Automated method and system for making painted vehicle body panel skins and vehicle body panels, such as instrument panels, utilizing same

A method of producing a painted vehicle panel comprising the steps of:

• placing a mold in an entrance station, the mold having an inner surface;
• transporting the mold along a first segment of a closed-loop guide path to a combined paint and spray station;
• painting the inner surface of the mold within the paint and spray station;
• spraying a layer of curable polyurethane elastomer onto the painted inner surface of the mold within the paint and spray station;
• transporting the mold along a second segment of the closed-loop guide path for receipt at one of a plurality of separate accumulator stations adjacent to and separate from the paint and spray station;
• exposing an entire surface of the layer of curable polyurethane elastomer to ambient air for a complete cure of the polyurethane elastomer in the mold at the accumulator station receiving the mold;
• transporting the mold along a third segment of the guide path for unloading of a painted vehicle panel skin thus formed from the mold;
• unloading the painted vehicle panel skin from the mold;
• placing the unloaded skin in a plastic injection mold;
• injecting molten plastic to at least partially cover a surface of the skin opposite the paint;
• and
• permitting the molten plastic to solidify and bond with the skin in the mold to form the vehicle panel.

A method of producing a painted vehicle panel comprising the steps of:

• placing a mold in an entrance station, the mold having an inner surface;
• transporting the mold along a first segment of a closed-loop guide path to a combined paint and spray station;
• painting the inner surface of the mold within the paint and spray station;
• spraying a layer of curable polyurethane elastomer onto the painted inner surface of the mold within the paint and spray station;
• transporting the mold along a second segment of the closed-loop guide path for receipt at one of a plurality of separate accumulator stations adjacent to and separate from the paint and spray station;
• exposing an entire surface of the layer of curable polyurethane elastomer to ambient air for a complete cure of the polyurethane elastomer in the mold at the accumulator station receiving the mold;
• transporting the mold along a third segment of the guide path for unloading of a painted vehicle panel skin thus formed from the mold;
• unloading the painted vehicle panel skin from the mold;
• placing the unloaded skin and a preformed injection molded part in a foam mold with a space between the skin and the part;
• providing a foamable material into the space between the skin and the part;
• and
• permitting the foamable material to cure and bond to the skin and the part in the mold to form the vehicle panel.