Method of forming a frame of a seat back for a vehicle

A method of forming a frame of a seat back for a vehicle, the frame including a first polymeric material and a reinforcing composite layer that includes a second polymeric material and a plurality of fibers impregnated in the second polymeric material, said method comprising the steps of:

• supporting the reinforcing composite layer on moveable members in a mold;
• extending the moveable members relative to the mold to an extended position in the mold;
• suspending the reinforcing composite layer from the mold on the moveable members in the extended position;
• introducing the first polymeric material in a molten state into the mold and into contact with the reinforcing composite layer;
• displacing the reinforcing composite layer away from the moveable members by introducing the first polymeric material in the molten state between the moveable members and the reinforcing composite layer while the moveable members are in the extended position;
• interposing the reinforcing composite layer between the first polymeric material in the molten state so that the first polymeric material contacts two sides of the reinforcing composite layer;
• causing the first polymeric material to solidify in the mold;
• and
• retracting the moveable members from the first polymeric material,
• wherein the reinforcing composite layer includes a first leg, a second leg spaced from the first leg, and a base extending between the first leg and the second leg,
• said step of supporting the reinforcing composite layer includes supporting the first leg of the reinforcing composite layer with a first group of the moveable members and supporting the second leg with a second group of the moveable members, and
• the mold includes a cavity, a core, and at least one slider configured to open relative to the cavity and/or the core and wherein at least one of the cavity and the core supports the first group of moveable members and the slider supports the second group of moveable members.

A method of forming a frame of a seat back for a vehicle, the frame including a first polymeric material and a reinforcing composite layer that includes a second polymeric material and a plurality of fibers impregnated in the second polymeric material, said method comprising the steps of:

• supporting the reinforcing composite layer on moveable members in a mold;
• extending the moveable members relative to the mold to an extended position in the mold;
• suspending the reinforcing composite layer from the mold on the moveable members in the extended position;
• introducing the first polymeric material in a molten state into the mold and into contact with the reinforcing composite layer;
• displacing the reinforcing composite layer away from the moveable members by introducing the first polymeric material in the molten state between the moveable members and the reinforcing composite layer while the moveable members are in the extended position and abutting the reinforcing composite layer against the mold by flowing the first polymeric material in the molten state against the one of the opposing sides;
• interposing the reinforcing composite layer between the first polymeric material in the molten state so that the first polymeric material contacts two sides of the reinforcing composite layer;
• supporting a second reinforcing composite layer on some of the moveable members in the mold spaced from the reinforcing composite layer, introducing the first polymeric material into contact with the second reinforcing composite layer while the some of the moveable members support the second reinforcing composite layer, and separating the second reinforcing composite layer from the moveable members by flowing the first polymeric material in the molten state between the moveable members and the second reinforcing composite layer;
• causing the first polymeric material to solidify in the mold;
• and
• retracting the moveable members from the first polymeric material,
• wherein the reinforcing composite layer includes a first leg, a second leg spaced from the first leg, and a base extending between the first leg and the second leg,
• said step of supporting the reinforcing composite layer includes supporting the first leg of the reinforcing composite layer with a first group of the moveable members and supporting the second leg with a second group of the moveable members, and
• the mold includes a cavity, a core, and at least one slider configured to open relative to the cavity and/or the core and wherein at least one of the cavity and the core supports the first group of moveable members and the slider supports the second group of moveable members.