Abstract: A method for forming a 360 degree integral skin handle in a thermoplastic part for use in automotive trim products includes the steps of forming a mold with a partial recess with raised side ribs joined to a removable plug with raised side ribs and thereafter selectively directing heat from a first source through the mold and from a second source through the plug to form a completely closed, curved, heated tube surface and thereafter casting thermoplastic material against the curved, heated tube surface to fuse and cure a layer of material thereon in the form of a tube skin segment which is releasable from the mold when the plug is removed. Apparatus for practicing the method includes a mold with a recess therein and a plug is supported on the mold for movement into a position for closing the tube surface and into a demolding position for releasing the molded part. The raised side ribs combine to form spaced parallel recesses in the tube to form an inner surface on a 360.degree. with a smooth feel.

Abstract: A two tone plastic vehicle door shell (10), FIG. 1 has a front surface (12) and a side surface (14) separated into two tone segments (18, 20) (18a, 20a) by an integral two tone trim line (22). The shell's side surface is joined to a return flange (16). The return flange is arranged generally parallel to the front of the shell and includes a side flap (26) thereon which covers a cut-out opening (24) in the return flange on either side of the trim line at the side of the door. The cut-out opening (24) is provided for removing a seal and divider wall assembly from the door shell when thermoplastic powder is cast on a heated mold to form the shell. A tool FIG.

Abstract: A method for forming a 360 degree integral skin handle in a thermoplastic part for use in automotive trim products includes the steps of forming a mold with a partial recess closed by a removable plug and thereafter selectively directing heat from a first source through the mold and from a second source through the plug to form a completely closed, curved, heated tube surface and thereafter casting thermoplastic material against the curved, heated tube surface to fuse and cure a layer of material thereon in the form of a tube skin segment which is releasable from the mold when the plug is removed. Apparatus for practicing the method includes a mold with a recess therein and a plug is supported on the mold for movement into a position for closing the tube surface and into a demolding position for releasing the molded part.

Abstract: An apparatus for practicing a method for forming a 360 degree integral skin handle in a thermoplastic part for use in automotive trim products. The apparatus includes a mold with a recess therein and a plug being supported on the mold for movement into a position for closing the tube surface and into a demolding position for releasing the molded part. A heater device directs heat from a first source through the mold and from a second source through the plug to form a completely closed, curved, heated tube surface on which thermoplastic material is cast against the curved, heated tube surface to fuse and cure a layer of material thereon in the form of a tube skin segment which is releasable from the mold when the plug is removed.

Abstract: Apparatus for making composite doors includes means to locate a plastisol skin cover having an integral sail pocket formed therein within a mold cavity having a lid thereon moveable between opened and closed positions. The lid includes a retractable tool for positioning a hollow substrate extension in the sail pocket to both seal against foam leakage into the hollow substrate extension and to center the substrate extension within the pocket for defining a foam reaction space between the pocket and the substrate extension. A method for making integral 360.degree. sails on a composite door includes the steps of casting a fused plastisol skin having an integral 360.degree.

Abstract: A method for forming a 360 degree integral skin handle in a thermoplastic part for use in automotive trim products includes the steps of forming a mold with a prtial recess closed by a removable plug and thereafter selectively directing heat from a first source through the mold and from a second source through the plug to form a completely closed, curved, heated tube surface and thereafter casting thermoplastic material against the curved, heated tube surface to fuse and cure a layer of material thereon in the form of a tube skin segment which is releasable from the mold when the plug is removed. Apparatus for practicing the method includes a mold with a recess therein and a plug is supported on the mold for movement into a position for closing the tube surface and into a demolding position for releasing the molded part.

Abstract: A tool for manufacturing the two tone plastic shell includes an electroformed mold (28) having a first surface (29) for forming a front of a shell; a second surface (32) for forming the side edge portion of a shell; and a third surface segment (34) for forming a return flange on a door shell and the third surface segment has a cut-out opening (36) therein and a runout surface (40) providing for entry and removal of a seal and divider wall assembly to seal against a sealing rib (38) in the mold which separates the first, second and third segments into first and second casting surfaces. The divider rib and runout surface are sprayed with thermoplastic material to form a joint between material cast on the first and second casting surfaces and a skin return flap for sealing the cut-out opening.