Double-cast slush molding method and apparatus

An apparatus for molding a thin shell having an outer layer and an inner layer, the apparatus comprising:

• a support structure supported for rotation around a horizontal axis;
• at least two tubs supported on the support structure and configured to hold charge materials for delivery to a mold cavity, each tub having a tub opening for dispensing charge materials;
• the tubs being rotatable with the support structure around the horizontal axis to an orientation where the charge materials will dispense from the tubs;
• the tubs being alternately movable on the support structure to a dispensing position, the support structure configured to unblock the tub opening of each tub in the dispensing position to allow the tubs to alternately dispense charge material into the mold cavity.

A method for molding a thin shell having an outer layer and an inner layer, the method including the steps of:

• providing a mold having a mold surface configured to complement the desired shape of the shell to be molded;
• heating the mold surface;
• providing a first polymer material in a first tub having a first tub opening;
• providing a second polymer material in a second tub having a second tub opening;
• blocking the second tub opening;
• tipping the tubs and the mold until at least a portion of the first polymer material dispenses from the first tub onto the mold surface to form an outer layer;
• righting the tubs and the mold;
• opening the second tub opening;
• blocking the first tub opening;
• tipping the tubs and the mold until at least a portion of the second polymer material dispenses from the second tub onto at least a portion of the outer layer to form an inner layer;
• cooling the mold surface;
• allowing the inner and outer layers to bond together;
• and
• removing the shell from the mold.

A thin shell for an automotive trim panel, said shell having an outer layer and an inner layer, the shell comprising:

• an outer layer comprising a first polymer material;
• an inner layer comprising a second polymer material;
• the second polymer material further comprising a polymer material at least a portion of which comprises a formed article prior to its use as the second polymer material;
• and
• the inner layer at least partially covering the inner surface of the outer layer and concealed from view by vehicle occupants.

A thin shell for an automotive trim panel, said shell having an outer layer and an inner layer, the shell comprising:

• an outer layer comprising a first polymer material;
• an inner layer comprising a second polymer material;
• the second polymer material further comprising a mixture of two or more different polymer formulations;
• and
• the inner layer at least partially covering the inner surface of the outer layer and concealed from view by vehicle occupants.

A thin shell for an automotive trim panel, said shell having an outer layer and an inner layer, the shell comprising:

• an outer layer comprising a first polymer material;
• an inner layer comprising a second polymer material;
• the second polymer material further comprising a polymer formulation which is more susceptible to ultraviolet degradation than the first polymer material;
• and
• the inner layer at least partially covering the inner surface of the outer layer and concealed from view by vehicle occupants.

A thin shell for an automotive trim panel, said shell having an outer layer and an inner layer, the shell comprising:

• an outer layer comprising a first polymer material;
• an inner layer comprising a second polymer material;
• the second polymer material comprising a composition at least partially different than the first polymer material;
• the outer layer comprising an average thickness in a range between and including 0.005 inches to 0.025 inches;
• and
• the inner layer at least partially covering the inner surface of the outer layer and concealed from view by vehicle occupants.