Abstract: A molded component is produced by heating a non-woven material web to bring it into a plastically deformable state, and then plastically deforming the non-woven material under pressure between two mold tools of a molding apparatus. The mold tools define therebetween at least one or preferably several mold cavities that respectively simultaneously form molded products therein. A cut is formed in the plastically deformable non-woven material web, preferably between two adjacent mold cavities, immediately before and/or during the molding step. The cut facilitates a pulling or flowing of the non-woven material away from the cut and toward a respective mold cavity to facilitate the molding deformation thereof while avoiding excessive stretching and thinning of the non-woven material, especially at the transition area between adjacent mold cavities.

Abstract: A one-shot molding apparatus and method press-mold a trim component body between upper and lower molds, and injection-mold a plastic rim onto an edge of the trim component body using an additional edge molding tool, in a single molding apparatus in a single molding cycle. The edge molding tool may have a cutting edge that cooperates with a counter edge on the upper or lower mold to remove excess material and form a precise cut edge of the trim component body before forming the molded rim. The edge molding tool is movable relative to the upper and lower molds in a direction parallel or perpendicular or oblique relative to a motion direction of the upper and lower molds. Additional movable nested tools can be provided on the upper and/or lower mold to achieve greater adaptability of the injection-molding cavity. The rim can be molded onto the cut edge, and molded around the edge onto the back and/or front side of the trim component body.

Abstract: A molding apparatus includes two mold tools that define and bound a mold cavity therebetween, for three-dimensionally press-molding a trim component. To minimize or avoid shrinkage or pull-back recession of the edge of the trim component during the molding process, at least one of the mold tools, on its molding surface bounding an end portion of the mold cavity, includes at least one grip-enhancing structure that provides increased grip on an edge portion of the trim component. The grip-enhancing structure may be or include a rough surface, a geometric configured surface, a geometric gripping edge, a surface coating, or mechanical engagement members. The grip-enhancing structure provides increased grip on the edge portion of the trim component by narrowing the mold cavity space, by increasing the surface friction or adhesion, and/or by mechanically engaging the material of the trim component.

Abstract: A molded component is produced by heating a non-woven material web to bring it into a plastically deformable state, and then plastically deforming the non-woven material under pressure between two mold tools of a molding apparatus. The mold tools define therebetween at least one or preferably several mold cavities that respectively simultaneously form molded products therein. A cut is formed in the plastically deformable non-woven material web, preferably between two adjacent mold cavities, immediately before and/or during the molding step. The cut facilitates a pulling or flowing of the non-woven material away from the cut and toward a respective mold cavity to facilitate the molding deformation thereof while avoiding excessive stretching and thinning of the non-woven material, especially at the transition area between adjacent mold cavities.

Abstract: A one-shot molding apparatus and method press-mold a trim component body between upper and lower molds, and injection-mold a plastic rim onto an edge of the trim component body using an additional edge molding tool, in a single molding apparatus in a single molding cycle. The edge molding tool may have a cutting edge that cooperates with a counter edge on the upper or lower mold to remove excess material and form a precise cut edge of the trim component body before forming the molded rim. The edge molding tool is movable relative to the upper and lower molds in a direction parallel or perpendicular or oblique relative to a motion direction of the upper and lower molds. Additional movable nested tools can be provided on the upper and/or lower mold to achieve greater adaptability of the injection-molding cavity. The rim can be molded onto the cut edge, and molded around the edge onto the back and/or front side of the trim component body.

Abstract: A molding apparatus includes two mold tools that define and bound a mold cavity therebetween, for three-dimensionally press-molding a trim component. To minimize or avoid shrinkage or pull-back recession of the edge of the trim component during the molding process, at least one of the mold tools, on its molding surface bounding an end portion of the mold cavity, includes at least one grip-enhancing structure that provides increased grip on an edge portion of the trim component. The grip-enhancing structure may be or include a rough surface, a geometric configured surface, a geometric gripping edge, a surface coating, or mechanical engagement members. The grip-enhancing structure provides increased grip on the edge portion of the trim component by narrowing the mold cavity space, by increasing the surface friction or adhesion, and/or by mechanically engaging the material of the trim component.