Method of making a sandwich-type, compression-molded, composite component having improved surface appearance

A method of making a sandwich-type, compression-molded, composite component having improved surface appearance and for use in a vehicle, the method comprising:

• heating a blank or stack of sandwich material including first and second resin skins and a core positioned between the skins and having a large number of cavities, the skins and the core being heated to a softening temperature of the resin;
• providing a compression mold including component-forming, upper and lower dies with opposing molding surfaces cooperating to define a mold cavity having a shape substantially corresponding to a desired shape of the component;
• placing the blank or stack on the lower die in an open position of the mold;
• moving the dies toward each other until the old is in a closed position;
• allowing the heated blank or stack to cool in the mold cavity in the closed position until inner surfaces of the skins are bonded to top and bottom surfaces of the core to seal the core cavities, air in the sealed cavities urging softened portions of the skins inwardly towards the cavities of the core as the air in the cavities cools;
• and
• applying a vacuum at a first outer surface of the stack or blank in the mold cavity sufficient to prevent debossing and improve appearance of the first outer surface during the step of allowing.

A method of making a sandwich-type, compression-molded, composite component having improved surface appearance for use in the interior of a vehicle, the method comprising:

• heating a blank or stack of sandwich material including first and second resin skins and a resin core positioned between the skins and having a large number of cavities, the skins and the core being heated to a softening temperature of the resins;
• providing a compression mold including component-forming, upper and lower dies with opposing molding surfaces cooperating to define a mold cavity having a shape substantially corresponding to a desired shape of the component;
• place the blank or stack on the lower die in an open position of the mold;
• moving the dies toward each other until the mold is in a closed position;
• allowing the heated blank or stack to cool in the mold cavity in the closed position until inner surfaces of the skins are bonded to top and bottom surfaces of the core to seal the core cavities, air in the sealed cavities urging softened portions of the skins inwardly towards the cavities of the core as the air in the cavities cools;
• and
• applying a vacuum at a first outer surface of the stack or blank in the mold cavity sufficient to prevent debossing and improve appearance of the first outer surface during the step of allowing.