Appeal No. 2005-1549
Application No. 10/193,407
APPEALED SUBJECT MATTER
Claims 11, 13, 18 and 21 are representative of the subject
matter on appeal and read as follows1:
11. A method of manufacturing a molded plastic
component, comprising:
providing a film sheet having top and bottom surfaces,
the film sheet being selected from the group consisting of
polyester, polyurethane and polycarbonate;
vacuum molding the film sheet in a mold cavity to
obtain a pre-form;
placing the pre-form in a mold cavity of an injection
mold having a shape defining the desired plastic component;
and
injecting a thermoplastic elastomer into the mold
cavity of the injection mold to generate a structural
carrier for the pre-form, the generation of the structural
carrier creating sufficient pressure and heat to bond the
structural carrier to the bottom surface of the pre-form to
form the molded laminate plastic component.
13. The method of claim 11, wherein the step of
injecting a thermoplastic elastomer into the mold cavity
occurs at a temperature of 420oF and at a pressure of 50 psi
to 15,000 psi.
18. A method of manufacturing a molded laminate
automotive component, comprising:
inserting a film sheet into a vacuum forming station to
form the film sheet into a predetermined automotive
component shape to create a formed film sheet having top and
1 We limit our consideration to only those claims which have
been separately argued in the Brief in accordance with 37 CFR
§ 41.37(c)(1)(vii)(2004).
2
Page: Previous 1 2 3 4 5 6 7 8 9 10 11 12 Next
Last modified: November 3, 2007