US 12,441,069 B2
Method of manufacturing a trim panel
Manthan Pareshkumar Patel, Scarborough (CA); Bruce Arthur Giroux, Port Hope (CA); Gregory James Farrar, Roblin (CA); Collin James Goody, Cobourg (CA); Zachary Paul Fedak, Courtice (CA); and Murali Mohan Reddy, Belleville (CA)
Assigned to CPK Interior Products Inc., Port Hope (CA)
Filed by CpK Interior Products Inc., Port Hope (CA)
Filed on Aug. 5, 2021, as Appl. No. 17/394,513.
Prior Publication US 2023/0041610 A1, Feb. 9, 2023
Int. Cl. B29C 45/16 (2006.01); B29C 45/14 (2006.01); B29C 70/78 (2006.01); B29L 31/30 (2006.01)
CPC B29C 70/78 (2013.01) [B29C 45/1418 (2013.01); B29C 45/14508 (2013.01); B29C 45/1671 (2013.01); B29C 2791/001 (2013.01); B29L 2031/3041 (2013.01)] 24 Claims
OG exemplary drawing
 
1. A method of manufacturing a trim panel, the method comprising:
(a) injecting a liquid substrate polymer into a first mold cavity to create a substrate;
(b) clamping a backside mold against a frontside mold to define a second mold cavity, the backside mold including a single-piece and continuous surface comprising a substrate-contacting section and a skin-contacting section, and a backside of the substrate created in step (a) being located against the substrate-contacting section in the second mold cavity;
(c) injecting a liquid skin polymer into the second mold cavity to create a skin on the substrate created in step (a);
(d) causing the skin polymer to directly adhere to a middle portion of a face of the substrate during step (c);
(e) causing the liquid skin polymer to wrap around at least one peripheral edge of the substrate and adhere to the backside of the substrate during step (c); and
(f) the wrap around portion of the skin polymer contacting against the skin-contacting section of the backside mold.