Method of making a door panel with integrated bolster

B - Operations – Transporting – 29 – C

Patent

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Details

B29C 69/00 (2006.01) B29D 99/00 (2010.01) B29C 51/10 (2006.01) B29C 51/14 (2006.01) B29C 51/36 (2006.01) B60R 13/02 (2006.01) B29C 51/08 (2006.01) B29D 31/00 (2006.01)

Patent

CA 2159364

A method of making an interior panel of an automotive vehicle door having an exterior surface which is to face toward the interior of the automotive vehicle when installed therein which comprises the steps of forming a bolster laminate (124) including a textile outer layer, a flexible imperforate layer and an inner surface layer of a material which becomes tacky when heated, mounting the bolster laminate in a vacuum mold part, heating a sheet (126) of predetermined material content presenting a vinyl surface, vacuum forming the heated sheet in the vacuum mold part so that the vinyl surface bondingly interengages the tacky material of the film inner layer of the bolster laminate, molding material (130) between the vacuum mold part with the bolster laminate and the sheet therein and a cooperating opposed mold part to form an integrally molded panel having a content between an exterior bolster and vinyl surface and an opposed surface which includes a relatively hard substrate defining the opposed surface, a layer of sheet vinyl presenting the vinyl surface and a layer of relatively soft foamed material adjacent the layer of sheet vinyl.

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