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Method for molding headliners

  • US 6,146,578 A
  • Filed: 03/26/1998
  • Issued: 11/14/2000
  • Est. Priority Date: 10/09/1997
  • Status: Expired due to Fees
First Claim
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1. A method for thermoforming an article, the method comprising:

  • providing at least one layer of formable plastic material;

    heating the at least one layer of formable plastic material;

    inserting the at least one layer of formable plastic material into a mold having first and second thin mold halves, each thin mold half having a non-planar configuration, one thin mold half having at least one aperture in fluid communication with a vacuum source;

    moving one of the thin mold halves toward the other thin mold half to effect a sealed relationship between the thin mold halves by compressing a compressible seal disposed about a periphery of one of the thin mold halves; and

    applying a vacuum pressure to the at least one aperture by the vacuum source to reduce air pressure within the mold to thereby cause ambient air pressure to forcefully bias the thin mold halves sufficiently together so as to further compress the seal and form the at least one layer of formable plastic material to a contour corresponding to the non-planar configurations of the thin mold halves;

    wherein each thin mold half is sufficiently rigid such that the thin mold halves do not substantially flex when the thin mold halves are forcefully biased together, thereby accurately forming the at least one layer of formable plastic material to the contour.

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