Appeal No. 2005-1549
Application No. 10/193,407
bottom surfaces, the film sheet being selected from the
group consisting of polyester, polyurethane and
polycarbonate;
placing the formed film sheet in a mold cavity of an
injection mold having a shape defining the automotive
component;
injecting a thermoplastic elastomer into the mold
cavity of the injection mold, such that the thermoplastic
elastomer is in mating contact with the bottom surface of
the formed film sheet, to generate a structural carrier for
the formed film sheet, the generation of the structural
carrier creating sufficient pressure and heat to bond the
structural carrier to the bottom surface of the formed film
sheet to form the molded laminate automotive component.
21. 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, wherein the film
sheet comprises a layer of acrylic color.
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