Patent ID: 6706222
Filing Date: 2004-03-16
Classification: B29C

Abstract:
A method of molding a plastic shell having an outer skin and a backing layer, the method comprising the steps of:providing a charge of a first plastic material configured to form a wear resistant first skin layer portion of the outer skin; providing a charge of a second plastic material configured to form a second skin layer portion of the outer skin that is less wear resistant than the first skin layer portion; providing an open-ended casting mold having a heated mold surface; forming the first skin layer portion by spraying the first plastic material against an isolated predetermined portion of the mold surface, the first skin layer portion including a backside surface spaced from the mold surface; andforming an integral backing layer united behind the first skin layer portion while simultaneously forming the second skin layer portion on a remaining exposed portion of the heated casting surface by casting the second material across the exposed heated casting surface and across the backside of the first skin layer portion.