Method of making a laminated trim component at a molding station

1. A method of making a laminated trim component at a molding station, the method comprising:

providing a natural fiber, plastic composite sheet having inner and outer surfaces;

heating the composite sheet to a first softening temperature, wherein the composite sheet is stretchable when heated to the first softening temperature;

providing a laminated sheet overlying the outer surface of the composite sheet, the laminated sheet having a support layer with inner and outer surfaces and a plastic cushioning layer laminated to the support layer at the inner surface of the support layer;

heating the laminated sheet to a second softening temperature, wherein the laminated sheet is stretchable when heated to the second softening temperature;

placing the laminated sheet and composite sheet between upper and lower mold halves;

pressing the composite sheet against the laminated sheet between the upper and lower mold halves after the steps of providing and the steps of heating to bond the plastic cushioning layer to the plastic composite sheet at the molding station, wherein the step of pressing compresses a portion of the laminated sheet spaced inwardly from an outer periphery of the laminated sheet to locally compact and thin the cushioning layer at the portion to form a compressed portion of the cushioning layer, and wherein interior portions of the sheets stretch during the step of pressing while remaining intact; and

molding a plastic compatible with the plastic of the composite sheet around the composite sheet to form at least one component at the inner surface of the composite sheet at the molding station and at least one plastic edge component about a periphery of the composite sheet;

folding the laminated sheet; and

bonding an outer peripheral portion of the laminated sheet to the plastic edge component.

2. The method as claimed in claim 1 , further comprising applying a vacuum at the outer surface of the support layer to pull the outer surface of the support layer into contact with a forming surface while the support layer is still soft to improve appearance of the outer surface and improve component shape.

3. The method as claimed in claim 1 , wherein the cushioning layer is a thermoplastic foam layer compatible with the plastic of the composite sheet.

4. The method as claimed in claim 1 , wherein the laminated plastic sheet is a polymer bi-laminate sheet.

5. The method as claimed in claim 1 , wherein the support layer is a thermoplastic outer skin layer.

6. The method as claimed in claim 5 , wherein the thermoplastic outer skin layer is a TPO outer skin layer.

7. The method as claimed in claim 1 , wherein the composite sheet includes a thermoplastic resin.

8. The method as claimed in claim 7 , wherein the thermoplastic resin of the composite sheet is polypropylene.

9. The method as claimed in claim 1 , wherein the at least one plastic edge component includes a plurality of plastic edge components.

10. The method as claimed in claim 1 , wherein folding the laminated sheet includes folding the laminated sheet at the compressed portion of the cushioning layer.

11. A method of making a laminated, vehicle trim component at a molding station, the method comprising:

providing a natural fiber, plastic composite sheet having inner and outer surfaces;

heating the composite sheet to a first softening temperature, wherein the composite sheet is stretchable when heated to the first softening temperature;

providing a laminated sheet overlying the outer surface of the composite sheet, the laminated sheet having a support layer with inner and outer surfaces and a plastic cushioning layer laminated to the support layer at the inner surface of the support layer; heating the laminated sheet to a second softening temperature, wherein the laminated sheet is stretchable when heated to the second softening temperature;

placing the laminated sheet and composite sheet between upper and lower mold halves;

pressing the composite sheet against the laminated sheet between upper and lower mold halves after the steps of providing and the steps of heating to bond the plastic cushioning layer to the plastic composite sheet at the molding station, wherein the step of pressing compresses a portion of the laminated sheet spaced inwardly from an outer periphery of the laminated sheet to locally compact and thin the cushioning layer at the portion to form a compressed portion of the cushioning layer and wherein interior portions of the sheets stretch during the step of pressing while remaining intact; and

molding a plastic compatible with the plastic of the composite sheet around the composite sheet to form at least one component at the inner surface of the composite sheet at the molding station and at least one plastic edge component about a periphery of the composite sheet;

folding the laminated sheet; and

bonding an outer peripheral portion of the laminated sheet to the plastic edge component.

12. The method as claimed in claim 11 , further comprising applying a vacuum at the outer surface of the support layer to pull the outer surface of the support layer into contact with a forming surface while the support layer is still soft to improve appearance of the outer surface and improve component shape.

13. The method as claimed in claim 11 , wherein the cushioning layer is a thermoplastic foam layer compatible with the plastic of the composite sheet.

14. The method as claimed in claim 11 , wherein the laminated plastic sheet is a polymer bi-laminate sheet.

15. The method as claimed in claim 11 , wherein the support layer is a thermoplastic outer skin layer.

16. The method as claimed in claim 15 , wherein the thermoplastic outer skin layer is a TPO outer skin layer.

17. The method as claimed in claim 11 , wherein the composite sheet includes a thermoplastic resin.

18. The method as claimed in claim 17 , wherein the thermoplastic resin of the composite sheet is polypropylene.

19. A method of making a laminated, vehicle interior trim component at a molding station, the method comprising:

providing a natural fiber, plastic composite sheet having inner and outer surfaces;

heating the composite sheet to a first softening temperature, wherein the composite sheet is stretchable when heated to the first softening temperature;

providing a laminated sheet overlying the outer surface of the composite sheet, the laminated sheet having a support layer with inner and outer surfaces and a plastic cushioning layer laminated to the support layer at the inner surface of the support layer;

heating the laminated sheet to a second softening temperature, wherein the laminated sheet is stretchable when heated to the second softening temperature;

placing the laminated sheet and composite sheet between upper and lower mold halves;

pressing the composite sheet against the laminated sheet between the upper and lower mold halves after the steps of providing and the steps of heating to bond the plastic cushioning layer to the plastic composite sheet at the molding station, wherein the step of pressing compresses a portion of the laminated sheet spaced inwardly from an outer periphery of the laminated sheet to locally compact and thin the cushioning layer at the portion to form a compressed portion of the cushioning layer, and wherein interior portions of the sheets stretch during the step of pressing while remaining intact; and

molding a plastic compatible with the plastic of the composite sheet around the composite sheet to form at least one component at an inner surface of the composite sheet at the molding station and at least one plastic edge component about a periphery of the composite sheet;

folding the laminated sheet; and

bonding an outer peripheral portion of the laminated sheet to the plastic edge component.

20. The method as claimed in claim 19 , further comprising applying a vacuum at the outer surface of the support layer to pull the outer surface of the support layer into contact with a forming surface while the support layer is still soft to improve appearance of the outer surface and improve component shape.

21. The method as claimed in claim 19 , wherein the cushioning layer is a thermoplastic foam layer compatible with the plastic of the composite sheet.

22. The method as claimed in claim 19 , wherein the laminated plastic sheet is a polymer bi-laminate sheet.

23. The method as claimed in claim 19 , wherein the outer skin layer is a thermoplastic outer skin layer.

24. The method as claimed in claim 23 , wherein the thermoplastic outer skin layer is a TPO outer skin layer.

25. The method as claimed in claim 19 , wherein the composite sheet includes a thermoplastic resin.

26. The method as claimed in claim 25 , wherein the thermoplastic resin of the composite sheet is polypropylene.