KR100463732B1 - Fabrication of multiple color, gauge, and textured interior auto components - Google Patents

Abstract

Automotive trim panel 10 is a trim coverstock segment 12, 20 and two rigid bases of different colors, sizes or textures into a single trim panel with two coverstock segments that meet along finish seam 40. It is made by using an apparatus and a method of bonding the elements 30 and 32 together. The method comprises joining the coverstock segments to each other such that a fastener 28 is formed, and having the mating flanges 34 and 36 extending into the space between the mold elements so that the fasteners are in the middle of the spaced apart mold elements. Supporting the base element on two spaced movable mold elements 52, 54 each having a disposed base element. Pressure is then applied along the joint to sandwich the coverstock between the base mating flanges and to move the mold element to a clamping position that is fastened to each other with pre-mounted fasteners 44, while at the same time surrounding the coverstock between the mold elements. do.

Description

Fabrication of Interior Automotive Parts with Multicolor, Size and Texture {FABRICATION OF MULTIPLE COLOR, GAUGE, AND TEXTURED INTERIOR AUTO COMPONENTS}

The present invention relates generally to automotive trim panels having a plurality of coverstock segments and to methods and apparatus for molding automotive trim panels having a plurality of coverstock segments.

BACKGROUND OF THE INVENTION Methods of thermoforming coverstock for synthetic plastic products such as PVC covered foam urethane parts used to construct automotive interior trim panels are known. It is also known to form a trim panel for automobiles by molding a composite or "synthetic" coverstock made of two or more coverstock segments and then bonding the composite coverstock to a rigid base.

Conventionally, trim panels with synthetic coverstock have been fabricated by stacking coverstock segments on base coverstock. The synthetic coverstock is then molded and molded into a rigid glass fiber or blowing agent in a separate process. Laminating such coverstock segments is labor intensive and wastes coverstock material covering additional laminates.

Another approach to providing synthetic coverstock is disclosed in US Pat. No. 4,562,025, issued December 31, 1985 and assigned to the co-assignee. This patent discloses a number of coverstock segments formed by casting a dry thermoplastic material against a heated mold. The divider separates the two different colored casting materials cast from the heated mold from the powder box. At that time, a molten joint is formed between the two castings. Such a method is inherently suitable for the purpose, but part of the casting material may be wasted during the process. In addition, this process still requires a separate process if the synthetic coverstock is to be bonded to the rigid body.

It is also known to wrap a coverstock segment by hand and sew it into a composite or synthetic coverstock. Although such a method is to protect the material, it is extremely labor intensive.

It is also known to form the trim cover by electrically bonding the edges of the various coverstocks. Using this method minimizes waste, but requires a considerable amount of labor, and it is difficult and practical to use for shaping the outer coverstock, such as the outer door panels for automobile interiors.

If the trim panel comprises one or more coverstock segments and the segments are fabricated by joining two or more materials, such as polyvinyl chloride (PVC) with different specifications or stiffness, the different materials can be bonded to create aesthetically superior segments between the segments. It may be difficult to form styling lines or seams. If, for example, one of the two joined coverstock segments is cut from a segment of material of greater thickness or stiffness than the other, the segment with the greater thickness or stiffness will have a larger bending radius and generally It will have more bending resistance than at the seam between the two segments. The joints can be twisted or twisted by different bending radii unless the process of permanently reinforcing and clamping the seam is taken behind. Similarly, if one coverstock segment is cut from a material with greater stiffness than the other, as described above, if the seam is permanently reinforced at the rear and is not clamped, it will spread along the surrounding seam and the other segments will overlap on it. .

Properly tightened seams may provide fine styling lines between coverstock segments cut from materials with different colors and surface textures. Extremely fine styling lines between segments can help conceal the fact that two different segments are joined together.

One method and apparatus for generating fine styling lines between segments while reducing material waste and labor requirements is disclosed in US Pat. No. 4,861,543, issued on August 29, 1989 and assigned to a joint assignee. According to this method, the coverstock segments are joined to each other edge to corner to form a composite coverstock with a slightly overlapping rough seam. Composite coverstock is automatically heated, wrapped and molded on a thermoforming tool. The thermoforming tool automatically opens and encloses the tightening joint by applying a vacuum inside the tool. The tool then clamps the enclosed portion to form a fine finish styling line on the Class A outer surface of the composite coverstock. The thermoforming tool has a relatively movable mold for forming a composite coverstock and includes an expandable joint adapted to enclose the seam. The method and apparatus produce a thermoformed composite coverstock with a finishing styling line formed by being clamped and enclosed on the concealed side of the composite coverstock. However, the coverstock is not bonded with a rigid body or foam backing to form a complete trim panel at one time. In addition, the method does not provide any means to permanently reinforce and support the clamped joints after the synthetic coverstock has been removed from the mold.

There is also known a method of joining coverstock segments to form an automotive trim panel by first adhering the first coverstock segment to the first base element and then adhering the second coverstock segment to the second base element. have. Finally, there is a third process of bonding or mechanically fastening the two coverstock base semi-assemblies.

Therefore, the conventional structure does not provide a trim panel with finishing permanent support stable styling lines between coverstock segments of different thicknesses or stiffness. The prior art also does not provide a method and apparatus for joining two different coverstock segments and two rigid base elements together to form a trim panel in a single operation.

What is needed is an automotive trim panel that includes two different coverstock segments that are bonded to two rigid base elements and bonded to each other at a clamped joint to form and permanently support a finishing styling line where two different coverstock segments meet. There is also a need for a method and apparatus for joining two different coverstock segments and two rigid base elements together to form a single trim panel that saves labor and materials and does not require multiple operations.

1 is a partial cross-sectional side view of a trim panel made in accordance with the present invention.

FIG. 2 is a partial cross-sectional side view of two joining coverstock portions prior to assembly into the trim panel of FIG.

3 is a partial cross-sectional side view of two base elements prior to assembly into the trim panel of FIG.

3A is a partial cross-sectional side view of a second embodiment of one of the base elements of FIG. 3.

4 is a cross-sectional side view of the base element of FIG. 3 mounted on a pair of mold elements during assembly into the coverstock of FIG. 2 and the trim panel of FIG.

5 is a cross-sectional side view of the base element of FIG. 3 mounted on the mold element of FIG. 4 after assembly into the coverstock of FIG. 2 and the trim panel of FIG.

The present invention provides a trim panel assembly for an automobile comprising two different coverstock segments and two rigid base elements joined together to form a single trim panel and permanently supporting a finishing styling line where the two different coverstock segments meet. And a method and apparatus for manufacturing a trim panel assembly in a single operation.

The trim panel assembly is bonded to two rigid base elements and bonded to each other in a clamped seam that forms and continuously supports a finishing styling line with two different coverstock segments and even one-segment grain, size, or backing that is fairly heavy. Two different coverstock segments. The two coverstock segments are joined together at the joints which join the coverstock segments to form a single synthetic coverstock. The bases each have a mating flange extending inwardly along the base periphery. The synthetic coverstock includes an enclosure formed along the seam. The enclosure is permanently sandwiched between the base mating flanges that form inwardly constricted joints that conceal the seam.

According to another aspect of the invention, the fastening element is disposed adjacent the coverstock enclosure and the base mating flange. The fastening element joins the base mating flanges to each other while sandwiching the coverstock enclosure between the mating flanges and engaging the clamped joint.

Trim panels made in accordance with the present invention differ from those disclosed in the prior art because the joints between the coverstock segments are folded inward and are permanently sandwiched between the base mating flanges. The base mating flange clamps the enclosure to create a clamped seam and fine styling line. The mating flange remains so sandwiched that it continues to support the seam contour even after the finished trim panel is removed from the mold surface. In other words, the base mating flange retains the appearance of the finishing styling line between coverstock segments even when the coverstock segments have different textures, colors, formulations and thicknesses.

According to the present invention, each of the two automotive trim coverstock segments is bonded to one of the two rigid base elements and the coverstock-based semi-assemblies are joined together along the base mating flange such that the coverstock segments meet along the finishing seam. There is provided a method of forming a trim panel for an automobile. The method comprises joining the mating edges of the coverstock segments to each other to form a tightening joint, supporting the base element on a movable mold element with a base mating flange engaged with the clamping surfaces of the mold element, and A base having a portion of a joint coverstock segment connecting the movable mold part in the open position and connecting the space between the open mold element with the fasteners laid along the space approximately in the middle between the mold element clamping surfaces. Bonding and vacuum or pneumatically forming the coverstock segment to the upper surface of the element and squeezing the joint to fold inwardly the connecting coverstock between the spaced mold element clamping surface while moving the mold element clamping surface together towards the clamp position. Accordingly including applying pressure. The mold element clamping surface moves the mold element with the base mating flange sandwiching the enclosing coverstock portion to form a finishing styling line between the coverstock segments and conceal the joint.

According to another aspect of the method a vacuum is applied to the coverstock segment via the base element. The vacuum ensures proper adhesion between the coverstock segment and the base element.

According to another aspect of the method, the base mating flanges are fastened to each other against the enclosing coverstock with a fastener. The fasteners serve to clamp the base mating flanges at clamped positions on both sides of the enclosing coverstock and to permanently clamp and retain the clamped joints, thereby maintaining the appearance of the finishing styling line between the coverstock segments.

According to another aspect of the method, the coverstock segment is heated prior to the step of supporting above the top surface of the base element, ie before a vacuum or air static pressure is formed in the coverstock segment.

The method of the present invention differs from that disclosed in the prior art because two coverstock segments with mating flanges and two rigid bases are joined together to form a fine styling line in a single operation. In addition, the enclosing portion of the bonded coverstock segment remains sandwiched between the base mating flanges, thus eliminating the need for dressing or cutting the seam with the enclosed material after forming the clamped seam.

According to the invention a mold assembly is provided for forming an automotive trim panel from two different coverstock segments and two rigid base elements, wherein each coverstock segment is curved along a corner to form a mating flange. And a mating edge portion pre-bonded with the mating edge portion of the element and the other coverstock segment to form a tightening joint. The assembly includes a movable mold element with each clamping surface. The mold element has an open position for receiving the base element. In the open position the clamping surface is separated to receive and engage the base mating flange. The bonded coverstock segment is draped over the base element with fastening seams extending along a portion of the bonded coverstock segment connecting the spaces between the clamping surfaces. The mold element also has a clamp position for clamping the connection of the joint coverstock segment between the base mating flange. The forming auxiliary member is supported out of and between the mold element clamping surfaces in the open position and is movable inward to provide internal pressure along the coverstock fastener so that the joint elements move together towards the clamp position. The coverstock portion is folded inward.

According to another aspect of the invention, the mold element is adapted to apply a vacuum to the coverstock segment via the base element. Alternatively, the mold element may cause pneumatic pressure to be applied over the coverstock. The application of vacuum or air static pressure causes the coverstock to form a base element.

According to another aspect of the invention, the mold element is adapted to support the fasteners which engage the base mating flanges with each other while clamping the enclosure of the coverstock.

The apparatus of the present invention is a prior art because the mold assembly includes a forming aid member that provides internal pressure when the two movable mold elements are adjacent to each other into the clamp position to form a clamped joint, thereby aiding the enclosing of the joint between the coverstock segments. Is different from that disclosed in.

To better understand the present invention, reference may be made to the following detailed description with reference to the accompanying drawings.

Automotive trim panel assemblies are generally shown at 10 in FIG. 1. Trim panel assembly 10 includes a first vinyl coverstock segment 12 having a Class A outer surface 14 and a concealed inner surface 16. The mating edge 18 is disposed along the periphery of the coverstock that joins both the outer surface 14 and the inner surface 16.

The assembly 10 has a second vinyl coverstock segment 20 having an outer surface 22, an inner surface 24 and mating edges 26 disposed along a common perimeter joining the outer surface 22 and the inner surface 24. ) Is also included. The second coverstock segment 20 has a first coverstock along each mating edge 18, 26 forming a seam, generally indicated at 28 in FIGS. 1, 2, 4 and 5. Adhered to the segment 12. The fasteners 28 join the coverstock segments 12 and 20 to be a single synthetic coverstock and the outer surfaces 14 and 22 to be a single synthetic outer surface. The first rigid base element, generally indicated at 30 in FIGS. 1 and 3 to 5, is bonded to the first coverstock inner surface 16. A second rigid base element, generally indicated at 32 in FIGS. 1 and 3 to 5, is bonded to the second coverstock inner surface 24. The mating flanges 34, 36 extend inwardly from each base element 30, 32 at an angle of 90 degrees from the peripheral edge of each base element 30, 32. The mating flanges 34 and 36 are arranged parallel to each other. As best shown in FIGS. 4 and 5, the composite coverstock 12, 20 includes a connection 38 surrounded along the fastener 28 and inwards between the parallel mating flanges 34, 36. It protrudes. As shown in FIG. 5, the enclosed connection 38 is sandwiched between the base mating flanges 34 and 36 to form a joint 40 clamped at the composite coverstock outer surfaces 14 and 22. Clamped joints 40 provide a finishing precision styling line between coverstock outer surfaces 14 and 22 and conceal joints 28.

As shown in FIGS. 1, 4 and 5, the adhesive layer 42 is formed between the first base element 30 and the first coverstock segment 12 and the second base element 32 and the second coverstock segment ( 20) in between. The adhesive layer 42 may include any one of the suitable adhesives or a combination of such adhesives as is well known in the art.

1 and 5, the fastening element 44 extends from one of the base mating flanges 36 and the fastener receiving hole (with the coverstock enclosing connection 38 in the other mating flange 34). 46) penetrate into. The fastening element 44 clamps the coverstock surrounding connection 38 between the mating flanges 34, 36 and permanently fastens the clamped joint 40, while joining the base mating flanges 34, 36 to each other. Preferably, the fastener 44 comprises a spray molded stud. In FIGS. 1 and 5 fastener 44 is a conical tip that is integrally connected with one of the base mating flanges 36 and extends through fastener receiving hole 46 and engages with another base mating flange 34. It is a stud with. Alternatively, as shown in FIG. 3A, the fastener 44 ′ may include a spring clip. The fastener can be any of several other mechanical connection devices known in the art, such as, for example, clamps, rivets, staples, screws or spray molded studs that are thermally soldered or snap fit in place.

In practice, the mating edges 18, 26 of the coverstock segments 12, 20 are first joined together to form a seam 28. Preferably, the coverstock feeder achieves this and discharges the prebonded composite coverstock 12, 20 assembled by the trim component manufacturer.

The adhesive layer 42 is then applied to the outer surfaces 60, 62 of the base elements 30, 32. Then, as shown in FIG. 4, the first rigid base element 30 and the second rigid base element 32 each have a mold element 52, 54 disposed in a spaced “open” position. It is mounted on the outer surfaces 48, 50 of the first movable mold element 52 and the second movable mold element 54. Once the base elements 30, 32 are mounted on the mold elements 52, 54, the base mating flanges 34, 36 extend downward and flush with respect to the respective mold element clamping surfaces 56, 58, thereby casting the mold. Join elements 52 and 54. This prevents the base elements 30, 32 from slipping away from the mold elements 52, 54 and places the base elements 30, 32 so that continuous operation is performed. In other embodiments, the adhesive layer 42 may be applied to the base outer surfaces 60, 62 after placing the base elements 30, 32 on the mold.

The bonded coverstock segments 12, 20 are then cast over the heated and adhesively coated base outer surfaces 60, 62. Coverstock segments 12, 20 are heated to conform to the shape of base outer surfaces 60, 62.

The portion 38 of the joined coverstock segment 12, 20 that connects the space between the open mold elements 52, 54 is such that the fastening joint 28 is approximately midway between the mold element clamping surfaces 56, 58. It is arranged to lie along the negative space. When the mold elements 52, 54 are moved to the clamp position shown in Fig. 5, internal pressure is applied to the connecting coverstock 38 along the fastening joint 28. As shown in Figs. The internal pressure folds the connecting coverstock portion 38 inwardly between the base element mounting flanges 34 and 36. When the mounting flanges 34 and 36 move together, the internal pressure stops and the base mating flanges 34 and 36 press against each other to sandwich the enclosed coverstock portion 38. By sandwiching the enclosed coverstock portion 38, the two Class A outer surfaces 14, 22 of the heated coverstock portions 12, 20 are melted together by force. A finishing styling line is formed between the Class A outer surfaces 14, 22 of the coverstock segment 12, 20 at the point where the two Class A outer surfaces 14, 22 are melted together. The finishing styling line hides the fasteners 28 invisibly.

A vacuum is applied to the coverstock segments 12, 20 through the base elements 30, 32 while simultaneously moving the mold elements 52, 54 together. The vacuum draws the bonded coverstock segments 12, 20 inward against the base elements 30, 32 which have improved coverstock adhesion to the base elements 30, 32. Alternatively, static air pressure may be applied to the top surface of the coverstock segments 12 and 20 such that the coverstock segments 12 and 20 form a base. In another embodiment, a combination of vacuum pressure and air static pressure may be employed.

With the mold elements 52, 54 spaced apart, the fastener 44 mounts or forms to protrude from one of the mating flanges 36 at a point opposite the fastener receiving hole 46 of the mating mating flange 34. do. When the mold elements 52, 54 move to the clamp position, the fastener 44 is pressed into the fastener receiving hole 46 at the opposite base mating flange 34 through the enclosed coverstock portion 38. This fastens the base mating flanges 34, 36 to each other in a position to sandwich the coverstock connection 38 surrounded between the base mating flanges 34, 36.

After molding, clamping and fastening the mold elements 52 and 54 are returned to the open position and the completed coverstock base assembly 10 is removed.

Apparatus for practicing the method is representatively shown in FIGS. 4 and 5 as including a single thermoforming tool or forming die operated to provide a composite coverstock with trace material waste, shape lines and concealed joints. have. The thermoforming tool or forming die comprises a mold assembly with expandable joints. The expandable joint is formed by the movable mold elements 52, 54 and the clamping surfaces 56, 58 described above.

The expandable joint in the open position is open and the mold elements 52, 54 are separated. The mold elements 52, 54 are moved to the open position so that the base mating flanges 34, 36 and the base elements 30, 32 extend between the open clamping surfaces 56, 58 of the mold elements 52, 54. Can be mounted. In other words, while the joined coverstock segments 12, 20 are joined to the outer surface of the base element, the clamping surfaces 56, 58 are joined with the mold elements 52, 54 in the open position with the base mating flanges 34, 36. ) Are spaced to accommodate and engage.

In practice, the bonded coverstock segments 12, 20 are formed by placing the base elements on the mold elements 52, 54 and then draping over the base elements 30, 32. The composite coverstock 12, 20 are disposed above the mold elements 52, 54 with fastening seams 28 extending longitudinally along the connection 38 of the bonded coverstock segments 12, 20. . The mold elements 52, 54 are adapted to apply vacuum to the coverstock segments 12, 20 via the base elements 30, 32. As described above, applying a pneumatic differential, ie vacuum, air static pressure, or both, helps to improve the adhesion between coverstock segment 12, 20 and base segment 30, 32.

As shown in FIG. 4, the shaping aid 64 is supported outside and between the mold element clamping surfaces 56, 58 when the mold assembly is in the open position. The shaping aid 64 is movable inwardly to provide internal pressure along the coverstock fastener 28 when the mold elements 52, 54 are moved together to the clamp position. When the mold elements 52, 54 are moved together to the clamp position, the connecting coverstock 38 is folded inward by the shaping aid 64. The shaping aid 64 is withdrawn before the mold elements 52, 54 reach a clamp position where the coverstock segments 12, 20 are sandwiched and clamped between the base mating flanges 34, 36 as described above. .

The mold elements 52, 54 engage the fasteners for fastening the base mating flanges 34, 36 with each other while the mating flanges 34, 36 sandwich the enclosed connection 38 of the composite coverstock 12, 20. 44 is accommodated. One mold element clamping surface for fastening 44 mounted on or integrally extended to one base mating flange 36 through the fastener receiving hole 46 in the other base mating flange 34. Concave 56) with a tool. In other words, one clamping surface 56 includes a recessed relief region 66 under the fastener receiving hole 46. The relief area 66 prevents the clamping surface 56 from blocking the passage of the fastener 44 through the fastener receiving hole 46.

Synthetic coverstock 12, 20 may be initially supported by a heating frame and may be transferred to the assignee of the present invention as described in U.S. Patent No. 4,861,543 and described herein by reference. (52, 54). The post-assembly finishing trim panel 10 is released from the mold by any one of several methods known in the art, including the method described in reference to US Pat. No. 4,861,543.

The production of the trim panel according to the invention makes it possible to use two different coverstock grains on automotive trim parts such as tool panels. For example, using the method according to the invention, trim panel manufacturers can improve the reflectivity and weather resistance by using coverstock with heavier grain, size or backing on top of the tool panel.

The present invention also combines molten vinyl, adhesives and fasteners to eliminate the need for thermal incineration. It also saves material in the area where the two coverstock segments are joined together by eliminating the need to include 4 to 5 inches (10.16 to 12.70 cm) of additional coverstock material or "runoff". If the first coverstock segment 12 and the base element are formed separately from the second coverstock segment 20 and the base element and are joined to each other in later operation, additional extra material is required.

The foregoing is an exemplary embodiment of the invention presented in an illustrative sense rather than a restrictive sense. It is obviously possible to modify and modify the invention in accordance with the above description. It is possible to practice other inventions than those described within the claims. For example, various types of thermoforming can be used, including contact thermoforming, pressure molding and air slip molding. The coverstock may be a polyvinyl chloride (PVC) material and may be in the form of a broadly deformable sheet or one of natural and synthetic coating materials. Rather than heating the vinyl coverstock material sufficiently to seal the clamped joint, a suitable induction electric heater may be used to complete the seal at the clamped joint. Various modifications may also be made to the device shape, product form and method to meet the design objectives of form, fit and function according to a particular coverstock for a particular synthetic product.

Claims (13)

In the automotive trim panel assembly, A first coverstock segment having a mating edge portion disposed along an outer surface and an inner surface and a portion of a common periphery of the outer surface and the inner surface, A mating edge disposed along a portion of a common periphery joining the outer and inner surfaces with the outer and inner surfaces, the joints forming the joints of the coverstock segments into a synthetic coverstock and joining the outer surfaces into a single synthetic outer surface. A second coverstock segment adhered to the first coverstock segment along each mating edge; A first rigid base element adhered to the first coverstock inner surface, A second rigid base element adhered to the second coverstock inner surface, Each base element having a periphery with a mating flange extending inwardly along a portion of each base periphery and ending at each flange inner edge, The composite coverstock is interposed between the base mating flanges having an enclosing portion formed along the fastening joints and protruding inwardly and forming a joint clamped at the composite outer surface, concealing the fastening joints, and the flange inner edge portion is A trim panel assembly, characterized by being spaced apart by an enclosure. The base assembly of claim 1, having a first end connected to one of the base mating flanges and a second end connected to the other of the base mating flanges, wherein the base mating flanges are arranged in parallel to each other on both sides of the coverstock enclosure. A trim panel assembly further comprising a fastener to keep it connected. The trim panel assembly of claim 2 wherein the fastener comprises a spring clip. The trim panel assembly of claim 1 wherein the mating flange is disposed perpendicular to an outer surface of the composite coverstock. The trim panel assembly of claim 1 further comprising an adhesive layer disposed between the composite coverstock and the base element. Adhering the first and second automotive trim coverstock segments to the first and second rigid base elements so that the respective bonded first and second coverstock base semi-assemblies meet along the joint of the coverstock segments. A method of joining each other along each of the first and second base mating flanges, Joining the mating edges of the coverstock segments to each other to form a tightening seam; Supporting the first and second rigid base elements on each of the first and second movable mold elements with base mating flanges engaged with the clamping surfaces of the mold elements; Placing the movable mold element in a spaced open position, Adhering the joint coverstock segment to an upper surface of the base element having a portion of the joint coverstock segment connecting the space between the open mold elements with the fastening joint situated along the space approximately in the middle between the mold element clamping surfaces; , Exerting pressure along the joint to fold the connecting coverstock inwardly between the spaced mold element clamping surfaces; Forming a finishing styling line between coverstock segments and concealing the fasteners by moving the mold element to the clamp position with the clamping surface causing the base mating flange to sandwich the enclosing coverstock portion. . 7. The method of claim 6, further comprising applying a vacuum to the coverstock segment through the base element. 7. The method of claim 6, further comprising applying a positive air pressure to the outer surface of the cover stock segment class A. 7. The method of claim 6, further comprising fastening the base mating flanges to each other with respect to the enclosed coverstock with fasteners. 7. The method of claim 6, further comprising heating the coverstock segment prior to supporting the coverstock segment on the top surface of the base element. Automotive trim panel from two different coverstock segments pre-bonded to the mating edges of the other coverstock segments to form a fastening joint and two rigid base elements curved along the corners to form a mating flange In a mold assembly used to form Each having a clamping surface, the opening receiving the base element with the clamping surface separated to engage the fastening joint extending along a portion of the joint coverstock segment that receives the base mating flange and connects the space between the clamping surfaces. A movable mold element having a position and a clamp position for clamping the connection of the joint coverstock segment between the base mating flange, Supported in and out of the mold element clamping surface in the open position and moved inward to provide internal pressure along the coverstock fastener such that the coverstock connection folds inward when the mold element is moved together to the clamp position. Mold assembly comprising a possible molding aid member. The mold assembly of claim 11, wherein the mold element is adapted to apply a vacuum to the coverstock segment through the base element. 12. The mold assembly of claim 11, wherein the mold element is adapted to support fasteners for fastening the base mating flanges to each other while sandwiching the coverstock enclosure.