Gm Global Technolgoy Operations, Inc.

John J Reynolds

Arthur C Stein

A method and mold apparatus are provided for forming and trimming a vehicle inner door panel. The panel is a shaped laminate including a vinyl cover layer and a structural foam backing layer having a glass fiber reinforcing substrate. Upper and lower mold members have peripheral seals which define a mold cavity when the mold is closed. A plurality of movable trim blades are carried by the lower mold member adjacent the seal. The trim blades move among retracted, intermediate and extended positions. Hydraulic rams open and close the mold and move the trim blades. Sheets of vinyl and substrate are placed across the lower mold member and the mold is closed to seal the substrate and vinyl layer about their periphery. As the mold closes, abutment surfaces on both mold members advance the trim blades to an intermediate position to pinch the cover layer against the substrate inwardly of the peripheral seals. A two-part polyurethane liquid foam system is injected into the cavity. The liquid permeates the substrate and sets up within the area delimited by the trim blades. When the foam sets up, the trim blades are hydraulically extended to sever the substrate and cover layer and trim the door panel to its finished shape as the foam fully cures. The mold members are opened, the blades are spring retracted, and the finished door panel is removed.

Method and mold for forming a shaped laminate

A retainer for receiving a fastener and adapted for loading into a mold for embedment in a trim article molded of molding material. The retainer has a housing having an upper portion for accepting the fastener and a lower portion for embedment in the molded trim article. A flexible lip encompasses the housing for sealingly engaging with the mold thereby preventing the molding material from making contact with the upper portion of the housing and allowing the molding material to make contact with the lower portion of the housing.

Growing community of inventors

Howell, MI, United States of America

John J Reynolds