U.S. patent application number 10/292013 was filed with the patent office on 2003-04-10 for method of making a combination speaker grill and automotive interior trim panel.
This patent application is currently assigned to Meridian Automotive Systems, Inc.. Invention is credited to Van Manen, Dick.
Application Number | 20030066596 10/292013 |
Document ID | / |
Family ID | 29218557 |
Filed Date | 2003-04-10 |
United States Patent
Application |
20030066596 |
Kind Code |
A1 |
Van Manen, Dick |
April 10, 2003 |
Method of making a combination speaker grill and automotive
interior trim panel
Abstract
A method of manufacturing a rear shelf trim and speaker grill
panel (12) for an automotive vehicle (10) includes steps of
punching a substrate layer (16) of a polypropylene and flax
material with a punch set (46) to form a grill section (60) and
placing a decorative carpet layer (18) over the substrate layer
(16) and molding the two layers into a combined speaker grill and
rear shelf trim panel (12).
Inventors: |
Van Manen, Dick;
(Canandaigua, NY) |
Correspondence
Address: |
Grantland G. Drutchas
McDonnell Boehnen Hulbert & Berghoff
32nd Floor
300 S. Wacker Drive
Chicago
IL
60606
US
|
Assignee: |
Meridian Automotive Systems,
Inc.
|
Family ID: |
29218557 |
Appl. No.: |
10/292013 |
Filed: |
November 12, 2002 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10292013 |
Nov 12, 2002 |
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09498445 |
Feb 4, 2000 |
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09498445 |
Feb 4, 2000 |
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09260799 |
Mar 1, 1999 |
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Current U.S.
Class: |
156/245 ;
264/156; 264/257; 264/259; 264/278 |
Current CPC
Class: |
B29C 49/22 20130101;
B26F 1/02 20130101; B29L 2031/3005 20130101; B29C 49/0691 20220501;
B29C 2793/0018 20130101; B29C 53/02 20130101; Y10T 156/1062
20150115; B29C 2791/001 20130101; B29K 2995/0002 20130101; B29C
49/02 20130101; B60R 11/0217 20130101; B29C 2793/0054 20130101;
B26D 7/1818 20130101; B29K 2105/06 20130101; B60R 13/0268
20130101 |
Class at
Publication: |
156/245 ;
264/156; 264/259; 264/257; 264/278 |
International
Class: |
B29C 043/20 |
Claims
I claim:
1. A process for forming a combined speaker grill and automotive
interior trim panel characterized by the steps of: providing a
substrate layer of a heated mat material having a content of
thermoplastic material such that it is moldable under heated
conditions; punching a plurality of apertures in said heated
substrate to form a grill section; providing a decorative layer
onto said substrate; molding said substrate and said decorative
layer into said automotive interior trim panel of a desired shape
such that said apertures form an integral speaker grill with said
panel.
2. A process as defined in claim 1 further characterized by: said
punching of said apertures is simultaneous with said molding step
such that said apertures are formed through both said substrate and
said decorative layer as said substrate and decorative layer are
shaped into said panel.
3. A process as defined in claim 2 further characterized by: a
first mold die having apertures therein and a second mold die
having a punch set that fits in said apertures to punch said
apertures through both of said decorative layer and said substrate
as said mold dies are closed to shape said substrate and said
decorative layer into said panel.
4. A process as defined in claim 3 further characterized by: said
decorative layer being a carpet which has a thermal plastic back
surface that is adhered to said substrate during the molding
process.
5. A process as defined in claim 1 further characterized by the
steps of: forming said apertures in said substrate before said
substrate is molded into its final shape; positioning pins in said
apertures after said apertures are formed; positioning said
decorative layer over said substrate and said pins in a mold;
closing the mold and molding the substrate layer and decorative
layer into a shape of an automotive interior panel under pressure;
and removing the substrate from said pins such that said molded
panel has the decorative layer spanning over the apertures in said
substrate.
6. A process as defined in claim 5 further characterized by the
steps of: extending said pins through a first mold die and
positioning said pins to align with the interior surface of the
mold; punching said apertures by a first punch set aligned with
said pins to push through said substrate and recess said pins;
raising said punch set to remove said punched scraps of substrate
and lifting said pins to intrude into said apertures in said
substrate; providing a second mold die that complements said first
mold die and closing said first and second mold dies for molding
said panel into shape with said pins extending through said first
mold die and remaining in said apertures in said substrate during
molding of said panel.
7. A process as defined in claim 5 further characterized by: said
decorative layer being a carpet with a thermal plastic back surface
that is adhered to said substrate during the molding process.
8. A process as defined in claim 1 further characterized by:
positioning a formed grill section over an opening through said
substrate with a periphery of said grill section overlapping a
peripheral edge of said opening in said substrate with pins
extending through said apertures; positioning said decorative layer
over said substrate, said grill section, and said pins in a mold.
closing the mold and molding under pressure the substrate layer and
decorative layer in a shape of an automotive interior panel;
demolding the substrate from said pins such that the molded panel
has the decorative layer spanning over the aperture in the grill
section.
9. A process as defined in claim 8 further characterized by:
punching out two additional grill sections upon said closing said
mold at an end section of said substrate.
10. A process as defined in claim 9 further characterized by:
placing hot melt on top of the grill section for enhanced bonding
with the decorative layer before said decoration layer is placed
over said substrate and said grill section.
11. A process for forming a combined speaker grill and automotive
interior trim panel characterized by the steps of: providing a
decorative layer that is capable of being bonded to said substrate
layer; placing the heated substrate layer and decorative layer into
an open mold; closing the mold and molding said substrate layer and
said decorative layer into a formed automotive interior panel under
pressure between two closed mold dies with a first mold die section
of said mold having a section with a plurality of holes therein and
a complementary mold die section having a plurality of punches that
mate with said plurality of holes to punch a plurality of apertures
in the formed panel to form an integral speaker grill with said
panel; opening said mold dies and cooling said panel to be
resolidified with the substrate and decorative layers being bonded
together and removing the molded formed combined speaker grill and
automotive interior trim panel from said mold.
12. A process as defined in claim 11 further characterized by:
applying said decorative layer on said substrate layer before said
substrate is compression molded into shape such that said
decorative layer is compression molded with said substrate layer
into the shape of the combined speaker grill and automotive
interior trim panel.
13. A process as defined in claim 12 further characterized by: said
plurality of punches punched through both the lower and decorative
layer simultaneously with the compression molding of said substrate
layer.
14. A process as defined in claim 13 further characterized by: said
decorative layer being a carpet layer with a back surface bonded
onto the substrate during the molding process.
15. A process as defined in claim 14 further characterized by: said
combined speaker grill and automotive interior trim panel being in
the form of an automotive rear shelf trim panel.
16. A process as defined in claim 12 further characterized by: said
plurality of punches punching through both the lower and decorative
layer simultaneously with the compression molding of said speaker
grill and automotive interior trim panel.
17. A process as defined in claim 11 further characterized by: said
decorative layer being a carpet layer with a back surface bonded
onto the substrate during the molding process.
18. A process for forming a combined speaker grill and automotive
interior trim panel characterized by the steps of: providing a
grill section and a substrate layer of a heated mat material having
a content of thermoplastic material such that it is moldable under
heated conditions; punching out a plurality of aperture in said
grill section of said substrate layer; positioning said grill
section such that a pin is received in each respective aperture
with an end of the pin substantially coplanar with one side of the
grill section; providing a decorative layer that is capable of
being bonded to said substrate layer and said grill section;
molding said substrate layer, grill section and said decorative
upper layer into a formed automotive interior panel under pressure
between two closed mold dies with said decorative layer spanning
over said pins in said holes in said substrate to form an
integrated speaker grill with said panel; removing the molded
formed panel and speaker grill after said thermoplastic material in
said panel is, cooled to allow said panel to be resolidified and
said substrate, grill section and decorative upper layers are
bonded together.
19. A process as defined in claim 18 further characterized by: said
pins being in a first mold die and being spring biased such that
said heated mat is positioned over said spring biased pins; said
punching of said holes being done by a punch set aligned over said
pins and pushing through said mat and pushing down on said pins;
said punch set withdrawn and said pins being biased to rise into
said apertures formed in said grill section.
20. A molded interior automotive panel and speaker grill
combination characterized by: a molded substrate layer having
thermal plastic content and a flax fiber content; a plurality of
apertures through said substrate to be aligned with a speaker
mounted therebehind; a decorative layer on top of the substrate
material and molded thereto.
21. A molded interior automotive panel and speaker grill
combination as defined in claim 20 further characterized by: said
decorative layer being a porous carpet layer that spans over said
plurality of apertures.
22. A molded interior automotive panel and speaker grill
combination as defined in claim 20 further characterized by: said
decorative layer also having apertures therethrough that align with
the apertures in said substrate.
23. A molded interior automotive panel and speaker grill
combination as defined in claim 22 further characterized by: said
decorative layer being a porous carpet layer.
Description
[0001] This application is a continuation-in-part of patent
application U.S. Ser. No. 09/260,799 now pending.
FIELD OF THE INVENTION
[0002] The invention relates to a method of making a rear shelf
trim panel with speaker apertures to accommodate a speaker mounted
under the rear shelf trim panel.
BACKGROUND OF THE INVENTION
[0003] Many motor vehicles now have FM stereo radios or more
elaborate sound systems such as tape players, compact disc players,
digital tapes and computer sound systems with accompanying speakers
for the enjoyment of the driver and passengers. Furthermore, the
electronics of the sound system have also greatly improved. As a
result, of all these improvements, the sound emanating from a car
stereo speaker has a quality that was unheard of only a few years
ago.
[0004] Many after-market speakers are free standing with their own
cases and speaker grills. The speaker grill is commonly used to
conceal and protect the actual speaker cone against puncture or
other damage. Factory mounted speakers are often mounted in
concealed places such as behind door panels and under rear trim
shelf panels. When the speakers are positioned behind or under such
panels, the panels must incorporate a speaker grill that has
apertures and cutouts to reduce muffling effects of the panels and
to promote the efficiency of sound emanating from the concealed
speakers into the interior of the motor vehicle.
[0005] Many known speaker grills are molded. Pins are used in the
mold to form apertures through the cover to allow sound emanation.
A porous cloth or non-woven fabric may provide a fabric covering
for the speaker grill. While the panel needs holes to allow
transmission of sound, a light porous cloth or fabric may cover the
holes in the panel structure without an overly undesirable amount
of sound blockage.
[0006] What is needed is an expeditious method of forming an
integrated speaker grill with an automotive interior panel that has
apertures incorporated therein to provide for the transmission of
sound from the speaker into the automotive vehicle interior.
SUMMARY OF THE DISCLOSURE
[0007] In accordance with one aspect of the invention, a process
for forming a combined speaker grill and automotive interior trim
panel includes the initial step of providing a substrate layer of a
heated mat material having a content of thermoplastic material such
that it is moldable under heated conditions. Preferably the mat
also has a content of flax fiber. The process also includes
punching a plurality of apertures in a speaker grill section of the
heated substrate. The punching of the apertures is, in one
embodiment; simultaneous with the molding step such that the
apertures are formed through both the substrate and the decorative
layer as the substrate and decorative layer are shaped into the
final panel contour.
[0008] A decorative layer is provided onto the heated substrate.
The decorative layer is preferably a porous carpet with a thermal
plastic back surface.
[0009] The substrate and the decorative layer are molded into the
desired shaped panel such as a rear shelf trim panel such that said
apertures form an integrated speaker grill section within the
panel.
[0010] Preferably, a first and second mold dies form the apertures
in the substrate. The first mold die has apertures therein and the
second mold die has a punch set that fits in the apertures of the
first mold die to punch apertures through both the decorative layer
and the substrate as the mold dies are closed to shape the
substrate and the decorative layers into the panel.
[0011] In one embodiment, the apertures in the substrate are formed
in the speaker grill section before the substrate is molded into
its final shape. The grill section is positioned such that pins are
then received in the apertures in the grill section and the
decorative layer is positioned over the substrate, grill section
and the pins in the mold. The mold is closed and the substrate
layer, grill section and decorative layer are molded into a shape
of an automotive interior panel under pressure.
[0012] In one embodiment, the speaker grill section is a separate
previously formed perforated member that is placed over an opening
of the substrate layer such that a peripheral edge of the
perforated grill section overlaps an edge of the substrate layer
about the opening. A hot melt adhesive is applied to the perforated
grill section for adhesion to the decorative layer.
[0013] The substrate is then removed from the pins and mold. The
apertures in the grill section are positioned under the decorative
layer, i.e., the molded panel has the decorative layer spanning
over the apertures in the grill section of the substrate.
[0014] Preferably, the pins extend through a first mold die and are
level with an interior surface of the first mold die. The apertures
in the substrate are formed by a first punch set aligned with the
pins to push through the substrate and recess the pins. The punch
set is then raised to remove the punched scraps of substrate. The
pins are then raised to intrude into the apertures in the
substrate. A second mold die that complements the first mold die is
provided and the panel is molded into shape with the pins extending
through the first mold die and remaining in the apertures in the
substrate.
[0015] In accordance with another aspect of the invention, a
process for forming a combined speaker grill and automotive
interior trim panel is characterized by the steps of providing a
decorative layer that is capable of being bonded to the substrate
layer; placing the heated substrate layer and decorative layer into
an open mold; closing the mold and molding the substrate layer and
the decorative layer into a formed automotive interior panel under
pressure between two closed mold dies with a first mold die section
having a section with a plurality of holes therein and a
complementary mold die section having a plurality of punches that
mate with the plurality of holes to punch a plurality of apertures
in the formed panel to form an integral speaker grill with the
panel; and opening the mold dies and cooling the panel to be
resolidified with the substrate and decorative layers being bonded
together and removing the molded formed panel and speaker grill
from the mold.
[0016] In accordance with another aspect of the invention, a
process for forming a combined speaker grill and automotive
interior trim panel is characterized by the steps of: providing a
grill section and substrate layer of a heated mat material having a
content of thermoplastic material such that it is moldable under
heated conditions; punching out a plurality of apertures in the
grill section; positioning said grill section such that a pin is
received in each respective aperture with an end of the pin
substantially coplanar with one side of the grill section;
providing a decorative layer that is capable of being bonded to the
substrate layer and said grill section; molding the substrate
layer, grill section, and the decorative layer into a formed
automotive interior panel under pressure between two closed mold
dies with the decorative layer spanning over the pins in the
apertures in the substrate to form an integrated speaker grill with
the panel; removing the molded formed panel and speaker grill after
the thermoplastic material in the panel is cooled to allow the
panel to be resolidified and the substrate and decorative layers to
be bonded together.
[0017] In accordance with another aspect of the invention, a
process for forming a combined speaker grill and automotive
interior trim panel is characterized by the steps of: providing a
substrate layer of a heated mat material having a content of
thermoplastic material such that it is moldable under heated
conditions; providing an aperture in the substrate layers; that is
slightly smaller than the grill section placing a perforated grill
section over the opening in the substrate with the respective edges
overlapping, positioning a pin in each respective hole in the grill
section with an end of the pin substantially coplanar with one side
of the grill section; providing a decorative layer that is capable
of being bonded to the substrate layer and grill section; molding
the substrate layer grill section and the decorative layer into a
formed automotive interior panel under pressure between two closed
mold dies with the decorative layer spanning over the pins in the
apertures in the substrate to form a integral speaker grill with
the panel leaving an edge of the substrate layer uncovered; and
punching out an additional grill section with a plurality of holes;
removing the molded formed panel and speaker grill after the
thermoplastic material in the panel is cooled to allow the panel to
be resolidified and the substrate and decorative layers to be
bonded together; and removing the punched out additional grill
section for placement in an aperture of an another substrate
layer.
[0018] In accordance with another aspect of the invention, a molded
interior automotive panel and speaker grill combination includes a
molded substrate layer having thermal plastic content and a flax
fiber content. A plurality of apertures through the substrate are
aligned with a speaker-mounted therebehind. A decorative layer is
bonded on top of the substrate material and molded thereto. In one
embodiment, the decorative layer is a porous carpet layer that
spans over the plurality of apertures. In another embodiment, the
decorative layer also has apertures therethrough that align with
the apertures in the substrate. In another embodiment, a separate
grill section is received over an opening through the substrate.
Both the grill section and substrate are made from the same
material. The grill is then bonded to the substrate about the
aperture with the carpet layer spanning over both the grill and
substrate.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] Reference is now made to the accompanying drawings in
which:
[0020] FIG. 1 is a perspective view of a rear shelf trim panel
according to one embodiment of the invention;
[0021] FIG. 2 is an enlarged segmented view of rear shelf trim
panel shown in FIG. 1 with a speaker mounted thereunder;
[0022] FIG. 3 is a fragmentary sectional view through the lower and
upper molds before molding of the rear trim panel shown in FIG.
2;
[0023] FIG. 4 is a view similar to FIG. 3 during a cutting and
molding step;
[0024] FIG. 5 is a view similar to FIG. 4 after the upper mold is
raised subsequent to the cutting and molding step;
[0025] FIG. 6 is a fragmentary, segmented and schematic view of a
lower mold and punch press illustrating a method of manufacturing a
modified embodiment according to the invention;
[0026] FIG. 7 is a view similar to FIG. 6 with the punch press
punching apertures through the substrate layer;
[0027] FIG. 8 is a view similar to FIG. 7 showing the punch press
lifted up after punching apertures in the substrate layer;
[0028] FIG. 9 illustrates the placing of a decorative layer and an
upper mold die over the substrate layer and lower mold die;
[0029] FIG. 10 is a view similar to FIG. 9 with the lower and upper
mold dies shown in the closed position;
[0030] FIG. 11 is a view similar to FIG. 10 with the mold dies
opened and the formed rear shelf trim panel lifted off the lower
mold die;
[0031] FIG. 12 is a perspective and exploded view of an alternate
embodiment with the upper and lower mold pieces before assembly and
molding;
[0032] FIG. 13 is a cross-sectional view of taken along the lines
13-13 shown in FIG. 12 with the upper and lower molds being
closed;
[0033] FIG. 14 is a view similar to FIG. 12 after molding and
opening of the molds; and
[0034] FIG. 15 is a cross-sectional view taken along lines 15-15
shown in FIG. 14.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0035] As shown in FIG. 1, an automotive vehicle 10 has a rear
shelf trim panel 12 mounted in the interior 11 of the vehicle and
has speakers 14 concealably mounted thereunder. The rear shelf trim
panel 12 as more clearly shown in FIG. 2 has a substrate layer 16
and a decorative carpet layer 18. A plurality of apertures 20 and
22 extend through the substrate layer 16 and carpet layer 18
respectively. The apertures 20 through the substrate layer 16 are
aligned with the apertures 22 through the carpet layer 18 to form
passages that allow sound to transmit from the speaker 14 and into
the automotive interior 11.
[0036] The particular shape and contour of the rear shelf trim
panel may vary depending on the model vehicle. It may also
accommodate a rear brake light that is not shown for simplicity of
the drawing.
[0037] The rear shelf trim panel has its substrate layer 16 made
from a blend of flax and polypropylene unwoven mat. While the
composition and ingredients of the mat may change it is desirable
to have a blend of 50% polypropylene and 50% flax by weight. It is
easily foreseen that the percentage of flax may vary between 40-70%
be weight depending on the particular requirements and
applications. The unwoven mat may have an uncompressed thickness of
11 mm. The mat may then be heated and compressed to 3 mm substrate
layer 16 in order to provide the desired structural rigidity for
most applications in a rear shelf trim panel environment. The mat
may be heated to 200.degree. C. to provide that the thermal
plastic, polypropylene, is in a molten and moldable state.
[0038] The preheated substrate layer 16 is positioned in a mold
assembly 24 that has a core side mold die 26 and a cavity or upper
die 28 as shown in FIG. 3. The core side 26 has a die insert 30 and
the cavity side 28 has a punch insert 32. The die insert 30 has a
plurality of holes 34 that receive the punch dies 36 of insert 32.
A decorative layer such as a porous carpet layer 18 with a
polypropylene back surface is placed over the substrate layer
16.
[0039] The mold dies 26 and 28 are at ambient temperature and are
heated only by the heated substrate layer 16 transfers to the mold
dies. A cooling mechanism (not shown) may be provided to dissipate
excess heat from the mold assembly 24.
[0040] The mold dies 26 and 28 are closed as shown in FIG. 4 such
that the punch dies 36 push into the holes 34 in die insert 32.
This causes punched scraps 38 of the carpet layer 18 and substrate
layer 16 to be punched out and drop through the holes 34 in the die
insert 30 to form apertures 20 and 22 simultaneously with the
molding of the panel 12. A pressure of five bars provides
sufficient compressive force to achieve part configuration within
the mold.
[0041] As shown in FIG. 5, after the rear shelf trim panel 12 is
molded, the mold dies are opened and the panel 12 is removed. The
scraps 38 are also removed by a mechanism (not shown) that strokes
once per cycle to remove the scraps 38.
[0042] Another embodiment can be made where the carpet layer 18
does not have apertures 22 therethrough. Alternatively, the carpet
layer 18 spans over the apertures 20 in the substrate layer 16. The
process for making this embodiment is schematically illustrated in
FIGS. 6-11. In this process, a set of retractable pins 40 are
biased upward by a platform 42 set on springs 44. The pins 40
extend through the apertures 34 in the die insert 30. The substrate
layer 16 is placed in the core side mold die 26 over the
retractable pins as shown in FIG. 6. As shown in FIG. 7, a die set
punch section 46 has punch pins 48 that are aligned with pins 40
and punched to be received in holes 40. As a result the pins 48
punch holes 20 through substrate layer 16. As shown in FIG. 8, the
punch set is lifted up and removed. The punched scraps 54 can be
removed by lifting the pins 40 such they extend now through formed
apertures 20 in layer 16. Alternatively, the pins 48 of the punch
set may have barbed lower ends which pull out the scrap pieces 54
and be removed from the pins 48 by a comb style sweeper. A further
modification may be that pins 48 have optional stripper sleeves to
remove the attached scrap members 54. The important aspect is that
the scraps 54 are removed so as not to interfere with the
subsequent described steps.
[0043] As shown in FIG. 9, a decorative layer 18 such as the
previously described carpet layer with a polypropylene back surface
can then be placed over the substrate layer 16 and apertures 20.
Pins 40 are retained in a lifted position and remain in the
apertures 20. As shown in FIG. 10, an upper mold die 56 is then
closed upon the lower mold die 26 and molds the carpet layer 18 and
substrate layer 16 into shape and bonds the two together. After
sufficient cooling, the upper mold die 56 is then lifted and the
mold is open. The pins 40 are retracted from the apertures 20 and
the formed panel 12 is then removed from core side mold die 26.
[0044] In this fashion, the apertures 20 are concealed by the
porous carpet layer 18 but function substantially the same as the
apertures 20 in the first embodiment, namely by allowing excellent
transmission of sound of all audible frequencies from a speaker 14
that is mounted under the substrate layer 12 and into an interior
11 of an automotive vehicle 10.
[0045] In the alternate embodiment disclosed in FIG. 12-15, each
perforated grill section 60 is a separate member that is laid over
as opening 62 in substrate layer 16. The opening 62 is through a
recessed peripheral edge 64 that is recessed a single thickness of
the grill section 60.
[0046] The grill section 60 contains the plurality of aperture 20
and is placed over aligned stationary pins 140 in lower mold are
126 after substrate layer 116 is positioned thereon with the mold
having recess section 164 to accommodate recessed peripheral edge
64. A hot melt or other adhesive is then applied to the top surface
66 of the grill section 60.
[0047] A carpet layer 118 is placed over substrate 116 to cover
over both grill sections 60 but leaving end section 168 exposed.
The mold dies 128 and 126 are closed where grill sections 60 and
carpet layer 118 are molded and bonded to the substrate layer 116
over openings 62 as shown in FIG. 15.
[0048] Simultaneously as shown in FIG. 13, two additional grill
sections 60 to be used in the future are formed with aperture 20
via the punch and die set 130 and 136. Two end sections 168 of the
substrate 16 are positioned over a die insert 130 in die 126. The
die insert 130 has a plurality of apertures 134 that receive punch
die 136 in the upper mold die 128. Scraps 138 drop through aperture
134. The molds 126 and 128 have cutters to also cut the grill
section 60 from the end section 168 of the substrate. The mold dies
opened after sufficient cooling and the parts are demolded forming
a complete panel 112; two additional grill sections 60 and two
scrap ends 168.
[0049] The cycle is then repeated with the additional grill
sections 60 being used to form another panel 112.
[0050] Other variations and modifications are possible without
departing from the scope and spirit of the present invention as
defined by the appended claims.
* * * * *