Patent ID: 9233490
Filing Date: 2016-01-12
CPC Classification: B29C,B32B,B60R,Y10T

Claim Text:
1. A method for forming a multilayer panel configured to enclose an opening, the method comprising: providing a first unlofted sheet; tethering a second unlofted sheet to a tethering frame; wherein the first and second unlofted sheets include a loftable polymer composite; wherein each of the first and second unlofted sheets is characterized by an unlofted thickness; activating the first unlofted sheet to loft the first unlofted sheet to provide a first lofted sheet with a thickness greater than the unlofted thickness; activating the second unlofted sheet on the tethering flame to loft the second unlofted sheet to provide a second lofted sheet with a thickness greater than the unlofted thickness tethered to the tethering frame; inserting the first lofted sheet in a mold such that the first lofted sheet is adjacent a first mold surface defined by the mold; inserting a core insert in the mold such that the core insert is layered adjacent the first lofted sheet; inserting the tethering flame including the second lofted sheet in the mold such that the core insert is layered between the first and second lofted sheets and the second lofted sheet is between the core insert and a second mold surface defined by the mold; molding the layered first lofted sheet, core insert and second lofted sheet to form a multilayer panel; wherein the first mold surface is configured to define an interior surface of the multilayer panel and the second mold surface is configured to define an exterior surface of the multilayer panel; wherein molding the multilayer panel includes moving the first and second mold surfaces toward each other to exert a forming pressure on the layered first lofted sheet, core insert, and second lofted sheet; wherein the forming pressure is sufficient to: