Abstract: An automobile interior trim component includes a molded substrate laminated onto a cover sheet including a foam backing and a skin film having a surface texture. The cover sheet is preheated so the skin film is in a melted viscous liquid state above its melting temperature, and the foam backing remains in a solid elastic foam state below its melting temperature. The preheated cover sheet is mechanically pre-molded by a back mold into a front mold. Pressurized air is applied through the back mold, to blow-mold the cover sheet against the front mold, so the melted skin film reproduces a surface texture of the front mold surface while the solid foam backing acts as a buffer and air barrier layer. Vacuum is applied through the front mold surface. The mold is opened, a substrate is introduced, and the back mold then molds and thermally laminates the substrate against the foam backing of the cover sheet.

Abstract: A combined tool for edge-folding and trimming a rim of a panel includes a cutting blade rigidly secured to a tool holder frame, an edge-folding tool slidably received in the tool holder frame, and a biasing spring arranged in the tool holder frame to bias the edge-folding tool outwardly away from the holder frame. The tool is moved in a linear stamping direction, whereby the edge-folding tool folds back and then holds and compresses a margin of a panel workpiece. The tool holder frame and cutting blade are pushed farther in the linear stamping direction, while the edge-folding tool is pushed back into the tool holder frame and compresses the biasing spring, whereby the cutting blade cuts through and compresses the panel workpiece. This forms a back-folded, compressed, and trimmed rim of the finished panel in a single work step using an integrated edge-folding and cutting tool.

Abstract: A trim component (1) includes a substrate (2) and two different cover materials (3, 4), which are not spliced together but are independently adhesively bonded onto the substrate (2) by a hot-melt contact adhesion. The junction (7) is received in a valley (6) of the substrate that is pinched closed using a molding apparatus that includes a horizontally movable pinching stamp (13) which forms a pinching gap (16) relative to a protruding edge (11A) of a fixed mold tool (11). A tucking blade (22) cooperates with a counter-clamping blade (26) to clampingly hold and then press the substrate and junction of the cover sheets into the pinching gap. The tucking blade is then retracted while the pinching stamp pinches closed the pinching gap, to form a tightly closed valley in the substrate with the junction cleanly pinched therein.

Abstract: A composite structural panel includes a cover sheet laminated onto a three-layered substrate including a thermoplastic foam core sandwiched between two composite outer layers. Each composite outer layer includes natural fibers embedded in a thermoplastic matrix. The thermoplastic material of all layers is preferably polypropylene, and the core consists of an expanded cellular polypropylene rigid foam. In a method for forming the composite structural panel, a first preheated outer layer is laminated and molded onto the foam core in a first molding step, and then the second preheated outer layer and the cover sheet are laminated and molded onto the foam core in a second molding step, with a cooling-down time allowed between the two molding steps. In this manner, each preheated outer layer provides enough heat to thermally fuse the outer layer onto the foam core, without overheating the foam core to the point of softening or melting the foam core.