Note: Descriptions are shown in the official language in which they were submitted.
.. 20()0133
AUlvllt:lllV~; DOOR TRIM PANEL PROTECTOR AND
METHOD OF USING THE SAME
Backqround of the Invention
The subject invention is directed toward the art of
protective devices and, more particularly, to a protector
sheet and method of using the same to protect vehicle door
trim panels.
Durinq the manufacture of vehicles, the final
assembly and delivery of the vehicles requires that workers
enter the vehicles for final testing and the like. In
addition, the vehicles must normally be driven at this
time. During this period, as can be appreciated the
interior surfaces of the vehicle are subject to soiling.
The inner trim panels of the doors are particularly
susceptible to dirt and are difficult to protect.
Previously, the inner trim panels have been
protected by continuous, sheets of plastic film that
extended over the exposed outer surface of the panels.
Some of the protective sheets were thermoformed to have a
contour to trim panel and appurtenant structures.
Typically, however, the sheets were flat. End portions or
tabs on the sheets were bent around the ends of the panels
and joined to the panel attachment clips or fasteners used
to attach the trim panels to the door body. When the
vehicle arrived at the dealership, the sheets were torn-off
and the tabs normally remained out of sight behind the trim
panel.
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The prior method of applying protector sheets as
described above had a distinct disadvantage. In
particular, the sheets had to be applied early in the
assembly process, i.e, simultaneously with the trim panels.
Moreover, the presence of the sheets tended to interfere,
at times, with subsequent assembly and inspection
processes. Consequently, it would be preferred to apply
such protector sheets at a later point in the assembly
process.
Further problems are present with the prior
protector sheets and their method of attachment. For
example, at times the tabs did not tear-off cleanly and
ends of the plastic tabs extended out from behind the trim
panels. This was unsightly and difficult to remove.
An additional problem present was that the protector
sheets could not be temporarily removed and then
reinstalled. Moreover, the protector sheet's shape and
method of attachment made it extremely difficult to access
and work on the door trim panel covered by the protector
sheet or the associated door mechanisms if such was
necessary.
As a consequence of the above, there has been an
ongoing need for a new protector sheet and method of
applying the same. The subject invention provides an
improved protector sheet construction which overcomes the
noted problems in an extremely efficient and effective
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manner. The invention also contemplates a method of using
the improved protector sheets which allows them to be
temporarily removed and subsequently replaced.
SummarY of the Invention
In particular, the subject invention provides a
protector sheet article intended for application to the
inner door trim panel of a vehicle door of the type which
includes laterally facing peripheral edge portion closure
areas that are generally perpendicular to the trim panel.
The protector sheet is intended to prevent soiling or
damage to the trim panel during vehicle assembly and
shipping. Specifically, the protector sheet article of
the invention comprises a continuous impervious sheet of
relatively thin and flexible plastic film material having a
width w and a length 1. The width w is at least
substantially as great as the height of the trim panel and
the length 1 is at least substantially as great as the
horizontal width of the trim panel. In addition, the outer
periphery of the sheet has a general extent and shape which
is at least correspondingly as large and coextensive to the
size and shape of the trim panel. Extending outwardly from
at least the opposite end portions of the sheet are a
plurality of tab members having a length sufficient to
extend over and beyond the side edges of the trim panel for
engagement with the peripheral edge portion closure areas
of the vehicle door when the sheet is positioned over the
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trim panel in alignment therewith. Additionally, each of
the tab members has a pressure sensitive adhesive applied
thereto to permit them to releasably and adhesively engage
the peripheral edge portions of the vehicle door.
Preferably, and in accordance with the preferred
embodiment of the invention, the tab members are integral
continuations of the sheet and the opposite surfaces of the
tab portions have a release agent applied thereto to allow
multiple numbers of the sheets to be placed in aligned,
stacked relationship during manufacture, shipping, storage
and handling.
In accordance with a further aspect of the
invention, there is provided a method of protecting the
door trim panel of a vehicle door of the type having
lS laterally facing peripheral edge closure portions lying in
planes generally perpendicular to the plane of the trim
panel. The method includes providing a generally
continuous and impervious sheet of a relatively thin,
flexible plastic film having a length 1 and a width w which
generally correspond to the height and width, respectively,
of the door trim panel. The continuous sheet is also
provided with a plurality of integral tab members which are
sized to extend outwardly from the end portions of the
sheet a distance d. In use, the sheet is placed over the
trim panel and aligned along the length and width of the
sheet to fully overlie the trim panel. Thereafter, the tab
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members are adhesively bonded to the peripheral edge
portions of the door to maintain the sheet in position on
the trim panel. Through the use of the subject protector
sheet, it is possible to readily remove and reconnect the
sheet during vehicle assembly and transport. This allows
inspection and/or repair of the various door mounted
assemblies and elements with the opportunity to merely
replace the same protector sheet after such inspection and
repair.
The protector sheets of the invention can also be
provided with expansible areas designed to deflect
laterally of the plane of the sheet to allow the sheets to
conform to discontinuities on the door trim panel. For
example, the expansible areas can overlie door handles and
other raised areas of the door. Preferably, the expansible
areas are provided by corrugations which are formed about
the area which is intended to be deflected. By the use of
the corrugations relatively deep and large contoured areas
can be provided. Moreover, even those deflectors having
relatively large corrugated areas can be stacked and stored
in a relatively flat condition.
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Other aspects of this invention are as follows:
A protector sheet article intended for
application to the inner door trim panel of a vehicle door
to prevent soiling or damage to the trim panel during
vehicle assembly and shipping, said protector sheet article
comprising:
a continuous impervious sheet of relatively thin and
flexible plastic film with a width w and a length l, said
width w being at least substantially as great as the height
of said trim panel and said length l being at least
substantially as great as the width of said trim, the outer
periphery of said sheet having a size and shape generally
corresponding to the size and shape of said trim panel:
a plurality of tab members extending from the
periphery of said sheet at least along the end portions
thereof, said tab members being of a length sufficient to
extend over and beyond the side edges of said trim panel
for engagement with the peripheral edge portion closure
areas of said vehicle door: and,
pressure sensitive adhesive applied to at least said
tab portions.
A method of protecting the door trim panel of a
2~ ~ehicle door f rom dirt and damage during assembly and
shipping comprisinq the steps of:
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a) providing a continuous impervious sheet of
relatively thin and flexible plastic film with a width w
and a length 1, width w being at least substantially as
great as the height of said trim panel and length 1 being
at least substantially as great as the width of said trim
panel,
b) providing a plurality of integral tab
members to extend outwardly from the end portions of said
sheet, said tab members having a pressure sensitive
adhesive thereon,
c) placing said sheet over said trim panel and
aligning the length and width of said sheet with the width
and height, respectively of said door; and,
d) bonding said tab members to the peripheral
edge portion closure areas of said door.
As is apparent from the foregoing, an object of an aspect
of the subject invention is the provision of a protector sheet
article which is removable and replaceable after original
installation.
An object of an aspect of the invention is the provision
of a protector sheet of the type described which can fully
enclose the trim portion of a door panel while permitting
repair and replacement access to the trim panel.
An object of an aspect of the invention is the provision
of a protector sheet of the type described which is simple and
inexpen~ive to manufacture.
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An object of an aspect of the in~ention is the provision
of a method of using a protector sheet to fully enclose and
protect the internal trim panel of a vehicle door by using the
laterally facing painted door closure areas for connection of
the protector sheet.
An object of an aspect of the invention is the provision
of a door trim panel protector sheet which can be easily
removed without leaving scraps of the sheet ext~n~;ng from
under the edges of the trim panel.
The above and other objects and advantages will
become apparent from the following description when read in
conjunction with the accompanying drawings wherein:
Figure l is plan view of a protector sheet article
formed in accordance with the subject invention;
Figure 2 is an elevational view of the interior of a
vehicle door showing a protector sheet of the type
illustrated in Figure 1 mounted in position over the
interior trim panel of the door;
Figure 3 is an elevational view taken on line 3-3 of
Figure 2 showing the peripheral edge portion of the door:
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and
Figure 4 is an elevational view taken on line 4-4 of
Figure 2.
Referring more particularly to the drawings wherein
the showings are for the purpose of illustrating a
preferred embodiment of the invention only, and not for the
purpose of limiting same, Figures 2 - 4 show the overall
arrangement of a typical vehicle door to which the
protector article and method of the subject invention are
particularly suited. As shown, the door comprises an outer
shell member or skin panel 12 which is joined to a
peripherally continuous inner frame or shell 14 that
includes a suitable window receiving frame and gasket
assembly 16. A window 18 is illustrated in position in the
frame and gasket assembly 16.
The shell or frame 14 extends inwardly from the
interior surface of the outer door shell 12 and in
combination therewith defines the door proper which houses
the various latch mechanisms, window operating assemblies
and the like. The interior face of the door is closed by
an inner panel of frame 14 which may carry such items as
radio speaker 20, a window operating and door latch console
assembly 22 and the like. In any event, an inner door
trim panel 18 overlies the inner panel of frame 14 and is
an exposed decorative portion of the door. Typically, the
trim panel 18 is covered with a fabric or the like and must
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be protected during vehicle assembly and shipment to the
ultimate vehicle purchaser. As discussed earlier, prior to
the present invention, protector sheets have been
connected to the door trim panel by being positioned over
the panel and having the ends of the sheet pulled behind
the panel and fastened to the clips which serve to join the
panel to the door frame assembly 14. The trim panel with
the protector sheet in place thereon was then mounted to
the door frame and the protector sheet was semipermanently
installed with the trim panel. When the vehicle finally
arrived at the dealership, the trim panel was removed by
tearing it from its connected position on the mounting
clips. Normally the end portions of the sheet could be
pulled from behind the panel so that no visible remains of
lS the protector sheet were present.
A problem with this particular type of protector
sheet connection and mounting was that if it became
necessary to repair or service any of the door components
prior to delivery to the customer, it was not possible to
reinstall the protector sheet. That is, once the sheets
were removed they could not be reused without major
disassembly and reassembly of the door trim panel.
Figure 1 shows a protector sheet article formed in
accordance with a preferred embodiment of the invention
that overcomes the problems discussed earlier. In
particular, the protector sheet article 24 generally
CA 02000133 1998-08-20
comprises a continuous, relatively thin and impervious
sheet of a suitable plastic film such as polyethylene,
polypropylene, or the like. The sheet has a general
overall length 1 which is at least substantially as great
as the width w which is at least as great or even
slightly greater than the height H of the door trim panel
18. Preferably, the sheet is provided with one or more
pocket forming sections such as section 26 which are
formed and positioned in accordance with the teachings of
the commonly assigned prior U.S. Patent No. 4,696,848.
In the subject embodiment, the area 26 is designed with
an array of corrugations extending thereabout so that it
provides an outwardly extending bulge or pocket that can
overlie the door latch and window operating mechanism
shown somewhat diagrammatically at 22.
The corrugations which function to allow lateral
deflection of predetermined areas to provide bulges or
contours do not prevent the sheets from being stacked
and/or maintained in a relatively flat condition. Also,
the deflectable areas do not affect the ability of the
sheets to be adhesively mounted.
Figure 1 illustrates the inner face of the protector
sheet 24. At least the opposite ends are, as shown,
provided with outwardly extending integral tab portions
28.
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A plurality of the tabs 28 are positioned to extend
generally longitudinally outwardly from the ends of the
sheet at suitably spaced positions. Additional tab
portions 30 can, if desired, by formed as illustrated on
the upper and lower edges of the protector sheet 24.
Preferably, the various tabs 28, 30 are provided on their
inner face with a suitable pressure sensitive adhesive
identified generally with the reference numeral 32. The
subject embodiment preferably has the pressure sensitive
adhesive only on the tab portions of the sheet. However,
it is contemplated that additional spots of adhesive could
be applied at other locations if desired or needed.
Additionally, the opposite sides of the tab portions 28,
30 are preferably treated so as to readily release from the
pressure sensitive adhesive so that a plurality of the
sheets can be stacked in aligned relationship to form
packages or assemblies of the sheets to facilitate
manufacture, storage and handling.
In accordance with the subject invention, the tabs
28, 30, preferably have a length such that when the
protector sheet is placed in position over the inner door
panel the tabs can extend into engagement with the
laterally facing peripheral closure areas of the door which
extend generally perpendicular to the plane of the trim
panel. In this regard, attention is directed to Figures 3
and 4 wherein the tabs 28 are illustrated as suitably
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engaged with the doors peripheral edge closure areas.
These areas are typically merely painted metal surfaces and
provide a very suitable bonding surface for the pressure
sensitive adhesive. In addition, if desired, and if the
sheet is provided with tabs 30, these tabs can also be
brought over the edge of the inner door panel and engaged
with the lower edge closure area and/or the window surface
along the upper edge thereof.
Because of the tabs and their pressure sensitive
adhesive, the sheets can be readily removed, replaced,
and/or repositioned. In addition because the tabs are
positioned to engage on the painted metal surfaces of the
closure area there is no possibility of damage to the
fabric of the trim panels. In addition the smooth painted
surfaces of the closure areas provides an extremely
desirable bonding surface for the pressure sensitive
adhesive.
The invention has been described with reference to
preferred and alternate embodiments. Obviously,
modifications and alterations will occur to others upon the
reading and understanding of this specification. It is
intended to include all such modifications and alterations
insofar as they come within the scope of the appended
claims or the equivalents thereof.
