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Method for forming plastic molded panels with inserts

  • US 5,411,688 A
  • Filed: 06/29/1992
  • Issued: 05/02/1995
  • Est. Priority Date: 06/29/1992
  • Status: Expired due to Term
First Claim
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1. A method for forming molded plastic panels having inserts, for use as trim panels, interior door panels and the like, comprising the steps of:

  • (a) positioning an insert into a first mold;

    (b) adding a polyurea elastomer material into said mold;

    (c) forming a thin, flexible, polyurea sheet, from said polyurea elastomer material, of a predetermined size and shape such that said insert is secured to said polyurea sheet to provide a blank having an outer surface adjacent said first mold and an inner surface on an opposite side of said blank;

    (d) positioning a mating mold adjacent said first mold and forming a cavity between said mating mold and said blank;

    (e) applying and bonding a relatively thick plastic substrate against the inner surface of the blank for bonding together surfaces of the blank and substrate;

    (f) thereafter, removing the molded panel from the mold to provide a composite plastic panel having an exposed exterior surface formed of outer surfaces of the blank and the insert; and

    (g) removing a portion of the sheet, which forms the blank, that overlaps the insert before bonding the substrate to the blank so as to simultaneously bond an inner face of the insert directly to the substrate.

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