Patent ID: 8202453
Filing Date: 2012-06-19
Classification: B29C,Y10T

Abstract:
1. A method for producing an interior covering element comprising a flexible outer skin, a rigid internal support, and a foam disposed between the flexible outer skin and the rigid internal support, the rigid internal support being deformable under action of high forces, said method comprises: producing the flexible outer skin, said flexible outer skin having an outer surface and an inner surface; producing the rigid internal support, said rigid internal support having an outer surface and an inner surface; arranging the flexible outer skin on a first mould part, and arranging the rigid internal support on a second mould part so that the outer surface of the rigid internal support lays on the second mould part; closing the first and second mould parts in order fully to delimit a moulding cavity between the inner surface of the flexible outer skin and the inner surface of the rigid internal support; and introducing a fluid material that is to form a foam into the moulding cavity between the inner surface of the flexible outer skin and the inner surface of the rigid internal support through an orifice in the rigid internal support by way of a nozzle having an end provided with an outlet for introduction of the fluid material, the nozzle is integral with the second mould part so that the end of the nozzle is facing the outer surface of the rigid internal support, the configuration of the rigid internal support near to the orifice for introduction of the fluid material being such that the rigid internal support tends to come away from the second mould part under the action of the fluid material that is introduced, wherein: production of the rigid internal support comprises providing at least one catch member on the outer surface of the rigid internal support, near to the orifice of the rigid internal support, the at least one catch member being located in a central area of the outer surface of the rigid internal support, the method comprises, prior to closing of the first and second mould parts, providing on the second mould part a complementary catch member complementary to the catch member of the outer surface of the rigid internal support, the complementary catch member being located in a central area of the second mould part, and arranging the outer surface of the rigid internal support on the second mould part comprises causing the complementary catch member of the second mould part and the catch member of the outer surface of the rigid internal support to cooperate, so that the outer surface of the rigid internal support does not come away from the second mould part during the introduction of the fluid material and the fluid material does not penetrate between the outer surface of the rigid internal support and the second mould part, wherein the catch member comprises a rib, and production of the rigid internal support comprises the provision of at least one said rib that is inclined relative to the outer surface of the rigid internal support, the complementary catch member of the second mould part comprising a finger having a tapered end.