US 6,805,542 B2 · Tool for forming a multiple foam substrate for impact energy absorption

Abstract

The present invention relates to a multiple foam substrate of predetermined shape and a method of manufacturing the substrate. The substrate is a multiple foam substrate which may be manufactured by the method with a mold having first and second mold cavities. The method includes injecting a first foam into the first mold cavity sufficiently to fill the first mold cavity and storing the first foam in the first mold cavity for a predetermined time sufficient to form a substantially non-mixing surface on the first foam. The method further includes injecting a second foam into the second mold cavity and onto the non-mixing surface on the first foam sufficiently to fill the second mold cavity. The method further includes storing the second foam in the second mold cavity for a predetermined time sufficient to bond the first foam to the second foam along the non-mixing surface.

Claims6

Dependent claims

A mold for manufacturing a multiple foam substrate of predetermined shape, the mold comprising:

an upper portion of the mold having a first surface from which a first mold face extends and a second surface from which a second mold face extends, the upper portion of the mold being pivotable about an axis, wherein the first and second surfaces are adjacent to each other and oriented at different radial angular orientations relative to the axis;
and
a lower portion of the mold having a lower surface from which a lower mold face extends;
the first mold face engaging the lower portion of the mold to define a first mold cavity in a first closed position, the upper portion of the mold being moved away from the lower portion of the mold, pivoted about the axis, and moved toward the lower portion causing the second mold face to engage the lower portion of the mold to define a second mold cavity in a second closed position.

1 more element

A mold for manufacturing a substrate for an interior vehicle trim component having at least two different foam portions, comprising:

a first mold part defining a first portion of a mold cavity;
a second mold part being received by the first mold part and defining a second portion of the mold cavity, a first foam being injected between the first and second mold parts through a first injection nozzle carried by the second mold part, the first foam having a first density and conforming to the first and second portions of the mold cavity;
a third mold part being received by the first mold part and defining a third portion of the mold cavity that includes the first foam, a second foam being injected into the third portion through a second injection nozzle carried by the third mold part after the first foam sets to form a non-mixing surface, wherein the second foam has a second density that is different from the first density and bonds to the non-mixing surface to provide a multiple layer foam interior trim substrate for energy absorption.

Dependencies are inferred from the claim text.

Tool for forming a multiple foam substrate for impact energy absorption

Life of this patent

Tool for forming a multiple foam substrate for impact energy absorption

Life of this patent

Abstract

Claims6