Molding method for making plastic foam-backed shells
AssigneeTextron Automotive Company Inc.
InventorsMichael J. Gallagher, Bruce A. Batchelder
Life of this patent
Estimating the term…
Abstract
A method of molding a plastic shell having an outer pliable skin layer and a foam backing layer comprises casting a first skin layer portion from wear resistant material in a first casting sequence for those areas of the panel susceptible to high wear and in a second casting sequence casting self-skinning foamable material against the remaining portion of the mold surface and over the first-cast skin layer portion to develop, simultaneously, the remaining outer skin layer portion of the shell and a foam backing layer which extends across the entire skin layer.
Claims12
A method of molding a plastic shell having a pliable outer skin and a backing layer, the method comprising the steps of:
- providing a charge of a first plastic material configured to form a wear resistant first skin layer portion of the outer skin;
- providing a charge of a second plastic material configured to form a second skin layer portion of the outer skin that is relatively less wear resistant than the wear resistant skin layer portion;
- providing a casting mold having a heated mold surface;
- forming the wear-resistant first skin layer portion by depositing the first plastic material against a predetermined portion of the mold surface, the wear-resistant first skin layer portion including a backside surface spaced from the mold surface;
- forming an integral backing layer behind the wear-resistant first skin layer portion while simultaneously forming the second skin layer portion on a remaining portion of the heated casting surface by casting the second material across the remainder of the heated casting surface and across the backside surface of the wear resistant first skin layer portion;
- and
- forming the wear-resistant skin layer portion by partitioning the predetermined portion of the mold surface from the remaining exposed portion during casting of the first plastic material to contain such material within the predetermined region of the mold surface.
A method of molding a plastic shell having a pliable outer skin and a backing layer, the method comprising the steps of:
- providing a charge of a first plastic material configured to form a wear resistant first skin layer portion of the outer skin;
- providing a charge of a second plastic material configured to form a second skin layer portion of the outer skin that is relatively less wear resistant than the wear resistant skin layer portion;
- providing a casting mold having a heated mold surface;
- forming the wear-resistant first skin layer portion by depositing the first plastic material against a predetermined portion of the mold surface, the wear-resistant first skin layer portion including a backside surface spaced from the mold surface;
- forming an integral backing layer behind the wear-resistant first skin layer portion while simultaneously forming the second skin layer portion on a remaining portion of the heated casting surface by casting the second material across the remainder of the heated casting surface and across the backside surface of the wear resistant first skin layer portion;
- and
- wherein the first plastic material is polyvinyl chloride.
Dependencies are inferred from the claim text.