Abstract: A method of manufacturing a multi-layer outer panel for a game ball includes three-dimensionally forming a top layer of an outer panel, as well as one or more backing materials disposed underneath the top layer, into a shape substantially corresponding to the surface of the ball. Multi-layer outer panels are then attached to or interconnected to surround an inflatable bladder, thereby producing a game ball while minimizing overstretching of the outer material or the backing material and improving resistance of the outer panels to delamination.

Abstract: Decorative system composites and methods for forming the same are described. The composites employ new and improved support film systems that have enhanced tensile strength under typical thermoforming conditions, including elevated temperatures. An optional release film can be used in conjunction with the support film. The support film is particularly suitable for use with decorative films used to impart a surface effect, such as paint or color-containing film systems, to a thermoformed plastic component. The support film systems also possess enhanced bag/sag/drape control characteristics.

Abstract: The present invention provides a shrink sleeve for use on a closure of an article. The present invention does so by providing a decorated closure for an article, such as a container, used to package an item or items. The decorated closure includes a shrink sleeve and a closure for an article. The closure has a top end, a bottom end, and a side surface. The closure may further include a centerpoint of the top end and a centerpoint of the bottom end with a longitudinal axis passing therethrough. The shrink sleeve is shrunk around at least the side surface of the article, and includes at least one visible decoration on a surface of the shrink sleeve.

Abstract: A manufacturing apparatus and process to effect substantial automatic wrapping of the edges of a covered article, namely, the wrapping of cover sheet flaps around the edges of a substrate and the adhesive securement of the cover sheet flaps to the back side of the substrate, to form an upholstered article such as a pad or panel in a highly automated process which eliminates significant manual manipulations.

Abstract: Non-limiting embodiments disclosed herein include components of a rain water collection system and methods of fabricating the components. The disclosed components include a down spout interface bladder and a rain water holding device. Also disclosed are a method of fabricating a down spout interface bladder and a method of fabricating a rain water holding device.

Abstract: Process for waterproofing semimanufactured footwear, clothing items and accessories, said semimanufactured product having a three-dimensional conformation with at least one inner surface and one outer surface, which comprises the following operative steps: arranging the semimanufactured product onto a shaped support (14; 27, 28; 30, 31) with at least one waterproofing sheath (18) shaped for entirely or partially cover the surfaces to be waterproofed of the semimanufactured product, at least one glue layer being arranged between these surfaces and the waterproofing sheath (18); pressing between two deformable plates (2, 2?) the semimanufactured product provided with the waterproofing sheath (18) and arranged on the shaped support (14; 27, 28; 30, 31). The present invention also relates to a machine that carries out said process, as well as the semimanufactured products obtained with said process or machine.

Abstract: An apparatus for obtaining “shrink sleeve” labels, comprises a carousel that is provided peripherally with a plurality of spindles configured for being wound from portions of plastic film, a sealing device cooperating with said spindles means for sealing opposite edges of said portions for obtaining said “shrink sleeve” labels, said sealing device comprising a laser device; a method for labelling containers, comprises in sequence: advancing a plastic film in an advancing direction; cutting said plastic film transversely to said advancing direction to obtain a portion of plastic film; winding said portion in such a way as to make opposite edges of said portion overlap one another; joining together said edges to obtain a “shrink sleeve” label, said joining comprising sealing by means of a laser beam.

Abstract: A bodyboard has an improved construction for ease of handling. A variety of different shapes and construction features allows the bodyboard a distinct yet stable performance in the water. A bodyboard has an improved construction for ease of handling. The bodyboard has a bottom finger bulb with a shallow lengthwise bottom depression and shallow rear tail depressions. The process for producing the board requires removal of foam core material, or molding the foam core in a specific shape mold to provide the profile. Rear tail depressions formed at a diagonal angle being no more than 1 cm in depth can extend from a deep portion at the tail of the board and blend into the board at approximately one-quarter of the length of the board.

Abstract: A method and a device for bonding at least two sheets, is disclosed. The sheets may be joined by a groove and are connected to each other at least in one contact area in the sheet surface of the first sheet. The sheets may first be shaped whereby the first sheet may be shaped with at least one hook which forms an angle with the sheet surface and the second sheet may be shaped with at least one groove and one leg. The hook may be accommodated by the groove and the leg may be substantially parallel to the contact area of the first sheet. The shaped sheets are then bonded to each other, whereby the hook is inserted in the groove and the leg is bonded to the contact area.

Abstract: A method for jacketing a product having a generally cylindrical outer surface locates a sheet of jacketing material on first and second belts for conforming the sheet of jacketing material to and pressing the sheet of jacketing material against the outer surface of the product and locates the product on the sheet of jacketing material. Preferably, the belts are mounted on frames that are pivoted from a first position where the sheet of jacketing material can be placed on the belts and the product can be placed on the sheet of jacketing material to a second position where the belts are each wrapped part of the way around the outer surface of the product while the product remains stationary to conform the sheet of jacketing material to and press the sheet of jacketing material against the outer surface of the product so that the sheet of jacketing material may be bonded to the outer surface of the product.

Abstract: A 360° tool for making a one-piece composite tubular structure, such as a skin of an acoustic liner, is adjustable between a molding position and a non-molding position. The tool includes a base, a fixed segment mounted to the base, first and second doors hingedly connected on either side of the fixed sector, and third door hingedly connected to the second door. The third door has a circumferential extent that is less than one-fourth that of either the first or second door. Sealing members are provided between the doors. Collectively, the fixed sector, and the first, second and third doors have a predetermined shaped surface that corresponds to a portion of the contour of the tubular structure to be formed. After composite material is applied on the outer surfaces of the fixed sector and the doors, a vacuum bag is formed to surround the composite material and also the joint areas on the inner surface of the tool. The entire tool may be placed in an autoclave for curing.

Abstract: A dunnage platform is in the general shape of a rectangular slab with legs extending form one side. The dunnage platform is made from an expanded polystyrene core. A chemical combination process is used to chemically combine portion of the core proximal to its surface with high impact polystyrene. In a first of two parts of the combination process, the core is placed in a forming mold with one of its two sides and two thirds of its thickness extending therefrom. A heated sheet of high impact polystyrene is brought into contact with the portion of the core extending from the mold. In a similar manner, the other of the two sides of the core is made to extend from the forming mold for contact with a heated sheet of high impact polystyrene.

Abstract: A method for applying web material to a substrate object. Web material on a thermoformable sheet can be adhered to the shaped object with a heat-actuated adhesive in a vacuum thermoforming process.

Abstract: A dunnage platform is in the general shape of a rectangular slab with legs extending form one side. The dunnage platform is made from an expanded polystyrene core. A chemical combination process is used to chemically combine portion of the core proximal to its surface with high impact polystyrene. In a first of two parts of the combination process, the core is placed in a forming mold with one of its two sides and two thirds of its thickness extending therefrom. A heated sheet of high impact polystyrene is brought into contact with the portion of the core extending from the mold. In a similar manner, the other of the two sides of the core is made to extend from the forming mold for contact with a heated sheet of high impact polystyrene.

Abstract: Disclosed is a surfboard (10) comprising a foam blank (10), a rail (14) formed using carbon fibre materials (22) on the blank, and a fibreglass laminate enveloping the rail and blank. Alternatively, the blank and rails may be enveloped in a thermally active PVC or similar material.

Abstract: A process for producing an upholstered article in a bladder mold. A cover sheet with adhesive is positioned over the opened bladder mold. A foam core is inserted into the bladder mold, carrying the cover sheet into engagement with the bladder. The bladder mold is then closed so that the bladder wraps the marginal portion of the cover sheet around the foam core. After the adhesive cures to bond the cover sheet to the foam core, the mold is opened; and the article is removed.

Abstract: A method for jacketing a product having a generally cylindrical outer surface locates a sheet of jacketing material on first and second belts for conforming the sheet of jacketing material to and pressing the sheet of jacketing material against the outer surface of the product and locates the product on the sheet of jacketing material. Preferably, the belts are mounted on frames that are pivoted from a first position where the sheet of jacketing material can be placed on the belts and the product can be placed on the sheet of jacketing material to a second position where the belts are each wrapped part of the way around the outer surface of the product while the product remains stationary to conform the sheet of jacketing material to and press the sheet of jacketing material against the outer surface of the product so that the sheet of jacketing material may be bonded to the outer surface of the product.

Abstract: Methods for providing a cable closure enclosing a cable splice include wrapping a flexible wrap including a gel layer and a flexible support layer around the cable splice with the gel layer adjacent the cable splice. The gel layer may have an adhesion-reducing substance applied on at least part of a surface of the gel layer facing away from the flexible support layer and a removable cover layer may be applied to a surface of the gel layer facing away from the flexible support layer on which the adhesion-reducing substance is not applied. The wrap is gathered into overlapping wrinkles around at least one longitudinal end of the cable splice without applying heat, other external energy source or catalytic agent to allow the gel layer to seal the at least one longitudinal end of the cable splice.

Abstract: A method for enveloping components arranged on a substrate, with a film which is made of an electrically insulating plastic material, and the substrate. The film is placed on the components to be enveloped on the side thereof facing away from the substrate. Elastically or plastically deformable impression material is placed onto the film on the side thereof which faces away from the components to be enveloped. The impression material is pressed against the film in the direction of the components and the substrate and the impression material is removed.

Abstract: A double-walled liner and an apparatus and method for manufacturing said liner, wherein the outer liner of the double-walled liner is seamed longitudinally and transversely, and wherein the apparatus includes: a frame; a supply section for providing webs of inner and outer liner material; a folding section for folding the webs and including a V-form frame structure comprising mutually converging arms which converge towards an apex.

Abstract: A frame for a window screen assembly is provided that uses corner locks to secure the rails and stiles. Interlocking features provided by the corner locks are used to secure the corner locks to the rails and stiles. A method of securing screens to different sized frames using a three-stage operation is disclosed. Adhesive and a movable flange are used to secure the screen to the frame in one disclosed embodiment.

Abstract: The present invention relates to methods of stabilizing and/or sealing core and stabilized and/or sealed core for manufacturing molded composite structures. In particular, the present invention relates to methods of stabilizing and/or sealing core and stabilized and/or sealed core for manufacturing aircraft. In one implementation, the core is stabilized or sealed by applying a layer of roll-coated adhesive on the core, applying a layer of stabilizing material on the roll-coated adhesive layer; and applying a layer of thermoplastic barrier film on the stabilizing material.

Abstract: In a method and apparatus for making an absorbent structure, an absorbent core and a wrapsheet are arranged in an unwrapped configuration with a first face of the absorbent core facing a first face of the wrapsheet, and with the absorbent core disposed laterally between laterally opposite side margins of the wrapsheet such that the side margins of the wrapsheet extend laterally outward beyond the side edges of the absorbent core. Gas is directed to flow over the first and second faces of the wrapsheet at the lateral side margins thereof in a direction which moves the lateral side margins of the wrapsheet from the unwrapped configuration around the side edges of the absorbent core and over at least a portion of the second face of the absorbent core to define a wrapped configuration of the wrapsheet.

Abstract: A backing sheet, and a system and method of manufacturing a backing sheet with stapling tabs. The system includes a roller device configured to apply an adherent material to a first side of the backing sheet continuously fed from a feed roll. The sheet is then fed to a first pair of folders configured to fold the backing sheet along the edges such that the adherent material holds the first fold in place. The sheet passes through a second pair of folders that form a second fold along the edges of the sheet by folding in the opposite direction as in the first fold. Advantageously, an applicator device is configured to apply a tacky substance, such as a starch solution, between the contacting portions of the second fold, prior to the formation of the second fold. The tacky substance maintains the second fold and prevents the stapling tab from opening during further manufacturing and packaging processes.

Abstract: A dunnage platform is in the general shape of a rectangular slab with legs extending form one side. The dunnage platform is made from an expanded polystyrene core. A chemical combination process is used to chemically combine portion of the core proximal to its surface with high impact polystyrene. In a first of two parts of the combination process, the core is placed in a forming mold with one of its two sides and two thirds of its thickness extending therefrom. A heated sheet of high impact polystyrene is brought into contact with the portion of the core extending from the mold. In a similar manner, the other of the two sides of the core is made to extend from the forming mold for contact with a heated sheet of high impact polystyrene.

Abstract: Disclosed is an apparatus and a method for at least partially encapsulating a fiber batt or other highly porous substrate by applying a polymeric foam layer to one or more surfaces of the fiber batt. The foam application assemblies are arranged and configured to extrude a polymeric foam or a foaming mixture onto the surface(s) of the fiber batt to be coated. A combination of foam application assemblies may be provided in either fixed or moveable configurations for coating one or more sides of the fiber batt. The encapsulation of the fiber batt may also include a premanufactured material layer on one or more surfaces that may be exposed or may also be encapsulated below the polymeric foam layer.

Abstract: Method of fitting products with stretchable sleeves. A stretchable sheath is placed on a reel by forming a tubular sheath made from a stretchable plastic material of the dimension required to fit the product, flattening the sheath whilst forming a gusset in each side of the contour to reduce the width of the flattened sheath, and winding the sheath onto a reel. The stretchable sleeves are placed on the products by unreeling the sheath with its gussets, aligning the sheath with the production line, feeding the flat sheath into the cutter in order to cut a sleeve, and picking up the cut sleeve in order to place it on the product.

Abstract: The invention concerns a process and a device for attaching a label jacket to objects, such as bottles or similar items, where a jacket label is seized by its forward margin by a spreading jaw unit and pulled in axial direction over the object, where the object, before the pull-over application, is held by the area of its mantle surface, by positive and/or friction lock, the pull-over process is started, the holding device on the mantle surface is temporarily released as soon as the spreading jaw unit at least partially surrounds the object at its mantle surface, and, at the latest before the desired adhesion height of the label jacket on the object is reached, the latter objects is again seized by the area of its mantle surface, which is now covered with the label, and in the process the label is affixed in a non-slip manner, while the spreading jaw unit is pulled off.

Abstract: A method of forming a cushioning pad includes placing a component formed of polyurethane foam onto a first web of polyethylene foam. A second web of polyethylene foam is then placed over the component to sandwich the component. Heat and pressure is applied to the sandwich, which flattens the component and forms a seam between the first web and the second web encircling the component. If an unsealed cushioning pad is to be formed, a hollow needle is inserted into one of the first web or the second web. Air passes through the hollow needle and into the component, which absorbs the air and expands. Later, the needle is removed. If a sealed cushioning pad is to be formed, an insertion point of the hollow needle is in the seam, between the first web and the second web. After the component absorbs air and expands, the needle is removed and the insertion point of the hollow needle is re-seamed.

Abstract: Cover pads for use on upright walls, wherein the pad provides an improved internal support which is of simplified construction, for example the center support and the surrounding frame being made of a one-piece monolithic support structure which permits a flexible covering or fabric to be attached to the center support and the exterior side surfaces of the edge frame while the fabric and support structure are in a flat and planar condition, following which the edge frame is folded and secured into position around the center support. The internal support structure for the pad, when in a flat condition, has voids at the corners so that the fabric can be easily tucked into the corners prior to the edge frame being folded into its closing or frame-defining position.

Abstract: An adhesive and material dispenser for dispensing single sheets of material from stacks of sheets of material or from rolls of material and applying an adhesive to the sheet. The adhesive is applied by contacting the adhesive portion of an adhesive transfer tape to the sheet. The sheet of material with the adhesive applied thereto can be used to wrap floral arrangements or flower pots or other articles. The dispenser 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: The present invention provides a method of achieving low tension, highly conformable elasticized areas in a nonwoven web construction such as may be suitable for the waistbands or leg openings of disposable absorbent pant garments, cuffs on sleeves of medical garments, or the like. A web, or webs, of nonwoven material which make up the substrate for the elasticized area are provided to be very light weight and flexible and provide the minimal amount of substrate to which an elastomeric liquid barrier material is affixed. The absorbent, or liquid retention, section of an absorbent garment article made according to the present invention will have its own barrier layer facing the backsheet, in order that the backsheet may be composed of a light and conformable material.

Abstract: The present invention is a unique prescription label, printed on one side that allows a consumer to check and verify the accuracy of the prescribed medication as well as to provide additional information on the medication container by increasing the usable size and area of the prescription label with an informational tab extending radially from the container, the present invention also provides a means for easy application of the prescription label onto the container by scoring the facing on the first portion and second portion of the label and scoring the backing of the second portion of the label in order to create an even fold between the two portions.

Abstract: The vehicle seat of the invention includes a cushioning material having a ridge surrounding and defining a seating area on the cushioning material and a skin material covering the cushioning material. The skin material and cushioning material are bonded together only within the seating area. The skin material is a laminate including, in succession, a PVC layer, a knitted fabric and a closed-cell synthetic resin foam. A water proof film may be interposed between the cushioning material and the skin material outside of the seating area.

Abstract: The present invention is directed to a method of preparing an article of manufacture. The method includes bringing at least a portion of a heated thermoplastic sheet into contact with at least a portion of the first surface of a support having a plurality of perforations. A vacuum is formed on the second surface of the support, and portions the heated thermoplastic sheet are drawn through the perforations of the support and to the second surface side of the support. Thermoplastic attachment heads are formed on the second surface side of the support, from the thermoplastic material of the sheet that is drawn through the perforations. The thermoplastic sheet and the support are fixedly attached one to the other by means of the edges of the perforations being embedded in the thermoplastic material of the sheet drawn therethrough, and the thermoplastic attachment heads. Also disclosed are articles of manufacture, such as interior and exterior automotive body panels and components.

Abstract: A method for producing an electrically conductive filler by placing a web of core material onto an interior surface of a web of conductive layer material. The webs of core material and conductive layer material are directed through a forming station for folding the conductive layer around the core. The filler having a substantially non-conductive core and a conductive layer. The conductive layer is wrapped around the core to form a closed loop thereby establishing conductivity from a bottom of the filler to a top of the filler by paths on each of two sides of the filler.

Abstract: A production method of an absorbent body is provided. The method includes the steps of: supplying a first cover sheet on an outer surface of a rotating pattern drum, said pattern drum being provided with a concavity formed in a predetermined shape on the outer surface thereof; adapting the first cover sheet to the shape of the concavity and supplying an absorbent material into the concavity to form an absorbent material layer adapted to the shape of the concavity on the first cover sheet; supplying a second cover sheet toward the outer surface of the pattern drum; and separating the first cover sheet together with the absorbent material layer from the outer surface of the pattern drum and superposing the first cover sheet together with the absorbent material layer on the second cover sheet to produce an absorbent body comprised of the first cover sheet, the second cover sheet and the absorbent material layer interposed between the first cover sheet and the second cover sheet.

Abstract: A cost effective manufacturing process encapsulates a light emitting polymer (LEP) device between two flexible sheet materials, where one sheet may act as the substrate for the LEP device and the other sheet may act as a cover for the LEP device, and at least one of the sheets is transparent. Both encapsulating sheets and, as required, an adhesive system binding the sheets together provide sufficient environmental barriers with low moisture vapor transmission rates (MVTR) and oxygen transmission rates (OTR). The encapsulating sheets may, for example, be laminated together, sandwiching the LEP device in a vacuum, or oxygen/moisture free, and inert gas environment. Prior to encapsulation the LEP device may be heated and placed in a vacuum to remove moisture, air and residual solvents.

Abstract: Apparatus for the application of adhesive to one side of a running web of tipping paper for use in filter cigarete makers has a single source of adhesive or two or more sources containing identical or different adhesives, and one or more conduits leading from the source(s) to one or more nozzles which applies or apply one or more films of a single adhesive or of different adhesives to selected portions of the one side of the web. The rate of admission of adhesive(s) to the nozzle(s), including interruption and restarting of admission of adhesive(s), is regulated by one or more valves each having a body receiving a rotary valving element provided with one or more peripheral projections and/or recesses serving to regulate the rate of flow of adhesive toward the single nozzle or the respective nozzles. The rotary elements of two or more valves can constitute disc-shaped sections of a single rotor confined in a valve body common to all valves.

Abstract: The present invention provides a method for encapsulating a secondary battery. The method first impregnates a fiber fabric with a resin composition, and then a first heating process is performed to form an adhesive sheet. A jelly-roll of a battery is encapsulated with the adhesive sheet, and then a second heating process is performed to cure the adhesive sheet completely. The first heating process initiates a preliminary reaction to transform the resin composition into a B state to form an adhesive sheet, and the adhesive sheet in the B state is convenient to be further processed or stored. Since the adhesive sheet in the B state possesses a property capable of further curing, the adhesive sheet can be processed into any shape when a further curing process is performed. Therefore, the battery can be easily manufactured with a curved, wound or any arbitrary shape, and the thickness of the battery will not be increased obviously.

Abstract: A laminate forming process includes installing a heater assembly in a processing chamber, the heater assembly having a lower diffusion screen; coupling a vacuum assembly to channels of a platform; conveying layers of titanium and solid adhesive at room temperature onto a workpiece on the platform heating the processing chamber to a predetermined temperature by the heater assembly through the diffusion screen for evenly applying heat to the layers of titanium and adhesive and the workpiece and melting the layer of adhesive; and activating the vacuum assembly for sucking the layers of titanium and adhesive onto the workpiece through a communication of the channels so as to secure the layers of titanium and adhesive onto the workpiece and smooth the layer of titanium.

Abstract: A sunshade of a sunroof for a motor vehicle includes superposing resin impregnated glass fiber mat layers (2,3) on both surfaces of a semi-rigid layer (1) made of an urethane foam and having a uniform thickness, superposing a skin material layer (5) on a surface of one of the resin impregnated glass fiber mat layers (2) via an adhesive film layer (4), superposing a back material layer (7) on the surface of the other resin impregnated glass fiber mat layer (3) via an adhesive film layer (6), and fusion bonding the layers by clamping the layers (8) by a press mold (9, 10) and heating and pressurizing the layers (8) so as to form a predetermined three-dimensional shape.

Abstract: An efficient method for making a vehicle seat. A vehicle seat is molded in a mold set which includes a base element and a series of upper elements with the cover supported in the mold cavity and layers of resins being molded thereon. The resultant seat, which is particularly well-suited for use on motorcycles, includes a cover, a cellular cushioning layer self-bonded directly to the cover, a generally ring-shaped support element disposed on the cellular cushioning layer, and a seat base layer self-bonded directly to the cellular cushioning layer and the skirt portion of the cover layer.

Abstract: An edge wrap machine for applying decorative laminate to an aircraft interior panel, particularly a stowbin door, lifts the edge to be wrapped with an actuator, wraps the edge automatically by drawing a vacuum between two silicone blankets sandwiching the panel, and lowers the actuator to achieve bonding pressure on the wrapped edge. The machine automates a hand operation that is relatively slow and potentially dangerous to the workers.

Abstract: A flexible wrap (10) for enclosing a cable splice (20) without external heating comprises a gel layer (1) and a support layer (2), the wrap having sufficient flexibility to be manually gathered into wrinkles around the smaller parts of the cable-to-splice transition with the gel sealing the resulting enclosure. The support layer (2), which is preferably made of low density polyethylene, provides mechanical strength and facilitates the application of the wrap (10). A vapour barrier layer (3), preferably made of aluminium, may be applied on the support layer (2). A protective layer (4) may be applied on the vapour barrier layer (3). An adhesion-reducing substance (6) may be applied on at least part of the side of the gel layer (1) facing away from the support layer (2) to allow adjustment of the wrap (10) when applied on the cable splice (20). Elastic or rubber tape (11) may be wound around the applied wrap (10) to compress the gel. A re-enterable closure having a long sealing length is obtained.

Abstract: A wall for making tanks includes two superimposed plates connected to each other at respective spaced apart connected points distributed on a surface of the plates, at least one of the two plates, between respective connecting zones, bulging outward, so that separation between the two plates increases in every radial direction with distance from each connected point to a maximum separation midway between neighboring connected points. The wall has a quilted appearance.

Abstract: A method for encasing a ceiling tile. The back surface of the ceiling tile is positioned adjacent to a vacuum table and a facing is placed over the front surface of the ceiling tile so that the facing overlaps each edge about the perimeter of the ceiling tile. In one embodiment, the facing is covered with an air-impermeable cover and a support frame can be placed surrounding the perimeter of the ceiling tile. The facing is drawn onto the ceiling tile by a vacuum applied through the vacuum table. The ceiling tile is then reversed so that the front surface of the ceiling tile is positioned adjacent to the vacuum table. An air-impermeable backing is placed over the ceiling tile so that the backing overlaps each edge about the perimeter of the ceiling tile. The backing is drawn onto the ceiling tile by the vacuum applied through the vacuum table.

Abstract: A method of covering a floral grouping by providing a wrap constructed of a flat sheet of material, the wrap having an opening disposed within the sheet of material, and inserting a portion of the stem end of a floral grouping through the opening in the wrap, and wrapping the wrap about the floral grouping.

Abstract: A method of making an interior trim panel for attachment to structure of a vehicle includes the steps of placing a trim insert into a cavity of an apparatus and over a first seal thereof. The method also includes the steps of loading a retainer over the trim insert to sandwich the trim insert between the retainer and the first seal and closing the apparatus. The method further includes the steps of filling the cavity with a plastic material and introducing steam into the apparatus to expand the plastic material to form a substrate and bonding the substrate against the trim insert to form an interior trim panel.

Abstract: Hot-melt webs are located on an outer surface of a pad member and an inner surface of a cover member, individually. The pad member and the cover member are heated to melt the hot-melt webs by means of heaters from the sides opposite the webs, individually. As fibrous hot-melt adhesive elements are cut at every turn and separated to insular pieces, they are distributed like mist drops in the outer surface of the pad member and the inner surface of the cover member. Thereafter, the pad member and the cover member are superposed and pressurized so that they are bonded to each other.