Lear Corporation

Steven M Christian

Glenn A Cowelchuk

Todd DePue

Anthony J Link

Cal A Lilienthal

David J Cauvin

A method for forming an integrated trim plate in a single processing step. An appliqu&#xe9; section is reversibly securing to the lower section of a mold. A layer of thermoplastic covering is applied onto and over the appliqu&#xe9; section and lower section of the mold. A layer of foam is then injected between the thermoplastic covering and a substrate used to secure the integrated trim plate within a structure such as an automobile frame. The appliqu&#xe9; section may be magnetically secured to the lower section of the mold or may be physically secured within a forming section of the lower section.

Integrated trim plate with a thermoplastic cover

A method of forming a part with a solid urethane elastomer skin is provided, wherein the mold is moved by a mold manipulation tool to present differently oriented surfaces of the mold in a horizontal orientation when the urethane elastomer is sprayed on each of the differently oriented surfaces. A multi-axis robot is provided with a spray head that sprays the urethane elastomer onto a mold surface. A mold manipulator moves the mold that has a plurality of differently oriented mold surfaces so that the surface to be sprayed is held in a horizontal orientation as they are coated with the urethane elastomer and for a predetermined time period after spray coating until the urethane elastomer sets up.

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Williamsburg, IA, United States of America

Steven M Christian