Patent ID: 6165404
Filing Date: 2000-12-26
Classification: B29C,B29K,B29L,B60R

Abstract:
A method of producing an essentially self-supporting stratiform article usable as an interior automotive panel, comprising the steps of:disposing a pre-formed, contoured laminate insert comprising a generally flexible outer cover and an inner thermoplastic layer in a female mold shaped in conformity with the outer cover of the insert, with the outer cover disposed in conformity with the female mold but having an exposed edge portion; andinjection molding a thermoplastic polymer composition that is substantially compatible with the inner thermoplastic layer into a mold cavity formed by a male mold and the female mold containing the insert so that the thermoplastic composition substantially fills the cavity, contacts the thermoplastic layer and interfuses therewith, and the thermoplastic polymer composition contacts and covers the exposed edge portion of the insert on its front, back and edge;allowing the thermoplastic polymer composition to solidify, thereby forming a substrate which is interbonded to the inner thermoplastic layer of the insert, and having a recess in which the edge portion of the insert is disposed, wherein the insert covers only a portion of an outer surface of the substrate, the substrate and insert together forming a panel member; andremoving the panel member from the mold cavity.