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US 7,115,225 B2Granted
Pseudo insert molding for trim parts using polyurethane spray process
AssigneeLear Corporation
InventorsKenneth R. Parrish, Jean-Jacques Katz, Gordon L. Ebbitt, Barry R. Wyerman
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Abstract
A method of making a composite part including an insert and an elastomer layer that is bonded to the insert. The insert is placed in a mold and an uncured elastomer is sprayed into the mold to form a composite part. The inherent adhesive properties of the uncured elastomer is the sole mechanism for bonding the elastomer to the insert.
Claims4
A method of making an interior trim part for a vehicle, comprising:
- providing a mold that defines a mold surface in a mold cavity wherein the mold has a pattern defined by the mold surface that has areas of greater depth and areas of lesser depth;
- spraying an elastomer material on the mold surface to partially fill the mold cavity wherein the areas of greater depth are filled by spraying to a greater depth than the areas of lesser depth;
- loading an insert into the mold and onto an upwardly facing surface of the elastomer material with a facing side of the insert facing upwardly and a backing side of the insert contacting the upwardly facing surface of the elastomer material;
- bonding the backing side of the insert to the upwardly facing surface of the elastomer material;
- curing the elastomer material to form a composite trim part having areas of a molded surface pattern on the composite part defined by the greater and lesser depth;
- and
- removing the composite part from the mold.
4 more elements
Dependencies are inferred from the claim text.