Cascade Engineering, Inc.

Laurie A Weeks

Matthew J Holwerda

Paul J Rugg

Chad R Haskin

S Noland Broaddus

Marlin D Broersma

Keith P Klobucar

A vacuum wrapping process and apparatus for adhering a flexible material to a rigid substrate. The temperature of the flexible material is monitored, processed, and controlled by a control unit. The material is supported over the substrate in a mold. Spring-loaded rotatable bars are supported within the mold and compress the marginal portion of the material against the mold. A vacuum draws the material toward the substrate, and the bars control the release of the material at a desired rate. The vacuum drawn on the material is monitored, processed and controlled by the control unit. The amount of vacuum applied to the material is inversely related to the temperature of the material. The control unit alters parameters of the vacuum molding process, such as the material temperature and the vacuum to reduce tearing, stretching, and/or wrinkling of the material. The spring-loaded bars control the rate at which the material is drawn toward the substrate under the vacuum, thus further reducing tearing, stretching, and/or wrinkling.

Process for controlling vacuum forming

A process for injection molding a thermoplastic backing (12) or other synthetic resin to a carpet layer (14) by suspending the carpet layer (14) between two mold halves (46,48), injecting a thermoplastic resin into the mold, and injecting an inert fluid such as nitrogen into the mold at a relatively low pressure to assist in distribution of the thermoplastic resin throughout all points of the mold. The invention also relates to a synthetic resin backed carpet, which resin backed carpet may constitute a vehicle dashboard (10). The vehicle dashboard (10) can include an internal runner or rib (16) which has a hollow portion (52) formed substantially along its length, the hollow portion (52) being formed by injection of the inert fluid during the injection molding process.

Gas-assisted injection molding with a carpet layer

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Traverse City, MI, United States of America

Laurie A Weeks