Abstract: In a method of manufacturing trim panels which are made of several trim components or trim materials, such as door trim panels of automobiles, the trim panel is essentially finished in a single work operation in one work station. A vinyl cover film (12) is formed, trim inserts (10, 11) are laminated onto the cover film with the aid of a nesting die (8a, 8b), soft touch inserts (26) are laminated underneath the cover film and the so produced laminate is further laminated onto a rigid substrate (2 or 2'). The substrate may be a prefabricated substrate (2), or may be a rigid foam substrate (2') back-foamed onto the formed vinyl film (12). An apparatus for carrying out the method is essentially a forming station with an upper form or mold (1) and a lower form or mold (15). The lower mold (15) includes nest dies (8a, 8b) for securely holding and then pressure laminating the trim inserts (10, 11), whereby a high placement precision of the inserts (10, 11) is achieved.

Abstract: Pieces of flat sheet material, such as films of synthetics or cloth, are fed by a transport apparatus in a stretched out condition into a processing station, for example a molding and laminating station or a treatment station. The transport apparatus uses either tentering type frames or a conveyer with tentering chains. A piece of flat sheet material is attached to a tentering frame or to the tentering chains by a respective apparatus. The tentering frames are moved vertically in a determined order between a lower position, an intermediate position, an upper position and a delivering position located in the processing station horizontally at the same level as one of the three other positions, whereby a tentering frame carrying a piece is moved into the processing station for delivering the piece of sheet material and back again for exchange with a tentering frame carrying another piece of sheet material.

Abstract: Sheet material to be laminated to a substructure is presented in a stretched out condition for enclosing between upper and lower laminating tools. For this purpose a sheet material transport mechanism such as a tentering frame is movable back and forth between the laminating station and a sheet receiving position. The sheet margins around outer and inner edges of the laminated work piece are then trimmed and bent over inwardly. These operations are performed while keeping the work piece on the same lower tool or mold during all operations. The lower tools are moved from laminating to trimming and vice versa on a turntable.

Abstract: A three-dimensional work piece, such as an interior part for a car, is manufactured by keeping the blank, such as a sheet of plastic on or in the same primary mold (24) for the initial shaping step, for the foaming step, for the curing step and for the final trimming step. The primary mold (24) shuttles back and forth in a given direction for sequential cooperation with two secondary molds (75 and 31 or 48 and 31) arranged for reciprocation in a direction extending perpendicularly to said given direction. Preferably, two primary mold members (66, 67) are arranged for horizontal back and forth shuttling in unison so that each primary mold member may cooperate with two out of three vertically reciprocable secondary molds. The efficiency is substantially doubled when each of two primary mold members (66, 67) cooperates with two out of three secondary molds.

Abstract: A system for manufacturing three-dimensional work pieces, such as interior automobile components, includes several cooperating stations arranged in such a way that a hingeable mold member connected to a hinging frame may cooperate with another mold member or with other tools such as trimming tools, curing tools, cleaning and waxing tools and the like. The hinging frame is engageable by hinging bolts of the same construction located in different work stations. The hingeable mold member is transportable, for example on an endless conveyor, when it is disengaged from the hinging bolts. The number of work pieces produced per unit of time is increased by the cooperation of a forming or shaping station with a trimming station, with a foaming station and several curing stations for the foamed material in a shaped work piece.

Abstract: A force is applied to a tool, such as a strip steel knife, a counter-holder or the like, through a linear pneumatic drive including a pressure expandable hose closed at its ends which expands in a given direction. The hose, a reaction plate and a force output plate extend in parallel to each other and through at least one modular reaction bail form a modular drive unit. Force transmission lever means extending at an angle to said given direction are operatively interposed between the force output plate and the tool for applying the force in a plane extending at an angle or in parallel to said given direction, whereby the compactness and versatility of a cutting apparatus employing such modular drive units is enhanced.

Abstract: A three-dimensional work piece, such as an interior part for a car, is manufactured by keeping the blank, such as a sheet of plastic on or in the same primary mold 24 for the initial shaping step, for the foaming step, for the curing step and for the final trimming step. The primary mold 24 shuttles back and forth in a given direction for sequential cooperation with two secondary molds 75 and 31 or 48 and 31 arranged for reciprocation in a direction extending perpendicularly to said given direction. Preferably, two primary mold members 66, 67 are arranged for horizontal back and forth shuttling in unison so that each primary mold member may cooperate with two out of three vertically reciprocable secondary molds. The efficiency is substantially doubled when each of two primary mold members 66, 67 cooperates with two out of three secondary molds.

Abstract: A force may be applied to any point along a line which may be straight or curved in a plane or in space. For this purpose a force applicator is used which includes a pressure expandable hose section closed at its ends, a reaction member against which the hose rests, and a pressure transmitting plate moving in response to an expansion of the hose. These three elements are held in an operative position relative to one another by a modular frame section which also holds a guide member and a reset element for restoring the hose section to a starting position when no pressure is applied inside the hose. A piston rod extends through the guide member and is operatively connected to the pressure transmitting plate. The modular frame section, the guide member and preferably also the reset element form a modular unit.

Abstract: The present apparatus applies force along a line or to a surface through one or more linear or rather longitudinal, elastically expandable or deformable members. The expansion of the elongated member, such as an elastic, reinforced hose or membrane, is transmitted to the tool proper, for example, a strip steel knife or a clamping device, along the entire length of the tool, whereby a linear force application is achieved. Several of such members may be arranged in parallel to obtain substantially a surface area force application. The force application member may also be curved for applying the force, such as a cutting force to an equally curved tool such as a strip steel knife. The force application member is returned to its starting position after a work stroke is completed. The work stroke is performed by expanding the member with the aid of a medium under pressure. The return is accomplished by a spring force or by a similar expansion member.

Abstract: Three-dimensional work pieces, such as instrument panels or dashboards, are made of initially flat stock or of synthetic material such as a two-component foamable material. The tools of the present apparatus include upper and lower holding tools which are preferably simultaneously shaping tools, and cutting or trimming tools. The upper tools and the cutting or trimming tools may have a common support which is preferably exchangeably secured in a main frame. The shaping tools are moved into a first cooperating position relative to each other, whereby the work piece is formed into the desired shape. The shaping tools may then be locked in the shaping position or they may be moved into a second cooperating position to be rigidly locked in the second position. A tool support such as a table carried by a scissors lift frame is used for moving the shaping tools into the desired positions. The cutting or trimming is then performed by applying pressure to the respective tools.

Abstract: Flat goods such as sheets of cardboard are destacked or removed from a stack for the purpose of further processing, especially in stamping, cutting, or break-out devices. A carrier is introduced into the stack. The carrier has a surface which remains stationary relative to that portion of the stack which is being removed when the carrier is withdrawn from the stack. For this purpose the carrier which is supported in a frame, is provided with a surface which is movable relative to the carrier. The movable surface is guided at least around the leading edge of the carrier.

Abstract: The present trimming apparatus is capable of trimming the margins of three-dimensional workpieces with the aid of strip steel knives which are driven, preferably by pneumatic piston cylinder means in any desired direction. The workpiece such as the dashboard of a car, is held on the outside thereof by a workpiece support which has such a shape and cut-outs that the strip steel knives may be moved through the workpiece support. A counter-holder presses the workpiece against the outer support. In this combination of elements the workpiece may be trimmed from any direction from its outer side inwardly. The trimming tools may be operable in sequence and may also be supported on a carriage which shuttles back and forth between a trimming station and a loading and unloading station. Power savings may be in the order of 90% as compared to the power requirements of conventional stamping tools.