PROCESS AND MOLD FOR CREATING A SKIN SUPPLIED WITH AT LEAST ONE ITEM
A method of forming a covering for a motor vehicle interior is disclosed, wherein a skin is disposed in a mold between a male part and a female part having an item disposed thereon and a vacuum is created in the mold to form the skin against the item.
1 . A method of forming a covering for a motor vehicle interior comprising the steps of:
providing a mold having a male part having a plurality of vent holes formed therein and a female part having a plurality of vent holes formed therein and having a functional surface;
disposing an item on at least a portion of the functional surface of the female part;
positioning a skin between the male part and the female part of the mold;
closing the mold to provide an airtight seal therein;
introducing air through the vent holes of the male part and against the skin; and
evacuating air from the mold through the vent holes of the female part to create a vacuum in the mold to form the skin over the item and against the female part.
2 . The method of claim 1 , further comprising the step of heating the skin prior to positioning the skin in the mold.
3 . The method of claim 1 , wherein the vent holes of the male part are in fluid communication with an air blowing device.
4 . The method of claim 1 , wherein the vent holes of the male part are in fluid communication with an air evacuation device.
5 . The method of claim 4 , further comprising the step of evacuating air from the mold to form the skin over the male part to facilitate a pre-shaping of the skin.
6 . The method of claim 1 , wherein at least one of the male part and the female part is formed from a porous material.
7 . The method of claim 1 , wherein the male part and the female part are formed from at least one of nickel, steel, aluminum, and synthetic resin.
8 . The method of claim 1 , wherein the functional surface of the female part is embossed.
9 . The method of claim 1 , wherein the item is disposed on the functional surface of the female part with one of an adhesive and a magnet.
10 . The method of claim 1 , wherein the vent holes of the female part are in fluid communication with an air evacuation means.
11 . The method of claim 10 , wherein the vacuum in the mold is created by evacuating the air from the mold through the vent holes of the female part with the air evacuation means.
12 . The method of claim 10 , wherein the vent holes are formed in the functional surface of the female part.
13 . The method of claim 10 , wherein the vent holes are formed in a surface outside of the functional surface of the female part.
14 . A method of forming a covering for a motor vehicle interior comprising the steps of:
providing a mold having a male part having a plurality of vent holes formed therein and a female part having a plurality of vent holes formed therein and having a functional surface;
disposing an item on at least a portion of the functional surface of the female part;
positioning a skin between the male part and the female part of the mold;
evacuating air from the mold through the vent holes of the male part to form the skin over the male part to facilitate a pre-shaping thereof;
closing the mold to provide an airtight seal therein;
introducing air through the vent holes of the male part and against the skin; and
evacuating air from the mold through the vent holes of the female part to create a vacuum in the mold to form the skin over the item and against the female part, wherein a transitional area between the item and the skin is substantially seamless.
15 . The method of claim 14 , further comprising the step of heating the skin prior to positioning the skin in the mold.
16 . The method of claim 14 , wherein at least one of the male part and the female part is formed from a porous material.
17 . The method of claim 14 , wherein the functional surface of the female part is embossed.
18 . The method of claim 14 , wherein the item is disposed on the functional surface of the female part with one of an adhesive and a magnet.
19 . A method of forming a covering for a motor vehicle interior comprising the steps of:
providing a mold having a male part having a plurality of vent holes formed therein and a female part having a plurality of vent holes formed therein and having a functional surface;
disposing an item on at least a portion of the functional surface of the female part;
heating a skin;
positioning the heated skin between the male part and the female part of the mold;
closing the mold to provide an airtight seal therein;
introducing air through the vent holes of the male part and against the skin; and
evacuating air from the mold through the vent holes of the female part to create a vacuum in the mold to form the skin over the item and against the female part.
20 . The method of claim 10 , wherein the functional surface of the female part is embossed.