Interior trim foam product and method of fabrication thereof

Details Interior trim foam product and method of fabrication thereof Interior trim foam product and method of fabrication thereof

1989-03-20

1990-01-09

Robinson, Ellis P.

Stock material or miscellaneous articles

Sheet including cover or casing

Foamed or expanded material encased

296 3712, 428 57, 428 76, 428138, 428192, 4283197, B32B 306, B32B 528

Patent

active

048927708

ABSTRACT:
A vehicle interior part such as a glove box door or console door and its method of manufacture includes an outer shell backed by foam material which is bonded to a mold insert that reinforces the part and defines an exposed back. The insert includes a peripheral edge spaced with respect to a continuously formed raw peripheral edge of the shell and further includes a flange portion that is post formed so as to be bonded to and located in a net out relationship with the raw edge to define a finished surface appearance. The door is formed by a process that includes the steps of providing a composite plastic structure having a molded shell and foam component with an insert located in spaced relationship with respect to the shell to define a foamed cavity with a raw edge of foam and shell around the periphery of the composite member; providing a post formed flange on the insert and loading the shell, foam and insert components into a female nest; and heat die post forming of the flange to upset it into net out overlaying relationship with both the raw edge of the shell and the exposed edge of foam formed in the composite part so as to produce a finished exterior surface on the composite part.

REFERENCES:
patent: 3676278 (1967-12-01), Stewart
patent: 3956549 (1976-05-01), Stoeberl
patent: 4385090 (1983-05-01), Sims
patent: 4725089 (1988-02-01), Langer
patent: 4786539 (1988-11-01), Grether

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