Patent ID: 6749794
Filing Date: 2004-06-15
Classification: B29C,B29K,B29L

Abstract:
A method of making a molded component having a molded-in surface texture, using a molding apparatus including a front mold having a front mold surface with a front mold surface texture, and a back mold having a back mold surface opposed to said front mold, said method comprising the following steps:a) providing a cover sheet including a skin film comprising a skin film material, and a foam backing comprising a foam backing materials; b) heating said cover sheet so as to heat said skin film to a first temperature equal to or above a melting temperature of said skin film material, and so as to heat said foam backing to a second temperature below a melting temperature of said foam backing material; c) arranging said cover sheet between said front mold and said back mold with said skin film facing toward said front mold and said foam backing facing toward said back mold, and then moving at least one of said front mold and said back mold relatively toward each other with said cover sheet therebetween; d) molding said cover sheet and bringing said skin film into direct contact with said front mold surface so as to mold into said skin film a molded-in surface texture that is the inverse of said front mold surface texture; e) after said step d), cooling said cover sheet and moving apart at least one of said front mold and said back mold relative to each other; and f) after said step e), introducing a substrate material between said foam backing and said back mold surface, and moving at least one of said front mold and said back mold relatively toward each other, so that said back mold surface presses against said substrate material and molds and bond said substrate material onto said foam backing so as to form a molded substrate from said substrate material.