Method and apparatus for making a trim component with a foam core having a smoothly varying thickness

摘要

A trim component includes a foam backing layer and a foam pad insert laminated between a cover material and a substrate. The foam pad insert provides an area of enhanced cushioning, and has smoothly tapered edges to ensure a smooth surface contour without a visible edge transition on the cover material. The foam pad insert has a lower melting temperature than the foam backing layer, both of which are thermoplastics. A foam pad insert is positioned and fixed on the back surface of the foam backing layer. A substrate material is heated and then laminated and molded with the foam and the cover material. The heat from the substrate partially softens and melts the foam backing layer and the foam pad insert. The partially melted foam pad insert is viscously deformed to form the tapered edges, as dictated by the smoothly varying mold gap spacing of the forming tools.