there is neither dif
nculty in forming a uniform contour nor (2) any
80 possibility of objectionable “fading”. Moreover,
the moldable material exhibits no tendency to
warp or distort and where used with a base
sheet, it has suiiicient strength to overcome the
possibilities of warping or distortion of the
35 base under extreme conditions.
Further characteristics of the moldable mate
rial are its temperature and moisture resistance,
and a resilience resembling hard rubber which
is compensatory under conditions of use. Fur
40 ther, the moldable material is such that the `trim
cloth may be easily adhered by any satisfac
tory, resistant adhesive so'that at all times a
neat and permanently attractive appearance is
Referring to the drawing:
Figure 1 is an elevation of a panel in ,accord
ance with the present invention;
Figure 2 is a sectional view of the panel;
Figure 3 is an elevational view partly broken
50 away with the trim cloth removed;
Figure 4 is a sectional view of a laminated
panel material;
Figure 5 is a sectional view similar to Figure 4
showing the panel provided with configurations
55 or raised portions;
mobile. It is to be understood that the panel
but preferably a stiiï paper-or fiber board of suit
able gauge or thickness. The ñber board is
preferably rendered waterproof by incorporation
in the fibers of a suitable water resistant agent, ’
or it is impregnated or coated with such a water 25
resistant material.
'I'here are any number of
satisfactory waterproofing agents commercially
available for this purpose which form a con
tinuous film.
The panel In is provided with a layer -lz of 30
moldable material forming a raised configura
tion. As shown in- Figures l, 2 and 3, the riser '
consists of a strip or spaced strips which may be
continuous about the margin- of the base asv
shown, or discontinuous and applied upon any 35
desired spaced areas of the base Il, i. e. thel
sectional designs or raised> portions are at
tached to the base without covering the whole
area thereof.
The configuration is therefore produced by
superposing on the base Il and adhering thereto
a layer I2 molded to any desired form' and po
sitioned with respect to the base, i. e., covering
any required areas thereof, to give the appro 45
priate predetermined contour and appearance.
The layer I2 of moldable material is preferably
an unvulcanized mixture of reclaimed rubber,
übers, and a suitable plasticizing, waterproofing
agent such as asphalt, for example, gilsonite. 50
This mixture, on setting, has the resilience and
ñrmness- characteristics of hard rubber. ,It may
be premolded and united to `the base Il by a l
suitable adhesive or directly molded upon the
base Il. ‘The adhesive is applied either to the> 55
‘ base or to the moldable composition or both, or
the mixture may be of itself adhesive.
In some cases, a v'ulcanizing agent is used
in the mixture vand adherence obtained by vul
canization of the layer I2 to the base II.
The area. of the layer I2 of moldable material,
is in some cases, coextensive with the base II,
as in Figures 4 and 5. Again the layer I2 com
prises a single narrow strip or strips, the latter
10 in some cases in connected relation, superposed
upon and adhered to the base. Where, as in
Figures 2, 5 and'7, the risers are in multiple,
they are formed integral with and connected by
a relatively thin web I3, or as shownl inI Figure 9,
15 the risers are adhered to a separate sheet or
web I3' of larger area than the web I3; the risers
' may likewise. be formed integral with the larger
web I3’ as shown in Figure 2, for example. The
layerA I2, including in some cases a web I3vor I3',
20 in any instance, is adhered to the base in the
manner already described.
This trim
over and adhered to the back of the board as at
I6. A neat and clean-cut ñt is thus produced
30 bringing out sharply the attractive' contour of
the board. The adhesive may be applied to the
cloth or to the layers I2, I3, or both; again the
rubber fiber-asphalt mixture may be inherently
adhesive or be vulcanizable, so as to secure, in
35 all cases, the required coextensive adhesion’of
-cloth to the board and its contoured surface.
In some cases a cloth finish is not used and
instead thereof a coating of temperature and
weather resistant lacquer or varnish of an ap
propriate color is employed.
Likewise, the layer I2 whether of spaced con
figurations or a coextensive layer has sometimes
a suitable color incorporated therein, whereby a
trim cloth or coating need not be used.
Referring to Figure 4, the board II is coated
or covered with a coextensive, relatively thin
layer I2 of the moldable material which may be
plain if desired', i. e., devoid of raised portions
or configurations.
Referring to Figure 5, the board II shown in
Figure 4 is provided with a coextensive layer I2
of moldable material having integral molded riser
portions to give the desired configuration I 2’.
The layer I2 may be preliminarily molded to the
55 contour- shown, or any other desired contour, or
the raised portions I2’ may be molded to form
after or simultaneously with the application of
moldable material to the board II.
In Figure 6, there is illustrated a plain layer
of 'moldable material winch, in some cases, is
quite satisfactory for panel purposes exhibiting
freedom from warping,.and resistance to the
factors of heat and moisture to which panels are
normally subjected. In Figure '7, the layer I2 is
65 thicker, but otherwise similar to the layer I2 illus
trated in Figure 5, the moldable material being
formed with- the integral raised portions or con
figurations I2’.
as shown in Figures 6, 7 and 8.
producing a very acceptable panel, in all cases.
The moldable material, as stated, is heat and
moisture resistant and permanent, i. e., the hol
lowindentations I'I do not exhibit any tendency
to return or fade such as is frequently encoun
tered where a fibre board is pressed in or em
In Figure 9, the layer I2 includes the raised
portions or> configurations either integral with
the web I3’ or adhesively united thereto. It is
to be noted that the area of the layer I2 in Figure
9 is somewhat greater than the area of the layer
I2 in Figure 2, the web whether integral or sepa
rable with respect to the raisèd portions extend 20
It is to be observed that the molded raised por
tions of the layer I2 as shown in Figures 2, 5, 7
and 9 are solid and this, of course, assures that 25
there will be no substantial contraction or return,
i. e., so-called “fading" of the configurations such
as would destroy the adherence of the cloth and
produce a looseness or sagging to mar the ap
pearance of the panel. -
The permanency and strength of the moldable
-layer I2 insures a similar resistance to contrac
tion or fading in the case of a panel constructed
in accordance with Figure 8.v
The moldable material of the layer I2, as here 35
tofore stated, upon setting, has the resilience and
firmness of hard rubber. When united to the
board II or to another layer of moldable mate
rial I2, it acts to reinforce the base and retard
any possible distortion or warping. Because of
the resilience and flexibility of the material, it
is compatible with the ordinary stiff paper board
sheets and will flex and bend suiiiciently after
the manner~ of such sheets to permit the panel
to »be vproperly positioned and attached on the 45
body structure.
With respect to a panel comprising the layer
I2, as shown in Figure 8, either used alone or
combined with a board Il or a base- layer I2 of
moldable material, the firmness and strength of
the configurated layer, whether it be coextensive
or simply have a strip form is quite marked.
While I prefer that the configurations be solid,
as shown in Figure 2 for example, there are
many instances where a structure of the type 55
shown in Figure 8 is useful either alone or in
combination as described.
It is to be noted that the conñgurations- or con
tours are very easily produced, are permanent,
and the rubber fibre, asphalt -mixture is compat
ible with most adhesives whereby ther moldable
mixture is readily united to the base and to the
trim` cloth I4. It is understood, of course, that
whenever the panels described will be covered
with the trim cloth I4, that this member will be
adhesively united to the board and to the moldable
mixture upon >the board, so~thatthe adhesive
union is co-extensive with the area of the board
Where the layer I2 is coextensive with the
70 board II as shown in Figures 4 and 5, or a webA
I3 or I3' is used as >shown in Figures- 2 and 9, the
layer or web, as the case may be,4 is preferably
thinner than the layer of moldable material I2,
upon and united to another moldable material
layer I2, i. e., a plain base as shown in Figure 6,
cloth is adhered to the board I I and the layer I2
substantially throughout the area `of they cloth,
as shown in Figure 2, and its edges are carried
layer I2 maybe (1) used alone; (2) superposed
upon and united to a board II, or (3) superposed
ing'làiterally from opposite sides thereof as shown
Over the board Il having the layer I2 compris
ing the configuration or raised portions is super
posed a trim cloth I4 as in Figure 2.
to that shown in Figure 6, but embossed or pressed
to have configurations l1. formed therein. 'I'his
In Figure 8, I have illustrated a layer I2 similar
and configurations and the cloth. A neat, close
fitting appearance, bringing out sharply and 70
clearly a uniform contour, is obtained and since
there is but little opportunity for warping in
view of the reinforcing action of the layer I2
upon the base and substantially no possibility of
fading due t0 the permanent character of the 75
layer I2, this adhesive union and hence the nice
appearance of the panel is preserved.
In preparing the reclaimed rubber-fibre-asphalt
mixture, the reclaimed rubber and gilsonite, for
example, are fed into a suitable rubber .mill and
worked cold for about flve minutes. As one ex
ample, thirty parts of'rubber to fifteen parts of
gilsonite are used. After a thorough mixing, the
fibres such as ground paper or any other fibrous
10 material or scrap, and/or comminuted cork, are
added gradually in the amount of about fifty
parts. The mixing operation consumes about
twenty minutes.
In addition to the fibrous material, a filler, such
as Whiting, is used in some cases in approximately
five parts.
After the complete mixing, in the course of
which the temperature, due to working, may go up
to 150° F., the mixture is taken to a calendering
20 machine and sheeted out to the desired gauge.
'I‘he mixture, as will be understood, is warm and
the temperature of the calendering rolls may be
as high as 150° F. as desired.
Following calender
ing, the sheets are cold-pressed or molded to the
The warming temper
ature or the temperature of the mixture should
not exceed 150° F.
'I’he unvulcanized moldable or plastic mass will
harden to the condition of ordinary hard rubber
30 without employment of a vulcanizing agent and
at normal atmospheric temperature and pressure,
i. e., no heating or other treating of the material
is required in order to cure or set it. This, it will
be appreciated, is of great importance in manu
25 desired form while warm.
35 facture, whether the layer I2 is preformed with
configurations or coated upon the base sheet and
the configurations molded thereon.
Thus, in carrying out the invention, a coex
tensive layer or a strip layer or a layer of any
40 desired configuration may be preliminariiy formed
In this connection. a board ci varying pliancy i
may be used and likewise the percentage ratio of
materials forming the moldable layer I2 may be
varied. ’ For example, the layer I2 may have in
creased or decreased stiffness by changing the
ñbre content.
In all cases, a panel structure is obtained which
is (l) highly resistant to warping, (2) free from
any “fading” characteristics, and> (3) weather
resistant and vibration resistant. All of these
factors are important when it is considered that
the panel’of the present invention, because of the
moldable material, is susceptible oi' providing any
desired contours regardless oi.' the complicated or
sharp angle characteristics required.
I also preparea mixture comprising rubber, an
asphalt such as gilsonite, and cork, the cork being
comminuted or granulated and comprising sub
stantially 10% by weight, i. e., approximately 35%
by volume. 'I'his mixture also comprises in some
cases> rubber, an asphalt, fibrous material, for ex
ample paper ñbres, and comminuted cork in the
percentage or weight just specified.
As stated, a facing is applied tothe surface of
the panel such as (l) a trim cloth, or (2) a re
sistant coating or finish of suitable color, or (3)
the layer I2 whether it (a) covers the whole area
of the base or (b) is applied to spaced areas there- ‘
of has incorporated
therein a suitable color.When the layer I2 includes a color and is applied
to leave exposed- portions of the base, the base may
have incorporated therein or be coated or ñnished
with the same or a contrasting color.
Further modifications of the invention may, of
course, be made all of which are comprehended
Within the scope of the appended claims.
I claim:
1. A panel comprising a relatively stil! base. a
layer of a moldable composition material adhered
and then adhesively united to the base, whether
to said base and forming a raised portion or con
it be a board II or a layer I2 of the moldable ma
figuration, and a trim cloth overlying said sheet
and said layer of »moldable material and united
to said sheet.
2. A panel comprising a layer oi' stili sheet ma
terial. Again, the moldable material may be ap
plied to the base and the configuration then pro
45 duced on the layer I2 simultaneously with its
adhesion to the base or thereafter.
terial and a layer of a composition of rubber and
In some cases, I apply a configuration layer or
a coextensive layer to each side of the base.l It is
to be noted that where the layer I2 is coextensive
50 with the base, that it is of less thickness than the
base and the coniigurated portions. Of course,
the thickness of the layer I2 may be of any de
sired gauge.
While I have referred to an unvulcanized mold
55 able mixture and prefer this, since the composi
tion described on setting is hard and resilient
fibers including a waterproofing agent united to
said sheet at spaced points and overlying spaced'
. areas of the sheet.
3. A panel comprising a layer of stiii' sheet ma
terial, a layer comprising a composition of rubber
and fibers including a waterproofing agent, said
layer having integral therewith a configuration
or raised portion extending above the plane of
the sheet.
4. A panel comprising a layer of stili.' sheet ma
after the manner of hard rubber, and quite strong,
terial, a coextensive layer comprising a moldable
in some cases I utilize a vulcanizing agent in the
mixture such as sulphur. A somewhat similar
composition of rubber and fibers including a wa
60 final set product is obtained and where the vul
canizing agent is present, in some cases it is possi
ble to eliminate the use of an adhesive for secur
ing the layer I2 to the base or the trim cloth to
the layer I2, since the adhesive union will be ob
65 tained by the vulcanizing action, i. e., the rubber
fiber composition will be vulcanized with the panel
in assembled relation.
The board II employed is preferably one con
structed to be very resistant to warping and, as
70 stated, waterproof. The moldable composition
described possesses characteristics similar to that
of the board, so as to be compatible therewith
whereby flexing or expansion and contraction will
not result in cracking of either layer nor breaking
75 down of the adhesive union.
terproofing agent, portions of said layer being
molded and raised above the plane of said sheet.
‘ 5. A panel comprising a layer of stiff, sheet ma
terial. a layer comprising a composition of rubber
and fibers including a waterproofing agent, said
layer having a configuration or raised contour ex
tending above the plane of the sheet and a web
portion adhered to the surface of the sheet.
6. A panel comprising a layer of a composition
of rubber and fibers including a waterproofing
agent, portions of said layer being indented to
form/configurations' extending laterally with re
spect to the plane of the layer.
7. A panel comprising a layer of a composition
of rubber and fibers including a waterproofing
agent, portions of said layer being indented to
form configurations extending laterally with re
4 '
spect to the plane of the layer, and a base to
which said layer is united.- y p
8. A panel comprising a relatively sti!! base, a
layer of a moldable, resilient, composition mate
rial including rubber adhered to said base and
forming a raised portion or conñguration at
spaced points overlying spaced areas of the base.
9. A panel comprising a layer of stii! sheet ma
terial, a layer comprising a composition of rub
10 ber, comminuted cork and ilbers including a wa
terprooilng agent, said layer having integral
therewith a connguration or raised portion ex
tending above the plane of the sheet.
10._A panel comprising a. layer of stiff sheet
material, a layer comprising a composition of
rubber, comminuted cork and including a water
prooflng agent, said layer having integral there
with a contlguration or raised portion extending
above the plane of the sheet. -
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