Patent ID: 6171419
Filing Date: 2001-01-09
Classification: B29C,B29K,B29L,B60R,Y10S,Y10T

Abstract:
A method of making an interior panel of an automotive vehicle door, the interior panel including an exterior surface which is to face toward the interior of the automotive vehicle when the interior panel is installed on the vehicle door, said method comprising the steps of:providing a composite sheet comprising a vinyl material and a reinforcing mat, said vinyl material and said reinforcing mat being tacked together at positions along an outer peripheral edge thereof;heating the composite sheet until the vinyl material sags relative to the reinforcing mat a predetermined amount;forming the composite sheet into a pre-form by placing the composite sheet while in the heated condition into a mold cavity having a molding surface shaped to define the exterior surface of the interior panel and thereafter applying a vacuum at the molding surface to draw the vinyl material into conformity with the molding surface and conforming the reinforcing mat to the vinyl material for effecting a bond between the reinforcing mat and vinyl material; andpouring foam into the pre-form and conforming the foam to the pre-form until the foam has sufficiently cured.