US 6,982,021 B2
Method and apparatus for making a trim component with a foam core having a smoothly varying thickness
Gerhard Spengler, Frankfurt (Germany)
Assigned to R+S Technik GmbH, Offenbach am Main (Germany)
Filed on Aug. 23, 2002, as Appl. No. 10/226,550.
Claims priority of application No. 101 44 027 (DE), filed on Sep. 04, 2001; and application No. 102 12 450 (DE), filed on Mar. 20, 2002.
Prior Publication US 2003/0041955 A1, Mar. 06, 2003
Int. Cl. B32B 31/04 (2006.01)
U.S. Cl. 156—221 27 Claims
OG exemplary drawing
 
1. A method of making a trim component including a cover material layer with a visible exposed surface, a structural substrate, a foam backing layer between said cover material layer and said structural substrate, and a foam pad insert at a limited area between said foam backing layer and said structural substrate, said method comprising the steps:
a) providing a cover material, a foam backing material comprising a first synthetic thermoplastic foam, a substrate material, and a foam pad insert block comprising a second synthetic thermoplastic foam;
b) in a pre-pressing apparatus, arranging said cover material, said foam backing material, said foam pad insert block and said substrate material with said foam backing material between said cover material and said substrate material, and with said foam pad insert block between said foam backing material and said substrate material at a given position;
c) in said pre-pressing apparatus, applying heat to at least said foam backing material and said foam pad insert block and pressing together said cover material, said foam backing material, said foam pad insert block and said substrate material, so as to soften and at least partially thermoplastically melt said foam pad insert block and so as to form a pre-laminated sandwich packet including said cover material, said foam backing material, said foam pad insert block and said substrate material laminated to one another by thermoplastically melt-bonding said substrate material respectively with said foam backing material and said foam pad insert block;
d) in a forming press distinct from said pre-pressing apparatus, applying pressure to said pre-laminated sandwich packet and thereby thermoplastically deforming said softened and at least partially thermoplastically melted foam pad insert block into a deformed shape having a tapered rim with a smoothly tapering thickness toward an edge thereof; and
e) after the above steps, cooling said cover material, said foam backing material, said substrate material and said deformed foam pad insert block, to form thereof respectively said cover material layer, said foam backing layer, said structural substrate, and said foam pad insert of said trim component.