A method for manufacturing a foam molded body which can allow the foam resin sheet to follow the shape of the cavity of the mold with high accuracy even when the thickness of the foam resin sheet is thick. The method includes an arranging step to arrange one sheet of a foam resin sheet between first and second molds, the foam resin sheet being formed by extruding and dangling a molten foam resin from a slit; and an expanding step to expand the foam resin sheet by subjecting the foam resin sheet to a reduced pressure suction.

A seat trim cover having a 3-dimensional shape for an automotive vehicle seat is formed by pre-cutting a laminate blank into a predefined shape having a predefined selvage extending around an outer periphery of the laminate blank, vacuum forming the laminate blank in a 3-dimensional mold to form a 3-dimensional laminate blank, and forming a molded foam backing on the 3-dimensional shaped laminate blank to form the seat trim cover. The molded foam backing has an outer perimeter that is spaced apart from the predefined selvage such that the predefined selvage is free of foam.

A mold configuration for forming a pocket in a film comprising: a film support surface; a perimeter edge at said film support surface; wall surfaces inward of the perimeter edge defining a mold cavity; the wall surfaces including transition wall surfaces extending to a bottom wall surface; and a plateau surface inward of the perimeter edge. In one form, the perimeter edge includes sharp corner profile perimeter edge portions defining at least one sharp corner profile. A method of forming a pouch, includes using the disclosed mold configuration.

An apparatus for manufacturing a display apparatus includes: a first mold configured to accommodate a cover member thereon; a magnetic first guide in the first mold; a second mold arranged to face the first mold; and a magnetic shape-variable unit in the second mold. The shape-variable unit is configured to come into contact with and move a panel member toward the cover member, and a first portion of the panel member is configured to contact the cover member before a second portion of the panel member contacts the cover member due to a magnetic force between the shape-variable unit and the first guide.

An apparatus for manufacturing a display apparatus includes: a first mold configured to accommodate a cover member thereon; a magnetic first guide in the first mold; a second mold arranged to face the first mold; and a magnetic shape-variable unit in the second mold. The shape-variable unit is configured to come into contact with and move a panel member toward the cover member, and a first portion of the panel member is configured to contact the cover member before a second portion of the panel member contacts the cover member due to a magnetic force between the shape-variable unit and the first guide.

A method for making a structural sandwich panel includes the steps of positioning a first and second thermoplastic skin elements in overlying relationship with respect to a heated male and heated female die molds respectively. A first pressure reduction is applied between the first thermoplastic skin element and the heated male die mold and a second pressure reduction is applied between the second thermoplastic and the heated female die mold. A core panel element is positioned between the heated male die mold and the heated female die mold wherein the core panel element has a first adhesive on a first side and has a second adhesive on a second opposing side. The male and female die molds are closed and exert a pressure onto the core panel element to secure the first and second thermoplastic skin elements to the core panel element and form the core panel element.

A method for making a structural sandwich panel includes the steps of positioning a first and second thermoplastic skin elements in overlying relationship with respect to a heated male and heated female die molds respectively. A first pressure reduction is applied between the first thermoplastic skin element and the heated male die mold and a second pressure reduction is applied between the second thermoplastic and the heated female die mold. A core panel element is positioned between the heated male die mold and the heated female die mold wherein the core panel element has a first adhesive on a first side and has a second adhesive on a second opposing side. The male and female die molds are closed and exert a pressure onto the core panel element to secure the first and second thermoplastic skin elements to the core panel element and form the core panel element.

The present disclosure is directed to a mold assembly for vacuum forming a component. The mold assembly includes plurality of support plates and a plurality of mold plates removably coupled to the plurality of support plates. The plurality of mold plates is stacked and removably coupled together to form a mold configured for forming the component. Each mold plate including a first surface partially defining a top surface of the mold, a second surface spaced apart from the first surface, a third surface extending from the first surface to the second surface, and a fourth surface spaced apart from the third surface and extending from the first surface to the second surface.

The present disclosure is directed to a mold assembly for vacuum forming a component. The mold assembly includes plurality of support plates and a plurality of mold plates removably coupled to the plurality of support plates. The plurality of mold plates is stacked and removably coupled together to form a mold configured for forming the component. Each mold plate including a first surface partially defining a top surface of the mold, a second surface spaced apart from the first surface, a third surface extending from the first surface to the second surface, and a fourth surface spaced apart from the third surface and extending from the first surface to the second surface.

A mold configuration for forming a pocket in a film comprising: a film support surface; a perimeter edge at said film support surface; wall surfaces inward of the perimeter edge defining a mold cavity; the wall surfaces including transition wall surfaces extending to a bottom wall surface; and a plateau surface inward of the perimeter edge. In one form, the perimeter edge includes sharp corner profile perimeter edge portions defining at least one sharp corner profile. A method of forming a pouch, includes using the disclosed mold configuration.