Flat plastic composite component manufacture, particularly for automotive components, involves foam expansion onto the rear face of an outer skin and inclusion of prefabricated or molded ribs

摘要

An outer skin layer (8) is positioned in the cavity of a first tool half (20). A layer of foamable plastic (26) is cast into the cavity of a second tool half (22) whose shape corresponds to the inner profile of the foamed layer and has recesses (24) which accommodate components (18) forming ribs on the final composite molding. The tool halves are closed against each other and the plastic foam expanded and adhered to the outer skin. An outer skin layer (8) is positioned in the cavity of a first tool half (20). A layer of foamable plastic (26) is cast into the cavity of a second tool half (22) whose shape corresponds to the inner profile of the foamed layer and has recesses (24) which accommodate components (18) forming ribs on the final composite molding. The tool halves are closed against each other and the plastic foam expanded and adhered to the outer skin. Ribs may comprise either prefabricated components or are injection molded in plastic. When a product is required with skins on both outer and inner faces an inner skin layer (12) is placed in the second tool half cavity and held by vacuum before introducing the foam (26). Alternatively, an inner skin may be applied to the inner side of the expanded foam after demolding the product. The inner skin layer may be flexible and shaped during placement in the tool or is semi-rigid and preformed to the shape of the inner contor of the second tool half (22) in a separate operation.