Abstract: The present invention relates to a process for the production of a polyurethane foam backed instrument panel. This process comprises slicing a free-rise bun of polyurethane foam to form a skived polyurethane foam, bonding the skived foam to a skin material to form a laminate, optionally, rolling the foam/skin laminate, thermoforming the foam/skin laminate into an instrument panel skin, positioning the instrument panel skin into the cavity of a mold, positioning a retainer into the core of the mold, adhering the retainer to the laminate by placing an adhesive film onto the retainer, closing the mold to apply heat and pressure, and removing the resultant instrument panel from the mold. Suitable polyurethane foams for the present invention may be flexible foams or semi-rigid foams. This invention also relates to the polyurethane foam backed instrument panels produced by this process.

Abstract: Structurally strong articles are formed from inherently weak materials, such as expanded polystyrene, coated with one or more layers of a thermoplastic sheet material, such as amorphous polyethylene terephthalate. The inherently weak interior members are either fluid permeable or perforated. These members are sandwiched or encapsulated by heat deformable outer layers. The articles are made by applying a fluid pressure between the stack of interior members and the thermoplastic sheet, with the thermoplastic sheet heated to conform to the interior members. The fluid pressure is maintained until the thermoplastic sheet is cooled so that tension extending in all directions is produced in the sheet. The resulting articles are useful as building elements, signs, motor vehicle panels, pallets, surf boards, and sail boards.

Abstract: Molding, such as that used in the manufacture of picture frames, is laminated with a covering wrap of foil, paper, plastic, cloth, or wood veneer and is embossed on the same machine shortly thereafter. The covering wrap is adhered by an adhesive and the embossed pattern is formed in part by pressure of a pattern against the substrate and through the covering wrap and partly by forcing of the adhesive used in the laminating process into various raised portions of the pattern, thus supporting and enhancing the embossed profile.

Abstract: A method for bonding together premolded skins of elastomeric material including the steps of providing at least a first and second premolded elastomeric skin. Providing a mold with first and second mold parts and positioning the first premolded elastomeric skin in the first part of the mold. The method also includes positioning fill material atop the first premolded elastomeric skin in the first part of the mold, then applying a layer of elastomer at points of connection of the first elastomeric skin to the second elastomeric skin. The method also includes pressing the first and second mold parts into connection, thereby binding the elastomeric skins. A mounting member is positioned on at least one premolded skin of elastomeric material. The method also includes the step of providing a reinforcement member positioned around the mounting member formed in at least one premolded skin of elastomeric material.

Abstract: A trim panel having an integral handle is made using a subassembly comprising a structural substrate that has a handle hole and a handle frame that spans the handle hole. The subassembly is mounted on a pneumatic buck and a sheet of pliable and stretchable expanded vinyl plastic is then draped over the subassembly to form a decorative cover for the trim panel. The plastic sheet is then vacuum drawn against the top of the subassembly and partially around the handle frame. Draped portions of the plastic sheet between the handle frame and the handle hole, are then cut and trimmed, to complete the wrapping of the handle frame and the edge of the handle hole. The cut ends of the draped portions wrapped around the handle frame are tucked in a longitudinal slot in the underside of the handle frame.

Abstract: A spherical body having a core and a surface layer is manufactured by a method comprising a preforming step in which a pair of sheet blanks (1) are formed into half-shells (11) in a two-part mold (2) having hemispherical concave mold halves by pressing each blank from one side while applying vacuum suction to the other side; a surface layer forming step in which the half-shells are loaded into another two-part mold (12) having pattern-forming projections, the core (19) is placed on one mold half, and the other mold half is joined thereto to close the mold, thereby pressing the core against the inner side of each half-shell, concurrent with which vacuum suction is applied to the outer side; and a molding step in which the surface layer is fused and solidified onto the core within the closed mold.

Abstract: A method of forming fabric for making foam-in-place molded articles such as preferably seat cushions. A film is secured to a frame and tacked by adhesive to a piece of fabric, not secured to the frame, that forms the outer covering of the seat cushion for permitting the fabric to move relative to the film during forming to enable fabrics which cannot stretch a considerable amount to be used. To form the fabric, the film and fabric are placed in a female mold and the film and fabric are drawn into a cavity of the mold and against a contoured surface in the cavity forming a recess in the film and fabric. To counteract compressive stresses in the fabric during forming, the frame can have one or more fabric tensioners that selectively apply tension to the fabric during forming. To mold the cushion, a foam is poured into the recess and allowed to cure until it hardens into a foam core and bonds with the film.

Abstract: A mold is provided having the shape of the trim panel and having a blade projecting from the mold at the juncture between the first and second regions to be covered by the different sheet materials. A first sheet material is provided and cut to fit the first region and also extend over the blade. This first sheet is draped over the mold and the blade. A second sheet material is bonded to a rigid substrate material, with the rigid substrate material having a flange structure along the edge margin thereof which is adapted to snap-fit over the blade of the mold and thereby hold in place the first sheet material which had previously been draped over the blade. The mold is then closed and a suitable molding material is injected to adhere to the back side of the first sheet material and the substrate layer of the second sheet material to thereby form the rigid trim panel. The mold is opened and the rigid trim panel is removed from the blade.

Abstract: A paint film assembly which includes a thermoformable paint film having a high gloss and DOI and a thermoformable masking film which is removably bonded to the paint film so as to better protect the paint film during shipping and handling, and during subsequent forming and processing (e.g., thermoforming and/or insert molding) of the paint film onto an article or part, while substantially retaining the surface finish of the paint film, particularly the gloss and DOI. The masking film comprises a urethane layer that is laminated or otherwise bonded to the paint film to form a masked paint film. The masking film is thermoformable and/or moldable with the paint film so as to form a thermoformable and/or moldable masked paint film. After the masked paint film is thermoformed and/or molded, the masking film is still readily removable from the paint film.

Abstract: Forming a structure of seat back with armrest is effected by pressingly adhering a covering material to a foam padding of a predetermined sheet back shape, through a foaming process and an adhering-type stamping process, using a die element having a protuberant die surface part in both of the foaming and adhering-type stamping processes. The protuberant die surface part includes at least two sloped die surfaces. Hence, in operation, the die element can be smoothly removed from a resulting foam padding in which a recessed portion with at least two sloped walls is formed, at the foaming process. Then, the covering material is bonded evenly in such recessed portion and other surrounding area of padding at the adhering-type stamping process.

Abstract: Methods for pre-shaping paint film laminates and co-molding processes using such laminates are disclosed. The methods comprise the steps of providing (e.g., forming or procuring) a plastic paint film laminate, softening the paint film laminate with heat such that one or more localized portions of the member absorb more heat than the remainder, and deforming the plastic film member to form a pre-shaped article. The formation of different heat absorption areas on the paint film laminate is referred to as the provision of heat sink areas. These heat sink areas can be provided for example by surface coating of heat retention means such as black paint or ink pigments on localized areas of the surface of the laminate followed by uniform heating of the laminate in an oven or the like or the sheet can be heated in localized areas to a greater extent (i.e. time and/or temperature) than in remainder portions by the means of heat guns or the like.

Abstract: A method for making a vehicle trim panel includes bonding an interior lining material to a preformable foam sheet and preforming the bonded lining material and foam sheet to provide a preformed blank, and joining the preformed blank to a second lining material and bonding both the preformed blank and the second lining material to a substrate to make the vehicle trim panel.

Abstract: A method for producing a heel mat-attached floor rug for a motor vehicle. A floor rug proper is prepared which has been previously compression-molded to have a three-dimensionally projected portion. Then, the floor rug proper is put on a lower die of a depression-molding device in such a manner that the three-dimensionally projected portion of the rug proper neatly covers a projected portion formed on a shaping surface of the lower die. Then, a heel mat of thermoplastic material is put on a shaping surface of an upper die of the compression-molding device. The shaping surface of the upper die has a depressed portion which is shaped to neatly receive the projected portion of the lower die. Then, the upper die is pressed against the lower die having the heel mat and the floor rug proper put therebetween. Then, a lower surface of the heel mat is melted, by means of high frequency induction welding, thereby to bond the heel mat to the floor rug proper.

Abstract: An improved method of forming a vehicle trim part includes the initial step of securing an insert to a vinyl skin in a vacuum mold. The cloth insert is attached to the outer face of the skin, and the two are then placed into a foam mold as a single preform. In this way, if the cloth is improperly connected to the skin, the part can be identified as scrap before foam is injected to complete the part. Once the preform is moved into the foam mold, foam is injected behind the part. Since the preform is positioned within the mold as a single part, the invention more accurately positions the insert and skin relative to the mold prior to foam injection. Again, this improves the quality and appearance of the vinyl part.

Abstract: A method and apparatus for bonding a cover (22) over the undulating surface of a foam cushion (10) includes placing the foam cushion (10) on a tool (18), piercing the cushion (10) with a plurality of needles (44), lifting the needles (44) to lift the cushion (10) as the cushion is frictionally retained on the needles (44), heating ambient air and ejecting the hot air from the needles (44) and into the cushion to elevate the temperature of the cushion. A compression plate (58) with holes (60) extending therethrough is disposed against the backside of the cushion (10) with the needles (44) extending through the holes (60). The needles (44) with the cushion (10) thereon are lowered to place the undulating surface of the cushion against an adhesive film (82) on the backside of the cover (22) so that heat is transferred from the cushion (10) to melt the adhesive.

Abstract: A process for making a composite substrate with cover utilizes heated dies of a forming tool to deform and heat the substrate. The heated substrate is then placed in a marriage tool having a room temperature lower die for receiving the substrate, and a heated upper die. A cover material layer is placed over the substrate and the marriage tool is closed. The cover material includes a heat activatable adhesive and with the marriage tool closed, the heat from the upper die adheres the cover material layer to the substrate while the room temperature die cools the substrate. In this way, when the marriage tool is opened, the composite structure can be removed without deformation.

Abstract: A method for forming a headliner including a fluted paper central substrate includes forming the fluted paper substrate in a first forming tool. The formed substrate is then moved to a second bonding tool. A cover layer and an adhesive layer are actuated in the bonding tool to secure the cover layer to the substrate. The bonding tool preferably consists of a heated upper portion adjacent the cover layer and the adhesive, and a cooled lower portion which receives the base material. The use of the cooled bottom portion maintains the dimensional accuracy of the base layer during the bonding process. The heated upper layer ensures efficient and quick actuation of the adhesive to bond the cover layer to the substrate.

Abstract: A material dispenser for dispensing single sheets of material from stacks of sheets of material or from rolls of material and applying an adhesive strip to the sheet. The adhesive strip is applied by contacting the adhesive portion of an adhesive transfer tape to the sheet. The sheet of material with the adhesive strip applied thereto can be used to wrap floral arrangements or flower pots or other articles. The apparatus may be combined with an automatic pot wrapping apparatus so the adhesive application and decorative pot wrapping sequence can be combined into one continuous operation.

Abstract: A leading edge structure for an aircraft has an outer wall, an inner wall disposed within the outer wall and including a partition with, the outer wall, the inner wall and the partition jointly defining a hot-air chamber, and a plurality of flow-rectifying fins or disposed in the hot-air chamber and compartmentalizing the hot-air chamber into a plurality of hot-air passages. The outer wall and the flow-rectifying fins are made of a fiber-reinforced synthetic resin and joined to each other by curing. The inner wall and the partition comprise a single component which is made of a fiber-reinforced synthetic resin, and being bonded to the outer wall. Alternatively, the inner wall and the partition are separate from each other and are joined to each other.

Abstract: A process for making a mineral fiber artificial log that can be used in vented and unvented gas fireplaces, fireplace inserts, and free-standing gas fire room heater to simulate the appearance of a real burning log. The process utilizes a screen mold formed from a pattern that can be made to give the desired exterior configuration and size for the formed log. The screen mold is placed in an outer porous jacket and then in a vacuum chamber. A slurry of the formulation containing mineral wool fibers, a suitable high temperature binder, and water is drawn into the mold while contained in the vacuum chamber, so liquid is drawn through the mold and mineral fibers are trapped in the mold. The log is formed to the size and shape of the mold. Once molded, the log is removed from the mold, dried in an oven, treated with a suitable rigidizing exterior coating, and again oven dried. The log is painted suitably, dried again, and packaged for sale.

Abstract: A method and apparatus (84,94) for controlling an assembly for bonding a cover (22) over the undulating surface of a foam cushion (10) controls a tool actuator cylinder (80) to tilt a tool (18) to a loading position to permit placing the cover (22) and an adhesive layer (82) on the tool, tilts the tool to a working position to permit placing the cushion on the tool, controls a plate actuator cylinder (62) to lower and raise a compression plate (58) to force air from an interior of the cushion, controls a ram actuator cylinder (90) to lower a ram (14) to pierce the cushion with a plurality of hollow needles (44) attached to a plenum chamber, controls a heater (38) to heat compressed air and eject the hot air from the needles into the cushion to elevate the temperature of the cushion and melt the adhesive, and lowers and raises the compression plate to force hot air from the interior of the cushion to cure the adhesive and bond the cover to the cushion.

Abstract: An automotive instrument panel includes a molded plastic retainer formed with an integral airbag deployment door surrounded by a channel defining a tear seam enabling the door to separate and hinge outwardly upon deployment of the airbag. A foam-backed cover of flexible plastic material is applied over the outer surface of the panel and is severed along the length of the channel to eliminate any influence that the cover may have on resisting the opening of the door. The severed cover portion can either be removed to expose the door or else be left in tact and bonded to the door.

Abstract: It consists of continuous production of a woven or unwoven piece of textile fibers, to whose piece a layer that is going to be the middle one is affixed on the back surface. It is thick enough to offer resistance to the passing of a thermostable material that will be finally affixed to the same, wherein it will remain imbedded. The textile compound formed of the two layers referred to first of all, the second layer being an unwover layer, is subjected to a hot pre-forming process. Then it is inserted in a mold in which the thermostable material formed by a polyester-fiber glass mass is placed, hot pressing the whole and obtaining a rigid and resistance sheet-like body, whose visible surface is covered with the layer of textile compound that is highly resistant to vandalism.

Abstract: The present invention relates to a process for the bonding by adhesion of a cover to a shaped padding, in particular of polyurethane foam, especially for the production of seat cushions. The process includes the step of arranging a cover (1) in a cold-shaping device (2) and fixing it thereto by means of a holding frame (3), then placing an adhesive (4) on the internal walls of the cover (1). The surface of the padding (5) intended to cooperate with the internal walls of the cover (1) is subsequently heated to a high temperature. After a predetermined temperature has been reached the heating is interrupted and the thus heated foam padding (5) is applied to the internal walls of the cover (1) coated with adhesive (4), so as to bring about instantaneous transmission of heat by direct contact with the adhesive (4) leading to extremely rapid setting thereof. The cold-shaping device (2) is then opened and the padding(5) equipped with its cover (1) is removed.

Abstract: A method and apparatus (84, 94) for controlling an assembly for bonding a cover (22) over the undulating surface of a foam cushion (10) by controlling a ram actuator cylinder (90) to lift a ram (14) to permit placing the foam cushion (10) on a tool (18), lowering the ram (14) to pierce the cushion (10) with a plurality of needles (44), lifting the ram (14) to lift the cushion (10) which is frictionally retained on the needles (44), controlling a heater (38) to heat ambient air and ejecting the hot air from the needles (44) into the cushion (10) to elevate the temperature of the cushion. A pair of plate actuator cylinders (62) are controlled to dispose a compression plate (58) with holes (60) extending therethrough against the backside of the cushion (10) with the needles (44) extending through the holes (60).

Abstract: A thermal and acoustic barrier for automotive floor pan carpeting is made by cutting synthetic foam sheet in a continuous process to create a foam surface complementary to the three dimensional shape of the floor pan surface. The cut foam sheet is bonded to the underside of the carpeting and installed with the complementary foam surface facing the floor pan.

Abstract: A method for producing an interior a product comprising a corrugated cardboard base formed into a predetermined shape and a decorative skin layer laminated to one side of the cardboard base. Using a hot-press, a substantially planar cardboard base comprising a corrugated core and liners laminated to both sides of the core through thermoplastic resin films is formed into a predetermined shape by heat and pressure at a temperature high enough for remaining heat to be sufficient to melt a hot melt adhesive on the surface of the cardboard base after removal of the formed cardboard base from the hot press but not so hot as to scorch the paper of the cardboard base. The formed cardboard base is then taken out of the hot press and transferred into a cold press, thereafter a decorative skin is put on the surface of the formed cardboard base through a hot melt adhesive.

Abstract: A method of forming fabric for making foam-in-place molded articles such as preferably seat cushions. A film is secured to a frame and tacked by adhesive to a piece of fabric, not secured to the frame, that forms the outer covering of the seat cushion for permitting the fabric to move relative to the film during forming to enable fabrics which cannot stretch a considerable amount to be used. To form the fabric, the film and fabric are placed in a female mold and the film and fabric are drawn into a cavity of the mold and against a contoured surface in the cavity forming a recess in the film and fabric. To counteract compressive stresses in the fabric during forming, the frame can have one or more fabric tensioners that selectively apply tension to the fabric during forming. To mold the cushion, a foam is poured into the recess and allowed to cure until it hardens into a foam core and bonds with the film.

Abstract: An automotive trim panel is made by using an apparatus and method that bond together two trim coverstock segments having different colors, gauges or textures and two rigid substrate components into a single trim panel with the two coverstock segments meeting along a finished joint line. The method includes joining the coverstock segments together to form a rough seam, supporting the substrate components on two spaced-apart movable mold components with each substrate component having a mating flange that extends into the space between the mold components, applying an adhesive layer to the substrate upper surfaces, heating the joined coverstock segments and vacuum or positive air pressure-forming them across the substrate upper surfaces with the rough seam lying midway between the spaced-apart mold components.

Abstract: An apparatus for welding a reinforcing member to a bag-like device or contraceptive device is disclosed. The apparatus includes at least one hollow mandrel. The hollow mandrel has an outer surface with an annular groove for holding the reinforcing member. The apparatus has a means for applying a closed end of the bag-like device into the hollow mandrel and an open end of the bag-like device over the hollow mandrel at the outer surface with the annular groove for holding the reinforcing member. The apparatus also includes a welding device for welding the reinforcing member to the bag-like device. A method for welding the reinforcing member to a bag-like device is also disclosed.

Abstract: A machine and method for forming a variety of predetermined shapes of curved laminations formed from a plurality of individual laminates bonded together by an adhesive. The laminating machine comprises a support frame, a rotating RF-conducting capstan mounted in the support frame, and an RF-conducting anvil supported by the support frame in opposing relation to the capstan. An RF energy source is operatively connected to the capstan, and a ground terminal is operatively connected to the anvil. Custom template flanges serve both as determinants of a particular lamination's curved shape and also preferably as components of the completed laminated structure, which includes the curved lamination. Each template flange includes a laminate retainer, preferably an elongated groove, which holds a foundation laminate in a predetermined curved shape.

Abstract: A method for bonding a cover fabric to a cushion body to form a seating component, preferably a seat cushion of a vehicle seat assembly, includes the step of supplying a heated atmosphere, preferably steam under pressure, to a forming tool of a forming apparatus, the forming tool diffusing the heated atmosphere and passing the heated atmosphere out of the tool, through the cover fabric, and into the cushion body to melt an adhesive layer between the cushion body and the cover fabric, while the cushion body and cover fabric are subjected to a pressurized environment, preferably by locating the forming apparatus, the cover fabric, and the cushion body in a pressure chamber maintained at relatively high pressure.

Abstract: A method of integrally bonding a foam seat pad or other article to a cover material, includes steps of coating a main surface of the pad with a heat activated adhesive. Then, the pad is affixed to an upper mounting member. A lower mounting member is positioned opposite the upper mounting member and the cover material is disposed on the lower mounting member. Heating is applied to the adhesive coating the main surface of the pad, and when sufficient heat is applied the upper and lower mounting members are pressed together for a predetermined time period. Clamps are provided on the mounting members for surely positioning the pad relative the cover material. Thus, accurate positioning and strong bonding are reliably assured.

Abstract: A process for forming decorative panels for automobile interiors uses a compression press, a grooved stationary platen die and a movable platen die with a metal blade edging mounted thereon. The blade edging has a peripheral shape matching the outer wall of the groove in the stationary platen die section, and the contour of the movable platen die matches the contour of the stationary die and a formed decorative panel having a downturned edge of the same peripheral shape as the groove and blade. This downturned edge becomes embedded in a sheet of mounting panel stock upon closing of the compression press.

Abstract: In accordance with the present invention, there is provided a process for preparing thermoplastic elastomer laminates which comprises placing a thermoplastic elastomer foamable sheet in an unexpanded state containing a polyolefin resin, an ethylene/.alpha.-olefin copolymer rubber and a foaming agent onto the back of a thermoplastic elastomer sheet containing a polyolefin resin and an ethylene/.alpha.-olefin copolymer rubber, heat fusion bonding both sheets to each other, and heating the resulting laminated sheet to expand the thermoplastic elastomer sheet containing the foaming agent.

Abstract: The heat insulator of this invention comprises a thermoformed open cell rigid polyurethane foam core enclosed in a gas barrier material and evacuated. The method of this invention comprises heating an open cell rigid polyurethane foam at a temperature not lower than the temperature at which its storage modulus of elasticity begins to decrease and enclosing the thus-thermoformed polyurethane foam in a gas barrier material and evacuating the interior of the enclosure. The heat insulator of the invention is highly heat-insulating and can be snugly applied to irregular surfaces.

Abstract: A method of making an interior panel of an automotive vehicle door having an exterior surface which is to face toward the interior of the automotive vehicle when installed therein which comprises the steps of forming a bolster laminate including a textile outer layer, a flexible imperforate layer and an inner surface layer of a material which becomes tacky when heated, mounting the bolster laminate in a vacuum mold part, heating a sheet of predetermined material content presenting a vinyl surface, vacuum forming the heated sheet in the vacuum mold part so that the vinyl surface bondingly interengages the tacky material of the film inner layer of the bolster laminate, molding material between the vacuum mold part with the bolster laminate and the sheet therein and a cooperating opposed mold part to form an integrally molded panel having a content between an exterior bolster and vinyl surface and an opposed surface which includes a relatively hard substrate defining the opposed surface, a layer of sheet vinyl p

Abstract: A method for fabricating plastic interior trim components having an insert with openings therein joined to a composite member including a shell and a foam layer, the method including die punching a hole through the shell and foam layer and die punching an edge extension on the shell to a predetermined parametric form; providing a press that is operable to compress a part therebetween and including a first platen and a second platen moveable between opened and closed positions with respect to one another; providing an insert having an opening; supporting the insert on one of said first and second platens and applying adhesive on a surface of the insert; loading the composite member on the other of said first and second platens so that the foam layer thereof is facing the adhesive sprayed insert inboard of the die cut edge extension; closing the press to compress the adhesive sprayed surface against the foam layer of the composite member for adhering the insert only to the foam layer without leakage of foam thr

Abstract: At a first station 202, flexible material 204 is deformed into a predetermined configuration defined by a mould recess 210. This configuration corresponds to the internal configuration of one of two housing parts 136, 138, situated at a second station 206. The deformed region of the flexible material 204 is advanced to the second station and secured between the housing parts 136, 138, to form a flexible partition within the container so formed.

Abstract: The method includes using a contoured mold (22) with copper tubing (40) coiled and embedded beneath the contoured surface. The fabric or trim cover (14) and an adhesive film (16) is placed on the mold (22) and drawn by a vacuum in to contour with the mold (22). The foam cushion (12) is placed thereon in compression. The adhesive film (16) includes a polyamide resin doped with micron sized ferromagnetic particles. Copper coil tubing (40) is energized by an oscillatory radio frequency generator (50) to produce a magnetic flux to induce eddy currents in the ferromagnetic particles to generate heat to thereby melt the polyamide resin. The adhesive film melts, creating a bond between the trim cover (14) and the foam cushion (12).

Abstract: High-quality photovoltaic devices can be produced while lowering manufacturing costs by the inventive process. In the process, solar cells are manufactured, connected, and placed on one or more curable plastic sheets at a solar cell manufacturing plant. The plastic sheets are then heated at a sufficient temperature to bond the plastic sheets to the solar cells without a substantial amount of curing and polymerization of the plastic sheet. The plastic sheet is then cooled. The plastic sheet can be coated with a protective water-resistant coating. The partially cured photovoltaic subassembly is subsequently shipped to a manufacturing facility, such as a glass plant or automobile plant, where it is contacted with a glass support member providing a superstrate or a substrate. The plastic sheet of the photovoltaic subassembly is then fully cured, polymerized, and bonded to the glass superstrate or substrate.

Abstract: A covered article such as an automotive trim panel comprises a substrate having a front surface to be covered, a back surface and a plurality of holes extending through it for vacuum drawing a trim cover stock against the front surface. The substrate has sets of parallel saw-tooth holder grooves in a peripheral margin of the back surface adjacent to an edge of the substrate that is to be wrapped by the trim cover stock and transverse manifold grooves that communicate with the holder grooves. An adhesive is applied to the front surface and the peripheral margin and the substrate is supported on a vacuum buck so that the peripheral margin overhangs the buck and the manifold grooves communicate with a vacuum source of the buck. The trim cover stock is drawn against the front surface of the substrate and a marginal portion of the trim cover stock is simultaneously drawn against the peripheral margin of the back surface by vacuum to wrap the trim cover stock around the edge of the substrate.

Abstract: A laminate is made by first forming a substantially closed mold cavity between a pair of mold halves, then injecting a plastified synthetic resin into the cavity under pressure to substantially fill the cavity and at least partially curing the resin in the cavity to form a base body. The mold halves are then separated to leave the partially cured body in one of the mold halves with a face of the body exposed and a deformable sheet is laid over the face of the body in the one mold half. A die having a face conforming at least generally to the shape of the body face is then laid down against the sheet onto the body to press the sheet into intimate contact with the body face and bond the sheet and body together.

Abstract: A method of producing an interior trim component using the steps of: impregnating a foam pad with a dielectrically heatable thermoplastic binder; placing the pad between a dielectrically heatable panel and decorative covering; compressing the pad; and applying an electric field to the pad and panel sufficient to heat and soften the thermoplastic binder and the panel whereby the thermoplastic binder bonds with the covering and panel.

Abstract: A drum for a photoplotter has a base having a partially cylindrical recess formed therein which recess being defined by in part by a plurality of elevated surfaces providing a support bed on which is mounted a sheet of material providing an exposed surface for supporting a substrate thereon. The drum is formed by a method whereby a tool is provided about which the sheet material is drawn and is moved into engagement with the bed and is caused to maintain this shape by an adhesive interposed therebetween. A method for mechanically compensating for surface irregularities by fixing the scanner relative to the support surface after displacements have been made is also provided.

Abstract: A structural component such as a car door panel or door trim insert panel is produced in a single molding operation. For this purpose at least one premolded hard foam material block or member is inserted in a respective nesting mold cavity. Then an intermediate fiber material layer preferably in fleece form is placed on top of the foam material block. Then, a surface cover layer, such as a layer with a decorative exterior surface is placed on the intermediate fiber material layer with the decorative surface facing an upper mold section. The mold is then closed and the necessary heat and molding pressure are applied to laminate the intermediate fiber material layer to the cover layer. Then a nesting die applies additional pressure to the hard foam block for bonding the hard foam block to the intermediate fiber material layer.

Abstract: A method of making an interior panel of an automotive vehicle door having an exterior surface which is to face toward the interior of the automotive vehicle when installed therein. An apparatus utilized in the method comprises a mold assembly including a first vacuum mold component having a mold surface shaped to form the exterior surface of an upper section of the door panel, a second non-vacuum mold component cooperable in side-by-side relation with the first vacuum mold component having a mold surface shaped to form the exterior surface of a lower section of the door panel and a third non-vacuum mold component cooperable in opposed relation with the first and second mold components having a mold surface shaped to form the entire opposite surface of the door panel. The method comprises the steps of heating a laminated sheet, and vacuum forming the heated sheet in the first vacuum mold component.

Abstract: A padded element of a motor-vehicle seat is made applying a cover onto a padding body by pressing with simultaneous application of steam. The covering fabric is provided on a lower mould with the back side thereof facing upwardly and the padding body is pressed against this back side by an upper mould. The upper mould includes a plurality of cannulae for steam injection, which project downwardly from the upper mould and are introduced through the padding body and have their steam outlet lower ends located inside this body adjacent to the surface thereof.

Abstract: In a method of manufacturing a seat by using adhesives in which an air permeable skin material and a cushioning pad are bonded to each other by means of reactive hot-melt adhesives, the method comprises a step of coating adhesives to the cushioning pad, a step of provisionally assembling the skin material to the cushioning pad from the side of the adhesive coating surface, a step of setting the provisionally assembled cushioning pad and skin material to an attaching die, a step of applying heating by a heating die to the skin material and the cushioning pad attached in the attaching die assembling step from the side of the skin material and a step of applying cooling under pressure by a cooling die from the surface of the skin material subsequent to the heating step. A seat comprising a skin material and a cushioning pad can be molded with a seat frame by this method.

Abstract: An aircraft wing, a fusion bonded thermoplastic fixed leading edge structure for aircraft aerodynamic surfaces and a method of manufacture are provided. The fixed leading edge structure comprises a leading edge skin (28), one or more aerodynamic profile defining stiffening members (17, 18) spaced spanwise therewithin and a sub-spar. Each of the components are of low modulus consolidated composite material and the leading edge skin (28) is attached to the stiffening members (17, 18) and to the sub-spar by a fusion-bonding thermoplastic process.