Appeal No. 2006-2962
Application No. 10/252,177
second outer surface portions 62, 69 of the soft first
material layer 60, as shown in FIG. 3. The outer surface
72 could, if desired, be painted or coated or otherwise
decorated, as desired, to be compatible with the vehicle
interior. An interconnecting surface 75 of the hard
second material layer 70 extends between the outer
surface 72 and the inner surface 74 [col. 3, ll. 1-28].
The interconnecting surface 75 on the hard material layer 70 adjoins an
interconnecting surface 65 on an interconnecting portion 66 of the soft material
layer 60 (see Figure 3). The surfaces 65 and 75 are in continuous adhered contact
along the U-shape of the projecting portion 76 (see col. 4, ll. 11-19). This joint
defines a U-shaped break line 30 bounding a flap portion 86 in the door 12.
With regard to the method of making the door, Cherry teaches that:
To manufacture the deployment door 12, the hard
second material layer 70 is molded first. The layer 70 is
molded by directing thermoplastic material which is used
to make the hard second material layer 70 into a first
injection mold. The resulting single piece of molded
thermoplastic material forms the hard second material
layer 70. The hard second material layer 70 is then
placed into a second injection mold with the inner surface
74 engaging one surface portion of the second injection
mold and the outer surface 72 engaging another surface
portion of the second injection mold. The thermoplastic
material which is used to make the soft first material
layer 60 is then directed at a relatively high temperature
into the second injection mold. This thermoplastic
material flows around the single piece of molded
thermoplastic material which forms the hard second
material layer 70.
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