Interior trim foam product and method of fabrication thereof

DETAILED DESCRIPTION OF THE INVENTION The article of the present invention and its method of manufacture will be described with reference to a composite plastic door such as a glove box door or a console door for use in association with the interior automotive body assembly.
FIG.
4 shows a representative type of glove compartment door 10.
The door includes an outer shell or skin 12 of flexible grained polyvinyl chloride material which can be formed by a process of the type set forth in U.
S.
Pat.
No.
4,562,032 thereby to retain a highly grained appearance on the exterior shell face 14.
An insert 16 forms the back of the door 10 The mold tooling apparatus in the present invention is configured as shown in FIGS.
1-3 to form a preformed part.
A cover 18 of the mold apparatus supports the mold insert 16 in spaced relationship to a mold cavity part 20.
Alternatively, the insert 16 can be preloaded as shown in dotted line at 16a in FIG.
2.
Cavity part 20 supports the outer shell 12.
More specifically, the insert 16, as shown in FIGS.
1 and 5, is a plastic part having a planar extent 24 substantially equal to that of an opening 26 in the outer shell 12 which is defined by a raw edge 28 formed thereon around the periphery of the outer shell 12.
The insert 24 includes a peripheral edge 30 that is located by the mold cover 18 to be located in close spaced relationship to the raw edge 28 which is turned thereover by pivotal tool inserts and/or slides 32 as shown in FIGS.
2 and 3 to cover the edge 30.
The insert 24 more particularly includes an integral post formed flange 34 with segments 34a on the sides and 34b on the ends of the insert 24 to be located in close relationship with the distal end of the raw edge 28.
Each segment 34a, 34b is arranged generally perpendicularly with respect to a planar extent 35 on the insert 24.
The cover 32 is closed and sealed with respect to the mold cavity part 20.
The insert 24 includes an opening 36 for receiving foam precursors from a foam pour nozzle 38 which will feed the foam precursors into a cavity 40 formed between the mold supported outer shell 12 and the mold supported insert 24