초록 ▼

An interior trim component, such as a door panel, having an outer skin backed by a low density molded mat foam substrate and an energy absorbing foam backing is manufactured in a single mold tool in a multiple stage foaming operation in which the outer skin and a glass reinforcement mat are position

An interior trim component, such as a door panel, having an outer skin backed by a low density molded mat foam substrate and an energy absorbing foam backing is manufactured in a single mold tool in a multiple stage foaming operation in which the outer skin and a glass reinforcement mat are positioned in the mold cavity and a mold insert corresponding to the energy absorbing foam layer is mounted to the lid of the mold tool. A polyurethane precursor mixture is poured into the open mold and the lid closed to generate the low density molded mat substrate. The mold is opened and the mold insert removed and a second urethane precursor mixture is poured onto the substrate and the mold closed to generate the energy absorbing foam backing within the space of the mold cavity previously occupied by the mold insert.

대표청구항 ▼

[ We claim:] [1.] A method of manufacturing an interior trim article having an outer flexible skin bonded to a low density rigid foam substrate and an energy absorbing foam backing, the method comprising the steps of:preparing a mold insert representing the energy-absorbing foam backing to be formed

[ We claim:] [1.] A method of manufacturing an interior trim article having an outer flexible skin bonded to a low density rigid foam substrate and an energy absorbing foam backing, the method comprising the steps of:preparing a mold insert representing the energy-absorbing foam backing to be formed;preparing an outer skin of flexible material;in a first stage foam molding operation, (a) positioning the mold insert in a mold cavity of an openable foam molding tool made from first and second mold sections and releasably mounted to one of said first and second mold sections to block off and preserve a secondary foam space in the cavity for subsequent molding of the energy absorbing foam backing, (b) positioning the outer skin in the mold cavity in spaced relation to the mold insert to provide a primary foam space between the skin and mold insert, and (c) reacting a first precursor mixture within the primary foam space to generate therein a low density rigid foam structural substrate bonded to the skin; andin a subsequent stage foam molding operation within the same molding tool made from said first and second mold sections, (a) removing the mold insert from the mold cavity and releasing it from the respective mold section to open the secondary foam space, and (b) reacting a second precursor mixture within the secondary space to generate therein an energy absorbing foam backing bonded to the substrate for absorbing the energy of an impact imparted to the article.