Composite molded article and method of making same

Claim 3

A method according to claim 1, wherein said blocking off step includes: positioning at least one plug member in contact with said predetermined area of said sheet material prior to introducing said first moldable material; and removing said plug member from said contact with said predetermined area prior to introducing said second moldable material into said mold assembly.

Claim 4

A method according to claim 2, wherein said blocking off step further includes: positioning said plug member in contact with said predetermined area of said sheet material; then closing said mold assembly prior to introducing said first moldable material; reopening said mold assembly after introducing said first moldable material; removing said plug member from said contact with said predetermined area of said conformed sheet material; and reclosing said mold assembly prior to introducing said second moldable material.

Claim 5

A method according to claim 2, wherein said plug member is movably interconnected with one of said mold members for extension toward the other of said mold members and for retraction away from the other of said mold members, said blocking off step further including: extending said plug member into said contact with said predetermined area of said sheet material prior to introducing said first moldable material; and retracting said plug member out of said contact with said predetermined area of said sheet material after introducing said first moldable material, said extension and retraction of said mold member being performed while said mold assembly is closed.

Claim 6

A method according to claim 1, wherein said step of introducing said second moldable material includes injecting a second moldable material that cures to a relatively soft, deformable state.

Claim 7

A method according to claim 1, wherein said step of introducing said first moldable material includes reaction injection molding a multiconstituent urethane material that cures to a relatively rigid state in said mold assembly.

Claim 8

A method according to claim 6, wherein said step of introducing said second moldable material includes reaction injection molding a multiconstituent material that cures to a relatively soft, deformable state in said mold assembly.

Claim 9

A method according to claim 1, wherein said step of drawing said sheet material is performed generally simultaneously with said step of introducing said first moldable material between said first molding surface and said sheet material.

Claim 10

A method according to claim 1, further including the step of heating said sheet material prior to said step of urging said sheet material.

Claim 11

A method according to claim 1, further including the step of vacuum forming sheet material prior to said step of urging said sheet material.

Claim 12

A method according to claim 1, wherein said mold assembly is provided with movable clamping members therein, said method further including moving said clamp members into a clamping engagement with predetermined portions of said sheet material in order to clampingly secure said sheet material to said mold assembly in at least one predetermined location thereon.

Claim 13

A composite molded vehicle interior panel member having a predetermined exterior shape and configuration, said panel member being formed by a process comprising the steps of: providing a selectively closable mold assembly including a first mold and a second mold having respective first and second molding surfaces, at least said second mold member having a shape complementary to said predetermined exterior shape of said panel; positioning a deformable sheet material on said second molding surface; urging said sheet material into said second mold in order to conform said sheet material to said second mold surface and to form an exterior shape of said sheet material corresponding to said predetermined exterior shape of said panel; closing said mold assembly; forming a relatively rigid substrate base for said sheet material by reaction injection molding a first moldable urethane material into said closed mold assembly between said first molding surface and said sheet material, said first moldable material being composed of a material having a rigidity when cured that is greater than the rigidity of said sheet material in order to retain said sheet material in said exterior shape corresponding to said predetermined exterior shape of said panel; blocking off at least one predetermined area of said sheet material during said reaction injection molding of said first moldable urethane material in order to substantially prevent said first moldable urethane material from contacting said predetermined area of said sheet material; and reaction injection molding a second moldable urethane material into said mold assembly between said first mold surface and said conformed sheet material at least at said previously blocked-off predetermined area.

Claim 14

A composite molded vehicle interior panel member having a predetermined exterior shape and configuration, said panel member being formed by a process comprising the steps of: providing a selectively closable mold assembly including a first mold and a second mold having respective first and second molding surfaces, at least said second mold member having a shape complementary to said predetermined exterior shape of said panel; positioning a deformable sheet material on said second molding surface; urging said sheet material into said second mold in order to conform said sheet material to said second mold surface and to form an exterior shape of said sheet material corresponding to said predetermined exterior shape of said panel; closing said mold assembly; forming a relatively rigid substrate base for said sheet material by reaction injection molding a first moldable urethane material into said closed mold assembly between said first molding surface and said sheet material, said first moldable material being composed of a material having a rigidity when cured that is greater than the rigidity of said sheet material in order to retain said sheet material in said exterior shape corresponding to said predetermined exterior shape of said panel; blocking off at least one predetermined area of said sheet material during said reaction injection molding of said first moldable urethane material in order to substantially prevent said first moldable urethane material from contacting said predetermined area of said sheet material; and reaction injection molding a second moldable urethane material into said mold assembly between said first mold surface and said conformed sheet material at least at said previously blocked-off predetermined area.

Claim 15

A composite molded panel member according to claim 12, wherein said blocking off step includes: positioning at least one plug member in contact with said predetermined area of said sheet material prior to said reaction injection molding of said first moldable urethane material; and removing said plug member from said contact with said predetermined area prior to said reaction injection molding of said second moldable urethane material into said mold assembly.

Claim 16

A composite molded panel member according to claim 13, wherein said plug member is movably interconnected with one of said mold members for extension toward the other of said mold members and for retraction away from the other of said mold members, said blocking off step further including: extending said plug member into said contact with said predetermined area of said sheet material prior to said reaction injection molding of said first moldable urethane material; and retracting said plug member out of said contact with said predetermined area of said sheet material after said reaction injection molding of said first moldable urethane material, said extension and retraction of said mold member being performed while said mold assembly is closed.

Claim 17

A composite molded panel member according to claim 12, wherein said step of introducing said second moldable material includes reaction injecting a second moldable material that cures to a relatively soft, deformable state.

Claim 18

A composite molded panel member according to claim 12, wherein said predetermined areas comprise a vehicle interior arm rest portion of said panel.

Claim 19

A composite molded panel member according to claim 12, wherein said predetermined areas comprise a vehicle interior energy absorption portion of said panel.

Claim 20

A composite molded panel member according to claim 12, wherein said step of urging said sheet material is performed generally simultaneously with said step of introducing said first moldable material between said first molding surface and said sheet material.

Claim 21

A composite molded panel member according to claim 12, further including the step of heating said sheet material prior to said step of urging said sheet material.

Claim 22

A composite molded panel member according to claim 12, further including the step of vacuum forming said sheet material prior to said step of urging said sheet material.

Claim 23

A composite molded panel member according to claim 12, wherein said mold assembly is provided with movable clamping members therein, said method further including moving said clamp members into a clamping engagement with predetermined portions of said sheet material in order to clampingly secure said sheet material to said mold assembly in at least one predetermined location thereon.

Claim 26

A method according to claim 22, wherein said blocking off step includes: positioning at least one plug member in contact with said predetermined area of said conformed sheet material prior to introducing said first moldable material; and removing said plug member from said contact with said predetermined area prior to introducing said second moldable material into said mold assembly.

Claim 27

A method according to claim 23, wherein said blocking off step further includes: positioning said plug member in contact with said predetermined area of said conformed sheet material; then closing said mold assembly prior to introducing said first moldable material; reopening said mold assembly after introducing said first moldable material; removing said plug member from said contact with said predetermined area of said conformed sheet material; and reclosing said mold assembly prior to introducing said second moldable material.

Claim 28

A method according to claim 23, wherein said plug member is movably interconnected with one of said mold members for extension toward the other of said mold members and for retraction away from the other of said mold members, said blocking off step further including: extending said plug member into said contact with said predetermined area of said conformed sheet material prior to introducing said first moldable material; and retracting said plug member out of said contact with said predetermined area of said conformed sheet material after introducing said first moldable material, said extension and retraction of said mold member being performed while said mold assembly is closed.

Claim 29

A method according to claim 22, wherein said step of introducing said second moldable material includes injecting a second moldable material that cures to a relatively soft, deformable state.

Claim 30

A method according to claim 22, wherein said step of introducing said first moldable material includes reaction injection molding a multiconstituent urethane material that cures to a relatively rigid state in said mold assembly.

Claim 31

A method according to claim 27, wherein said step of introducing said second moldable material includes reaction injection molding a multiconstituent material that cures to a relatively soft, deformable state in said mold assembly.

Claim 32

A method according to claim 22, wherein said mold assembly is provided with movable clamping members therein, said method further including moving said clamp members into a clamping engagement with predetermined portions of said sheet material in order to clampingly secure said sheet material to said mold assembly in at least one predetermined location thereon.

Claim 33

composite molded vehicle interior panel member having a predetermined exterior shape and configuration, said panel member being formed by a process comprising the steps of: providing a selectively closable mold assembly including a first mold and a second mold having respective first and second molding surfaces, at least said second mold member having a shape complementary to said predetermined exterior shape of said panel; positioning a deformable sheet material on said second molding surface; heating said sheet material; vacuum forming said sheet material into said second mold in order to conform said sheet material to said second mold surface, said conformed sheet material having an exterior shape corresponding to said predetermined exterior shape of said panel; closing said mold assembly; forming a relatively rigid substrate base for said sheet material by reaction injection molding a first moldable urethane material into said closed mold assembly between said first molding surface and said conformed sheet material, said first moldable material being composed of a material having a rigidity when cured that is greater than the rigidity of said sheet material in order to retain said sheet material in said exterior shape corresponding to said predetermined exterior shape of said panel; blocking off at least one predetermined area of said conformed sheet material during said reaction injection molding of said first moldable urethane material in order to substantially prevent said first moldable urethane material from contacting said predetermined area of said conformed sheet material; and reaction injection molding a second moldable urethane material into said mold assembly between said first mold surface and said conformed sheet material at least at said previously blocked-off predetermined area.

Claim 34

composite molded vehicle interior panel member having a predetermined exterior shape and configuration, said panel member being formed by a process comprising the steps of: providing a selectively closable mold assembly including a first mold and a second mold having respective first and second molding surfaces, at least said second mold member having a shape complementary to said predetermined exterior shape of said panel; positioning a deformable sheet material on said second molding surface; heating said sheet material; vacuum forming said sheet material into said second mold in order to conform said sheet material to said second mold surface, said conformed sheet material having an exterior shape corresponding to said predetermined exterior shape of said panel; closing said mold assembly; forming a relatively rigid substrate base for said sheet material by reaction injection molding a first moldable urethane material into said closed mold assembly between said first molding surface and said conformed sheet material, said first moldable material being composed of a material having a rigidity when cured that is greater than the rigidity of said sheet material in order to retain said sheet material in said exterior shape corresponding to said predetermined exterior shape of said panel; blocking off at least one predetermined area of said conformed sheet material during said reaction injection molding of said first moldable urethane material in order to substantially prevent said first moldable urethane material from contacting said predetermined area of said conformed sheet material; and reaction injection molding a second moldable urethane material into said mold assembly between said first mold surface and said conformed sheet material at least at said previously blocked-off predetermined area.

Claim 35

A composite molded panel member according to claim 29, wherein said blocking off step includes: positioning at least one plug member in contact with said predetermined area of said conformed sheet material prior to said reaction injection molding of said first moldable urethane material; and removing said plug member from said contact with said predetermined area prior to said reaction injection molding of said second moldable urethane material into said mold assembly.

Claim 36

A composite molded panel member according to claim 31, wherein said plug member is movably interconnected with one of said mold members for extension toward the other of said mold members and for retraction away from the other of said mold members, said blocking off step further including: extending said plug member into said contact with said predetermined area of said conformed sheet material prior to said reaction injection molding of said first moldable urethane material; and retracting said plug member out of said contact with said predetermined area of said conformed sheet material after said reaction injection molding of said first moldable urethane material, said extension and retraction of said mold member being performed while said mold assembly is closed.

Claim 37

A composite molded panel member according to claim 30, wherein said step of introducing said second moldable material includes injecting a second moldable material that cures to a relatively soft, deformable state.

Claim 38

A composite molded panel member according to claim 30, wherein said predetermined areas comprise a vehicle interior arm rest portion of said panel.

Claim 39

A composite molded panel member according to claim 30, wherein said predetermined areas comprise a vehicle interior energy absorption portion of said panel.

Claim 40

A composite molded panel member according to claim 30, wherein said mold assembly is provided with movable clamping members therein, said method further including moving said clamp members into a clamping engagement with predetermined portions of said sheet material in order to clampingly secure said sheet material to said mold assembly in at least one predetermined location thereon.

Claim 41

A composite molded panel member according to claim 13, wherein said blocking off step further includes: positioning said plug member in contact with said predetermined area of said sheet material; then closing said mold assembly prior to introducing said first moldable material; reopening said mold assembly after introducing said first moldable material; removing said plug member from said contact with said predetermined area of said conformed sheet material; and reclosing said mold assembly prior to introducing said second moldable material.

Claim 42

A composite molded panel member according to claim 31, wherein said blocking off step further includes: positioning said plug member in contact with said predetermined area of said sheet material; then closing said mold assembly prior to introducing said first moldable material; reopening said mold assembly after introducing said first moldable material; removing said plug member from said contact with said predetermined area of said conformed sheet material; and reclosing said mold assembly prior to introducing said second moldable material.