Abstract: A method of manufacturing a panel having a foam interlayer. A flexible cover is placed adjacent a first mold in an open tool. A rigid substrate is placed adjacent a second mold, or alternately, is place atop the flexible cover in the first mold, of the opened tool. The first and/or second molds are electrically isolated from one another and from the associated manufacturing equipment. A vacuum draws the cover against the first mold and retains the cover in position during the manufacturing operation. The tool is moved to a closed position and the cover is positioned juxtaposed the substrate. The cover and substrate are positioned a distance apart thus creating a space therebetween. A vacuum is created in the space and a radio frequency (RF) electric field is applied between the first and second molds. The RF electric field causes a plasma to be created within the space. The plasma activates both the cover and the substrate. While the space is still under vacuum, a foaming material is injected into the space.

Abstract: A method of manufacturing an uncoated covering for an automotive instrument panel. The method comprises the steps of providing an electroplated nickel tool having a grained surface. A quantity of melt fusible powered vinyl is dispensed within the tool. The tool is heated to melt the vinyl and to form the covering. The vinyl leaves deposits on the tool surface. The vinyl covering is cooled and removed from the tool. The tool is periodically cleaned with an aqueous solution of 14% by weight glycol ether DPM and 4% by weight triethanolamine to remove the unwanted deposits before they can mar the finish on the vinyl covering.