Patent ID: 7101503

Claim:
A molding apparatus for forming a multi-layered molded component, comprising: a first mold tool including a first mold half; a second mold tool including a second mold half; an intermediate mold tool including a first auxiliary mold half and a second auxiliary mold half; a first carrier frame that is movably arranged between said first mold half and said first auxiliary mold half; and a second carrier frame that is movably arranged between said second mold half and said second auxiliary mold half; wherein: said first mold half is arranged facing and aligned with said second mold half; said first auxiliary mold half and said second auxiliary mold half are movably arranged so as to be movable between a working position in which said first auxiliary mold half and said second auxiliary mold half are respectively located aligned in a working space between said first mold half and said second mold half, and an idle position in which said first auxiliary mold half and said second auxiliary mold half are respectively located away from and clear of said working space; said first auxiliary mold half and said first mold half are respectively contoured to cooperate and mate with each other while enclosing a first pre-molding cavity therebetween; said second auxiliary mold half and said second mold half are respectively contoured to cooperate and mate with each other while enclosing a second pre-molding cavity therebetween; said first carrier frame is arranged and adapted to carry and hold in said first pre-molding cavity a first material layer to form a cover layer of the multi-layered molded component; said second carrier frame is arranged and adapted to carry and hold in said second pre-molding cavity a second material layer to form a supporting substrate layer of the multi-layered molded component; said first mold half and said second mold half are respectively contoured to cooperate and mate with each other while enclosing a final molding cavity therebetween; and at least one of said mold halves is movable to selectively open and close said first mold half relative to said first auxiliary mold half and to selectively open and close said second mold half relative to said second auxiliary mold half so as to selectively open and close said first pre-molding cavity and said second pre-molding cavity respectively in a first molding step when said first auxiliary mold half and said second auxiliary mold half are respectively located in said working position, and to selectively open and close said first mold half relative to said second mold half so as to selectively open and close said final molding cavity therebetween in a second molding step when said first auxiliary mold half and said second auxiliary mold half are respectively located in said idle position.