Claims:We Claim:

1. A method 300 of fabricating an interior panel 100 for a vehicle, the interior panel 100 is being molded inside a mould structure 200 having a first surface 210 and a second surface 220, the method 300 comprising the steps of:
arranging a first member 110 in the first surface 210 of the mould structure 200;
configuring at least one second member 120a or 120b inside a predefined cavity 230a or 230b of the second surface 220, the cavities 230a or 230b hold the second member 120a or 120b securely therein;
wherein a cushioning material 130 is injected between the surface of the first member 110 and the at least one second member 120a or 120b and the second surface 220 of the mould structure 200;
wherein the second member 120a or 120b is partially covering the cushioning material 130.

2. The method 300 as claimed in claim 1 wherein, the cushioning material 130 may be foam.

3. The interior panel 100 as claimed in claim 1, wherein the cavities 230a or 230b may be of predefined shape and size and is arranged in a predefined position on the first surface 210 of the mould structure 200.

4. An interior panel 100 for a vehicle comprising:
a first member 110;
at least one second member 120a or 120b arranged adjacent to the first member 110;
a cushioning material 130 injected between the surface of the first member 110 and the at least one second member 120a, 120b and a second surface 220 of a mold structure 200; and
wherein the second member 120a or 120b is partially covering the cushioning material 130 and is adapted for attaching fasteners 112 passing through the first member 120 for providing rigidity for mounting article holders on the interior panel 100.

5. The interior panel 100 as claimed in claim 1, wherein the first member 110 and the second member 120a or 120b are moulded to a predefined shape and size.

6. The interior panel 100 as claimed in claim 1, wherein the first member 110 is a flexible member which forms the exterior part of a vehicle seat 1000.

7. The interior panel 100 as claimed in claim 1, wherein the second member 120a, 120b is made of a plastic substrate
, Description:Field of the Invention

[0001] The present invention relates to interior panels of a vehicle interior. More particularly, the present invention relates to interior panels and a method of fabricating an interior panel for a vehicle.

Background of the Invention

[0002] Vehicle interiors are primarily intended to provide a secure and comfortable journey for the passengers. Vehicle interiors are subjected to mount many external structures with loaded features which may offer additional comfortability for the passengers. This may require a lot of space inside the interior, which is a concern. To overcome the concern, effective utilisation of the interior is preferred. Further, most of the interiors are made of soft and flexible materials which may not be effectively utilised for holding or mounting other structures.

[0003] Especially, the back panels of the vehicle seat can be utilised for additional structures. However, these back panels are made up of foam and fabric. It is unsuitable to mount any external attachments like a cup holder, snacks tray and the like on it because of absence of rigid areas for attachment thereon.

[0004] Therefore, there is a need to provide an interior panel or back panel for a vehicle seat, which overcomes few or all of the drawbacks of the existing interior panels.

Objects of the Invention

[0005] An object of the present invention is to provide an interior panel and a method of fabricating the interior panel for a vehicle.

[0006] Another object of the present invention is to provide an interior panel and a method of fabricating the interior panel for a vehicle, wherein the interior panel can be attachable as a back panel for vehicle seats.

[0007] Yet another object of the present invention is to provide an interior panel and a method of fabricating the interior panel for a vehicle, wherein the interior panel enables to mount external attachments such as a cup holder in a rear portion of the vehicle seat.

[0008] Further object of the present invention is to provide an interior panel and a method of fabricating the interior panel for a vehicle, wherein the interior panel is provided with foam and fabric which allows more leg space for the occupants.

[0009] One more object of the present invention is to provide an interior panel and a method of fabricating the interior panel for a vehicle, which is simple and economical in construction.

Summary of the invention

[0010] According to the present invention, an interior panel and a method of fabricating the interior panel for a vehicle is provided. The interior panel is moulded inside a mould structure using injection moulding process. The interior panel particularly in this embodiment is a back panel arranged for a vehicle seat. It may be obvious to a person skilled in in the art to use this interior panel to configure, a door trim, a dashboard, an armrest and the like. The interior panel provides sufficient strength to hold a cup holder or similar arrangements.

[0011] At first, a first member is arranged inside the mould structure for performing injection moulding process. The mould structure has a first surface and a second surface. The first member is arranged inside the first surface of the mould structure. Further, at least one second member is arranged inside a predefined cavity of the second surface. The present embodiment is shown to have two second members which is arranged inside the respective cavities of the second surface. The cavities hold the second member securely there inside. The second members may be a plastic substrate which is filled in the cavities to provide substantial rigidity to the first member.
[0012] After that, the second members are arranged adjacent to the first member at a predefined position. Further, the interior panel is moulded inside the mould structure with a cushioning material injecting between the first member and the second member and the second surface of the mould structure.

[0013] Specifically, the second members partially covers the cushioning material. The present invention has the second members only where it is needed thereby enabling mounting of external attachments. Rest of the area of the interior panel is made up of cushioning material such as a foam or fabric which enables the flexibility of the interior panel. The second members may be adapted to attach fasteners passing through the first member for providing rigidity for mounting the article holders on the interior panel.

Brief Description of the Drawings

[0014] The advantages and features of the present invention will be understood better with reference to the following detailed description and claims taken in conjunction with the accompanying drawings, wherein like elements are identified with like symbols, and in which:

[0015] Figure 1 illustrates a flowchart representing a method for fabricating the interior panel in accordance with the present invention:

[0016] Figure 2 illustrates schematic representation of an interior panel for a vehicle in accordance with the present invention; and

[0017] Figure 3 illustrates another schematic arrangement of the interior panel attached to a vehicle seat.

Detailed Description of the Invention

[0018] An embodiment of this invention, illustrating its features, will now be described in detail. The words "comprising, "having, "containing," and "including," and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items.

[0019] The terms “first,” “second,” and the like, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another, and the terms “an” and “a” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item.

[0020] The disclosed embodiments are merely exemplary of the invention, which may be embodied in various forms.
[0021] Referring to figure 1, a method 300 of fabricating an interior panel for a vehicle in accordance with the present invention is illustrated. The interior panel 100 is shown in figure 2. The interior panel 100 is moulded inside a mould structure using injection moulding process. The interior panel 100 particularly in this embodiment is a back panel arranged for a vehicle seat 1000 as shown in figure 3. It may be obvious to a person skilled in in the art to use this interior panel 100 to configure, a door trim, a dashboard, an armrest and the like. The interior panel 100 provides sufficient strength to hold a cup holder or similar arrangements as shown in figures 2 and 3.

[0022] The method 300 starts at step 310.

[0023] At step 320, a first member 110 is arranged inside the mould structure 200 for performing injection moulding process. The mould structure 200 has a first surface 210 and a second surface 220 as shown in figure 2. The first member 110 is arranged inside the first surface 210 of the mould structure 200. The first surface 210 and the second surface 220 is having a predefined size and shape. The first member 110 is a flexible sheet which is arranged inside the mould structure 200.

[0024] At step 330, at least one second member is configured inside a predefined cavity of the second surface 220. The present embodiment is shown to have two second members 120a and 120b which is arranged inside the respective cavities 230a and 230b of the second surface 220. The cavities 230a and 230b hold the second member 120a and 120b securely there inside. The second members 120a and 120b may be a plastic substrate which is filled in the cavities 230a and 230b to provide substantial rigidity to the first member 110. The second members 120a and 120b may be a molten material which upon filling the cavities 230a and 230b solidify therewithin. The second members 120a and 120b may be configured with openings for fastening an article holder 140 or similar arrangements as shown in figure 2.

[0025] Further, at step 340, the second members 120a, 120b are arranged adjacent to the first member 110 at a predefined position. Specifically, the second members 120a and 120b partially covers the first member 110.

[0026] At step 350, the interior panel 100 is moulded inside the mould structure 200 with a cushioning material 130 injected between the surface of the first member 110, the second member 120a and 120b and the second surface 220 of the mould structure 200. Specifically, the second member 120a and 120b partially covers the cushioning material 130. Partially covering here means, a part of the cushioning material 130 rather than the whole part of the cushioning material 130. By way of non-limiting example, 50 to 60 percentage area of the cushioning material 130 is covered between the first member 110 and the second members 120a and 1202b. The remaining percentage area of the cushioning material 130 is covered between the first member 110 and the second surface 220 of the mould structure 200.
[0027] The cushioning material 130 may be foam or any other filler material which enhances the cushioning effect of the seat 1000. The second members 120a and 120b is adapted for attaching fasteners 112 passing through the first member 110 for providing rigidity for mounting the article holders 140 on the interior panel 100.

[0028] The method ends at step 360.

[0029] Referring now to figures 2 and 3, a schematic representation of the interior panel 100 for a vehicle in accordance with the present invention is illustrated. The interior panel 100 is provided with the first member 110, two second members 120a and 120b and the cushioning material 130. The first member 110 and the second member 120a and 120b are moulded to a predefined shape and size. The first member 110 is a flexible member moulded by an injection moulding process. The first member 110 has sufficient strength and may be attached and surrounded over a frame of the vehicle seat 1000.

[0030] Further, the second members 120a and 120b are arranged over the first member 110. Specifically, the second members 120a and 120b are partially covering the cushioning material 130. The first member 110 is a flexible sheet which forms the exterior part of the vehicle seat 1000 and the first member 110 is an interior part of the vehicle seat 1000. The cushioning material 130 is injected between the first member 110, the second member 120a and 120b and the second surface 220 of the mould structure 200. Specifically, the second member 120a and 120b partially covers the cushioning material 130. Partially covering here means, a part of the cushioning material 130 rather than the whole part of the cushioning material. By way of non-limiting example, 50 to 60 percentage area of the cushioning material 130 is covered between the first member 110 and the second members 120a and 120b. The remaining percentage area of the cushioning material 130 is covered between the first member 110 and the second surface 220 of the mould structure 200.

[0031] The cushioning material 130 is preferably a foam. The cushioning material 130 can be any filler material or foam which provides sufficient flexibility to the vehicle seat 1000. The cushioning material 130 provides comfort for the rear seat occupants by providing knee legroom in case of large size occupant is seating and the same time sufficient rigidity to the interior panel 100. Also, it absorbs impact on knees of the rear seat occupant upon collision of the vehicle. A soft fabric cover (not shown) can be arranged over the first member 110 which may add further cushioning to the seat 1000.

[0032] Referring again to figure 2 and 3, the interior panel 100 is capable of providing rigidity for mounting article holders 140 or similar arrangements configured thereon the interior panel 100. Specifically, the second members 120a and 120b help in holding such an arrangement. The present invention has the second members 120a and 120b only where it is needed thereby enabling mounting of external attachments. Rest of the area of the interior panel 100 is made up of cushioning material 130 such as a foam or fabric which enables the flexibility of the interior panel 100. For example, as shown in figure 2, the article holder 140, specifically a cup holder is arranged on the interior panel 100. Specifically, the second members 120a and 120b provide sufficient strength to hold the weight of the article holder 140 therewith. The second members 120a and 120b may also be adapted to attach fasteners 112 passing through the first member 110. The first member 110 may be provided with predefined openings (not shown) for allowing the fasteners 112 to fasten the article holder 140 with the respective second members 120a and 120b. It may be obvious to a person skilled in the art to attach any other article holders 140 with the interior panel 100.

[0033] Therefore, the present invention of the interior panel 100 and the method 300 of fabricating the interior panel has advantage of mounting external attachments such as an article holder 140 in a rear portion of the vehicle seat 1000. Further, the interior panel 100 is provided with cushioning material 130 or foam and fabric which allows more leg space for the occupants. Also, the interior panel 100 is simple and economical in construction.

[0034] The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the present invention and its practical application, and to thereby enable others skilled in the art to best utilise the present invention and various embodiments with various modifications as are suited to the particular use contemplated. It is understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but such omissions and substitutions are intended to cover the application or implementation without departing from the scope of the claims of the present invention.