Ford Motor Company
METHODS OF FORMING WRAPPED COMPONENTS WITH REUSABLE INJECTION MOLDED THIN WALLED DUMMY SKINS AND WRAPPED COMPONENTS FORMED THEREFROM

Abstract:

A method of forming wrapped components includes positioning an injection molded skin in a mold, forming a foam-in-place (FIP) foam substrate against the injection molded skin, removing the injection molded skin from the FIP foam substrate, bonding an external wrap to the FIP foam substrate, and reusing the injection molded polyolefin skin to form additional FIP foam substrates. A spacer layer may be bonded between and to the FIP foam substrate and the external wrap. The injection molded skin may be formed from a polyolefin polymer and may be a thermoplastic elastomer such as a thermoplastic vulcanizate. The FIP foam substrate may a FIP urethane foam substrate and the external wrap may be a leather wrap or a faux leather wrap. The injection molded skin reusable and may used a predetermined number of times, e.g., at least ten times, before being replaced by a replacement injection molded skin.