Patent ID: 6280666
Filing Date: 2001-08-28
Classification: B29C

Abstract:
A method of molding a plastic shell having a pliable 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 relatively less wear resistant than the wear resistant skin layer portion;providing a casting mold having a heated mold surface;forming the wear-resistant first skin layer portion by depositing the first plastic material against a predetermined portion of the mold surface, the wear-resistant first skin layer portion including a backside surface spaced from the mold surface;forming an integral backing layer behind the wear-resistant first skin layer portion while simultaneously forming the second skin layer portion on a remaining portion of the heated casting surface by casting the second material across the remainder of the heated casting surface and across the backside surface of the wear resistant first skin layer portion; andforming the wear-resistant skin layer portion by partitioning the predetermined portion of the mold surface from the remaining exposed portion during casting of the first plastic material to contain such material within the predetermined region of the mold surface.