초록 ▼

Instrument panels or other such panels are made by injection and distribution of foam precursors into a cavity between rigid and flexible sheets tightly clamped at their borders. FIG. 3 shows relative portion of rigid sheet (A), flexible sheet (B) and mold members (M1) and (M2). Injection preferably

Instrument panels or other such panels are made by injection and distribution of foam precursors into a cavity between rigid and flexible sheets tightly clamped at their borders. FIG. 3 shows relative portion of rigid sheet (A), flexible sheet (B) and mold members (M1) and (M2). Injection preferably occurs through an injection port at a parting line between (M1) and (M2) defined also by sheets (A) and (B).

대표청구항 ▼

A method for manufacture of a contoured panel that has a flexible side, a rigid side and a flexible foam therebetween, which method comprises: A. providing a contoured cavity in a mold, said cavity having definition comprising: 1. a flexible sheet having its inner area conforming to and optionally d

A method for manufacture of a contoured panel that has a flexible side, a rigid side and a flexible foam therebetween, which method comprises: A. providing a contoured cavity in a mold, said cavity having definition comprising: 1. a flexible sheet having its inner area conforming to and optionally drawn by vacuum against a first member of said mold, said inner area comprising a generally desired configuration for a first side of said panel and a border of said flexible sheet having runner and gate halves; 2. a rigid sheet comprising substantially the desired configuration for a second side of said panel, having its inner area (a) selectively spaced from said inner area of said flexible sheet and (b) held by a second member of said mold in spaced relation to said flexible sheet and the border of said rigid sheet having runner and gate halves; 3. closure of said mold members clamping borders of said rigid and flexible sheets along a peripheral portion of said cavity, said closure being interrupted by (a) an injection port for injection of liquid foam precursors and (b) an exhaust vent for exhaust of air from said cavity; 4. said clamped sheets forming: (a) a runner communicating with said injection port and extending from said injection port to a location within said cavity remote from said injection port so as to direct passage of foam precursors to said location after their injections; and (b) a gate communicating between said runner and said cavity, said gate adapted to meter foam precursors from said runner into said cavity; B. injecting under pressure an amount of foam precursors, sufficient to fill said cavity with said foam, through said injection port, into said runner and through said gate so as to provide a flow front of foam precursors at least about as long as said runner, which flow front travels into said cavity. The method in accordance with claims 1, or 2 or 3, wherein said liquid foam precursors comprise a polyurethane foam precursors. A panel made in accordance with claim 4.