Abstract: Plastic panels which are useful as automotive interior trim panels, interior door panels and the like decorative and structural panels, are made by a method which integrates insert sections in the surfaces of the panels and eliminates insert edge trim molding strips. The method includes bonding, via an adhesive film, at least the edge portions of the inserts upon a thin plastic sheet, pre-sized blank, then removing the plastic sheet portions and adhesive film that overlap the insert within the bonded portions; next, positioning the blank in a mold against a mold face and molding in situ and simultaneously bonding a plastic substrate against the blank and the exposed surface of the insert. A substantially continuous, channel forming means, such as a narrow rib or a groove, on the mold face, is overlapped by the bonded insert edge portions and sheet portion, which are folded by said means to form a narrow, relatively deep channel. The insert edges are part of and, consequently, are concealed within the channel.

Abstract: Plastic panels which are useful as automotive interior trim panels, interior door panels and the like decorative and structural panels, are made by a method which provides an underturned edge onto the panel. The method includes positioning blanks into a mold cavity over top of a mold ring. The blanks are secured to the mold ring and the blank is secured to the mold cavity via a vacuum. The two piece mold is mated together and a substrate is injected into the mold cavity. The cavity is opened, the ring is lifted and the formed part is removed from the mold.

Abstract: Plastic panels which are useful as automotive interior trim panels, interior door panels and the like decorative and structural panels, are made by a method which integrates insert sections in the surfaces of the panels and eliminates insert edge trim molding strips. The method includes positioning inserts into a mold, adding plastic to the mold to form a thin plastic sheet, presized blank, then removing the plastic sheet portions with the inserts; next, positioning the blank in a mold against a mold face and molding in situ and simultaneously bonding a plastic substrate against the blank and the exposed surface of the insert. Alternatively the blank can remain in the same mold and a suitable mating half of the mold can close off the plastic sheet and the plastic substrate can be injected or poured into the mold.

Abstract: Plastic panels which are useful as automotive interior trim panels, interior door panels and the like decorative and structural panels, are made by a method which integrates insert sections in the surfaces of the panels and eliminates insert edge trim molding strips. The method includes bonding at least the edge portions of the inserts upon a thin plastic sheet, pre-sized blank, then removing the plastic sheet portions that overlap the insert within the bonded portions; next, positioning the blank in a mold against a mold face and molding in situ and simultaneously bonding a plastic substrate against the blank and the exposed surface of the insert. A substantially continuous, channel forming means, such as a narrow rib or a groove, on the mold face, is overlapped by the bonded insert edge portions and sheet portion, which are folded by said means to form a narrow, relatively deep channel. The insert edges are part of and, consequently, are concealed within the channel.

Abstract: Plastic panels which are useful as automotive interior trim panels, interior door panels and the like decorative and structural panels, are made by a method which integrates insert sections in the surfaces of the panels and eliminates insert edge trim molding strips. The method includes positioning inserts into a mold, adding plastic to the mold to form a thin plastic sheet, presized blank, then removing the plastic sheet portions with the inserts; next, positioning the blank in a mold against a mold face and molding in situ and simultaneously bonding a plastic substrate against the blank and the exposed surface of the insert. Alternatively the blank can remain in the same mold and a suitable mating half of the mold can close off the plastic sheet and the plastic substrate can be injected or poured into the mold.

Abstract: Plastic panels which are useful as automotive interior trim panels, interior door panels and the like decorative and structural panels, are made by a method which integrates insert sections in the surfaces of the panels and eliminates insert edge trim molding strips. The method includes bonding at least the edge portions of the inserts upon a thin plastic sheet, pre-sized blank, then removing the plastic sheet portions that overlap the insert within the bonded portions; next, positioning the blank in a mold against a mold face and molding in situ and simultaneously bonding a plastic substrate against the blank and the exposed surface of the insert. A substantially continuous, channel forming means, such as a narrow rib or a groove, on the mold face, is overlapped by the bonded insert edge portions and sheet portion, which are folded by said means to form a narrow, relatively deep channel. The insert edges are part of and, consequently, are concealed within the channel.

Abstract: Plastic panels which are useful as automotive interior trim panels, interior door panels and the like decorative and structural panels, are made by a method which integrates insert sections in the surfaces of the panels and eliminates insert edge trim molding strips. The method includes bonding at least the edge portions of the inserts upon a thin plastic sheet, pre-sized blank, then removing the plastic sheet portions that overlap the insert within the bonded portions; next, positioning the blank in a mold against a mold face and molding in situ and simultaneously bonding a plastic substrate against the blank and the exposed surface of the insert. A substantially continuous, channel forming means, such as a narrow rib or a groove, on the mold face, is overlapped by the bonded insert edge portions and sheet portion, which are folded by said means to form a narrow, relatively deep channel. The insert edges are part of and, consequently, are concealed within the channel.