Plastic slush skin manufacture involves molding a given powder amount in a heated cavity formed by a tool and an opposing shell to create a visible skin and compressed rear foam layer

摘要

Open sided tool(7) is used in conjunction with opposing, correspondingly shaped shell(15) to form closed cavity(16) for molding slush skin. A quantity of powdered plastic(8') is introduced into cavity and is heated to process temperature to form molding with both leather-like closed visible surface and foam layer at rear side. After cooling the molding, the shell is removed and completed slush skin molding is demolded. Powder(8') is vibrated during introduction into the tool cavity(16) as the tool(7) is heated. The heated tool is then rotated(10). Both the tool and opposing shell(15) may be heated or merely the tool or shell. Vibration in the plastic is created by shaking the tool cavity and/or use of sound waves, the latter being produced by vibration generators(18) on the tool and/or shell. Following the forming of the closed skin the tool temperature is reduced below the plastic gelation temperature and the foamed backing layer is then formed. When one or more of the powdered plastics is heated it supports or produces a cross-linking reaction which releases gas for forming the foam layer. Plastic powder may also include a blowing agent and/or a chemical retarder for the foaming process and/or further ingredients for creating a rigid foam layer. Independent claims are included for: a) powdered plastic(8') used in the process which comprises one or more different plastic types and one or more blowing agents; b) the molding tool whose cavity(16) is penetrated by compressed air channels for demolding the slush skin.