Undercut plastic molding manufacture involves locating foam blocks on the rear of outer skin and pressing supporting layer onto foam blocks and skin so that the blocks fill undercut areas

摘要

A prefabricated skin(1) with undercuts is manufactured and foamed blocks are applied onto the skin in the undercut areas. A supporting layer(6) is pressed onto the back of the skin using a press tool and the foam blocks are melted and/or molded so that they form fillers(5) in chambers between the skin and supporting layer in the undercut areas. The tool can then be removed from the undercut-free surface(C) of the molding(7) without problems. Press tool action deforms the foamed blocks(4) to create fillers(5) with the shape of each chamber in the undercut areas. A foam backing may be applied onto the prefabricated skin(1) before pressing the supporting layer(6) onto the skin and the foamed blocks applied to the rear of the backing layer. Application of the foam backing and foam blocks made be performed simultaneously.