US 5,718,791 AGranted

Method of laminating a trim panel and folding a cover sheet edge around the panel rim

AssigneeR + S Stanztechnik GmbH

InventorGerhard Spengler

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Abstract

An improved method and apparatus for laminating a cover sheet onto a substrate, and folding and laminating the cover sheet edges around the back side of the substrate rim are especially suited to making finished trim panels having a strongly contoured three-dimensional configuration. A carrier frame holds the cover sheet material with a desired tension until the lamination has begun, to avoid wrinkling and sagging of the cover sheet material on a strongly contoured three-dimensional substrate. A lower mold receives the substrate, while an upper mold laminates the cover sheet onto the substrate. The upper mold can be retracted into or extended from a frame that forms a nest, while edge-folding tools are laterally movably arranged around the perimeter of the upper mold nest. The lamination and molding is initiated with the upper mold extended beyond or below the plane of the edge-folding tools and the cover sheet still held by the carrier frame, and then the two molds together are retracted above the plane of the edge-folding tools to begin the edge-folding step.

Claims23

Dependent claims

A method of producing a trim panel including a substrate and a cover sheet laminated onto said substrate with a cover sheet edge folded and laminated around a substrate rim in an apparatus including a first mold having a first mold surface, a second mold having a second mold surface, a carrier frame, and an edge-folding tool movable laterally relative to a direction of motion of said molds, said method comprising:

(a) disposing said substrate on said first mold surface;
(b) positively holding said cover sheet on said carrier frame at a position between said first mold surface and said second mold surface and spaced away from said edge-folding tool;
(c) moving at least one of said first mold and said second mold relatively toward each other until said substrate and said cover sheet are brought into contact with each other between said first mold surface and said second mold surface while continuing said holding of said cover sheet;
(d) applying a laminating pressure to said substrate and said cover sheet between said first and second mold surfaces while continuing said holding of said cover sheet, and releasing said cover sheet from said holding and moving said first and second molds toward said edge-folding tool in a first direction so that said substrate and said cover sheet together move toward said edge-folding tool and then cross from a first side to a second side of an edge-folding plane passing through said edge-folding tool perpendicularly to said first direction;
(e) moving said edge-folding tool laterally toward said molds to push said cover sheet edge around said substrate rim;
and
(f) moving said first and second molds relative to said edge-folding tool in a second direction opposite said first direction to move said substrate rim relatively toward said edge-folding tool so that said edge-folding tool laminates said cover sheet edge onto a back surface of said substrate rim.

4 more elements

A method of producing a trim panel including a substrate and a cover sheet laminated onto said substrate with a cover sheet edge folded and laminated around a substrate rim in an apparatus including a first mold having a first mold surface, a second mold having a second mold surface, a carrier frame having non-contiguous open spaces therethrough, and an edge-folding tool movable laterally relative to a direction of motion of said molds, said method comprising:

(a) disposing said substrate on said first mold surface;
(b) holding said cover sheet on said carrier frame at a position between said first mold surface and said second mold surface;
(C) heating said substrate and said cover sheet, including heating at least a portion of said cover sheet edge in the form of non-contiguous areas along said cover sheet edge through said non-contiguous open spaces of said carrier frame;
(d) moving at least one of said first mold and said second mold relatively toward each other until said substrate and said cover sheet are brought into contact with each other between said first mold surface and said second mold surface while continuing said holding of said cover sheet;
(e) applying a laminating pressure to said substrate and said cover sheet between said first and second mold surfaces, and moving said first and second molds relative to said edge-folding tool in a first direction so that said substrate rim crosses from a first side to a second side of an edge-folding plane passing through said edge-folding tool perpendicularly to said first direction;
(f) moving said edge-folding tool laterally toward said molds to push said cover sheet edge around said substrate rim;
and
(g) moving said first and second molds relative to said edge folding tool in a second direction opposite said first direction to move said substrate rim relatively toward said edge-folding tool so that said edge-folding tool laminates said cover sheet edge onto a back surface of said substrate rim.

5 more elements

Dependencies are inferred from the claim text.

Facts

Application: 08/462,200Filed 5 Jun 1995
Granted: 17 Feb 1998
Term ends: Not estimatedThe source records don’t support an estimate.

Classification17 codes

B29C 51/16
Shaping by thermoforming , i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing;…:…
B29C 63/0065
Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor: heat treatment
B29C 63/0073
Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor: of non-flat surfaces, e.g. curved, profiled
B29C 63/025
Using sheet or web-like material: applied by a die matching with the profile of the surface of resilient articles, e.g. cushions, seat pads