CA1278660C - Method and apparatus for blow molding automotive component - Google Patents

Method and apparatus for blow molding automotive component

Info

Publication number
CA1278660C
CA1278660C CA000541938A CA541938A CA1278660C CA 1278660 C CA1278660 C CA 1278660C CA 000541938 A CA000541938 A CA 000541938A CA 541938 A CA541938 A CA 541938A CA 1278660 C CA1278660 C CA 1278660C
Authority
CA
Canada
Prior art keywords
mold
parison
sheet
cover
parts
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
CA000541938A
Other languages
French (fr)
Inventor
Changize Sadr
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
ABC Technologies Inc
Original Assignee
ABC Group Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by ABC Group Inc filed Critical ABC Group Inc
Priority to CA000541938A priority Critical patent/CA1278660C/en
Application granted granted Critical
Publication of CA1278660C publication Critical patent/CA1278660C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/24Lining or labelling
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/24Lining or labelling
    • B29C2049/2404Lining or labelling inside the article
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/24Lining or labelling
    • B29C2049/2412Lining or labelling outside the article
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C49/00Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
    • B29C49/02Combined blow-moulding and manufacture of the preform or the parison
    • B29C49/04Extrusion blow-moulding

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)

Abstract

ABSTRACT OF THE DISCLOSURE
A vehicle instrument panel, glove compartment or box, door panel or other automotive component is produced in a simple, efficient manner by feeding a sheet of cover material from a roll thereof between the open halves of a two-part mold; the cover material having a layer of hot melt adhesive on one surface thereof; pressing the sheet of material into a recess in one mold part while applying a vacuum thereto to hold the cover material in the recess; cutting the cover material to length;
dropping a thermoplastic parison between the mold parts; closing the mold; and blowing the parison to conform the shape thereof to that of the mold cavity, whereby the thermoplastic material expands against and melts the adhesive to form a backing layer of material adhering to the cover material. The same method can be effected using two sheets of cover material which are pressed into both mold parts, whereby the thermoplastic material expands against and melts the adhesive to form cover layers on both sides of the backing layer or core of thermoplastic material.

Description

}7~3660 This invention rel~tes to a method and appara-tus for producing an automotive component, and in particular to a me-thod and apparatus for blow molding a part or component for use in a motor vehicle.
The method and apparatus of ~he present invention can be used to produce, inter alia, an instrument panel, a glove compartment or box, or a door panel. For the sake of simplicity the following description is limited to the production of an instrument panel.
In general instrument panels for motor vehicles are prepared by producing a skin or cover, placing the preformed skin or cover in an open mold, injecting a foamable plastic into the mold, placing a premolded backing in the mold, and closing the mold. The method is expensive in terms of tool cost, production time and the quantities of materials used in the molding process.
The inventor is aware of no literature relating to a method of the type disclosed herein. U.S. Patent No. 4,347,276, issued to K. Weber et al on August 31, 1982 is of general interest in that the patent describes a foamed plastic, reinforced dashboard, ~0 and U.S. Patent No. 4,373,745, which issued to Y. Matsuno on February 15, 1983 discloses a method of producing an instrument panel in the manner described above.
An object of the present invention is to solve the above mentioned problems by providing a relatively simple apparatus and an efficient method for producing an automotive component.

!G6~

Another object of the i.nvention is to provide a method and apparatus which enable the relatively inexpensive production of an automotive component using small quantities of materials when compared to an injection molding method~
Accordingly, the present invention relates to a method of producillg an automotive component comprising the steps of:
(a) placing a sheet of cover material carrying a layer of hot melt adhesive between the parts of an open two part mold;
(b) pressing the sheet into a mold cavity in one said mold part while applying a vacuum to the sheet to hold the sheet in the mold cavity;
(c) cutting the sheet to a predetermined lengthi (d) loading a parison of thermoplastic material into the area between said mold parts;
(e) closing the mold to define a complete mold cavity;
and (f) blowing the parison to conform the shape of the parison to that of the mold cavity, whereby the thermoplastic material expands against and adheres to the layer of hot melt adhesive to define a flexible backing for the cover material.
The invention also relates to an apparatus for producing an automotive component comprising:
2; (a) first and second mold parts for defining a mold cavity;

1f~7~36,~C~

(b) firs-t roll means for carrying a roll of first sheet material adapted to define a cover for one side of the component, with a layer of hot melt adhesive on one surface thereof;
(c) first drive means for dispensing said sheet material into the area between said mold parts when the mold is open;
(d) second drive means for pressing said sheet material against one of said mold parts;
~ e) first vacuum means in said one mold part for applying a vacuum to a surface of said mold cavity to cause the other surface of said sheet material to adhere to said surface of the mold cavity.
(f) extruder means for extruding a thermoplastic parison into an open mold;
(g) third drive means for moving said mold parts together to close the mold, thereby defining a mold cavity around an extruded parison; and (h) blow pin means for blowing air under pressure into said parison to cause the latter to assume the shape of the mold cavity, whereby the hot parison can soften the hot melt adhesive to bond a blow molded, thermoplastic backing material to a cover to define a complete automotive component.
The invention will be described in greater detail with reference to the accompanying drawing, the single figure of which A ~ _ . _ _ . ~ ~ . . . _ . _ . _ _ . ~ . . _ . . _ . ~ _ . ~ _ _ _ . _ _ . _ . _ _ _ _ . . _ ~ _ _ _ ~ _ _ _ _ _ . .. _ . _ . . .. . _ _ _ . .. _ _ . _ . _ _ .. _ .. _ .. ..
. . .. . .. . .. ' -- --1;~78!6~

is a schematic, longitudinal sectional view of an apparatus in accordance with the present invention.
With reference to the drawing, the apparatus of the present invention includes a pair of mold parts 1 and 2, which can be moved between the open position (shown in solid lines in the drawing) and a closed position (shown in phantom outline) where the parts 1 and 2 define a mold cavity 3. The parts are moved between such open and closed positions by hydraulic cylinders 4 and pistons 5. One mold part 1 contains a recess 6 for defining the mold cavity 3, which is closed or completed by a projection 7 on the other mold part 2.
Thermoplastic sheet material 9 is fed into the space between the mold parts 1 and 2 in the open position of the mold from a roll 10 carrying a roll of such material. The roll 10 is driven by an electric motor 12, which is connected to the roll 10 by pulleys 13 and 14, and a belt 15. Material is unrolled from the roll 10 by a drive 17, which is mounted on an arm 18 for movement between an idle position (shown in phantom outline) and a drive position (shown in solid lines).
The sheet material 9 is transported between a drive roll 20 and guide rolls 21 to a location between the mold parts 1 and 2. The roll 20 is driven by the motor 12 via pulley 22 and belt 23. A roller 24 mounted on a movable arm 25 is used to 1~786~0 press the material 9 into the recess 5. Orifices 26 and lines 27 in the mold part 1 are connected to a source of vacuum (not shown) so that the material 9 can be drawn into the recess 6 in the mold part 1. The material 9 is then cut at the rollers 22 by a knife 28, movement of which is controlled by a cylinder 29.
While the sheet material 9 is being loaded into the mold part 1, a tubular parison 30 of thermoplastic material is extruded by an extrusion head 31. The mold is closed by means of the cylinders 4 and pistons 5, and cylinders 33 are actuated to move piston rods 34 carrying parison pinch off blades 35 from the retracted positions (shown in solid lines) to the extended positions (shown in phantom outline). Blowing is then effected using blow pin 37 to conform the shape of the parison 30 to that of the mold cavity 3.
In greater detail, the cover material 9 includes an outer layer which is vinyl or fabric-type material and a backing layer of a woven fabric-type (e.g. Bevelan - a trademark), or a suede-type outer layer and a vinyl-type backing layer (available under the trademark Bevella). The backing layer must include a hot melt adhesive, which faces the extruded parison 30. The adhesive is activated when its temperature is at least 160F, which is easily reached when the adhesive contacts the hot parison 30.
The cover material 9 is pulled from the main feed roll 10 and fed along the length of the moid. The cover material 9 is ~ ~13Çi6~

cut to the shape of the core beiny blow molded prior to use.
Shrinkage of individual cover materials are calculated prior to use, and the material 9 is cut to lenyth automa-tically by the knife ~8. Each cover is cut slightly larger than the core or backing, so that the cover can be folded over the edges of the backing material for complete coverage and possible trimming. The exact length of the cover material required for each instrument panel is determined prior to starting. Such length is based on the size of the mold cavity 3, the extent of coverage of the backing material produced using the parison 30 and cover material shrinkage.
The length datum is fed into the design system to ensure consistent coverage of the core. The use of a vacuum in the recess 6 ensures that no air is trapped between the cover and the blown parison 30.
It will be appreciated that the air ducts and other elements normally incorporated in instrument panels can be in-corporated in the instrument panel during the blow molding process.
It will also be appreciated that both halves of the mold can contain orifices 26 and vacuum lines 27, i.e. that both halves of the mold can be essentially the same as mold part 1. In this case, sheet material from separate rolls is pressed against both mold parts by separate rollers 24, retained by both mold parts and attached to opposite sides of the thermoplastic material to product an automotive part having a cover layer on both sides of a core.
Thus, there has been described a relatively simple, ~ ~7~366~

inexpensive method and apparatus for producing an automotive part using b]ow molding techniques. The use of an adhesive backing on the cover material obviates the need for fasteners, or slots in the cover material through which parison material can flow for flattening by the mold. The resulting product includes the outer cover layer or layers and a blow molded, shock absorbing flexible backing material or core.

Claims (6)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A method of producing an automotive component comprising the steps of:
(a) placing a sheet of cover material carrying a layer of hot melt adhesive between the parts of an open two part mold;
(b) pressing the sheet into a mold cavity in one said mold part while applying a vacuum to the sheet to hold the sheet in the mold cavity;
(c) cutting the sheet to a predetermined length;
(d) loading a parison of thermoplastic material into the area between said mold parts;
(e) closing the mold to define a complete mold cavity and (f) blowing the parison to conform the shape of the parison to that of the mold cavity, whereby the thermoplastic material expands against and adheres to the layer of hot melt adhesive to define a flexible backing for the cover material.
2. A method according to claim 1, wherein the parison is loaded into the open mold simultaneous with the pressing of the cover material into the mold cavity.
3. A method according to claim 1, wherein two sheets of cover material each carrying a layer of hot melt adhesive are placed between the mold parts, one sheet is pressed against each mold part while applying a vacuum to the sheet, the sheets are cut to length, a parison is loaded into the area between the mold parts, the mold is closed and the parison is blown to produce a component including a core of thermoplastic material with a sheet of cover material of opposite surfaces thereof.
4. An apparatus for producing an automotive component comprising:
(a) first and second parts for defining a mold cavity;
(b) first roll means for carrying a roll of first sheet material adapted to define a cover for one side of the somponent, with a layer of hot melt adhesive on one surface thereof;
(c) first drive means for dispensing said sheet material into the area between said mold parts when the mold is open;
(d) second drive means for pressing said sheet material against one of said mold parts;
(e) first vacuum means in said one mold part for applying a vacuum to a surface of said mold cavity to cause the other surface of said sheet material to adhere to said surface of the mold cavity;
(f) extruder means for extruding a thermoplastic parison into an open mold;
(g) third drive means for moving said mold parts together to close the mold, thereby defining a mold cavity around an extruded parison; and (h) blow pin means for blowing air under pressure into said parison to cause the latter to assume the shape of the mold cavity, whereby the hot parison can soften the hot melt adhesive to bond a blow molded, thermoplastic backing material to a cover to define a complete automotive component.
5. An apparatus according to claim 4, wherein said second drive means includes elongated arm means for movement between said first and second mold parts of an open mold, and a roller on the free end of said arm means for pressing said sheet material against one mold part.
6. An apparatus according to claim 4, including second roll means for carrying a second roll of sheet material adapted to define a cover for a second side of the component; fourth drive means for dispensing said sheet material from said second roll means into the area between said mold parts when the mold is open; fifth drive means for pressing the sheet material from said second roll means against the other said mold part; and second vacuum means in said other mold part for applying a vacuum to a surface of said other mold part to cause said sheet material from said second roll means to adhere thereto, whereby the hot parison can soften the hot melt adhesive to bond a blow molded, thermoplastic core to a pair of covers to define a complete automotive component.
CA000541938A 1987-07-13 1987-07-13 Method and apparatus for blow molding automotive component Expired - Lifetime CA1278660C (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
CA000541938A CA1278660C (en) 1987-07-13 1987-07-13 Method and apparatus for blow molding automotive component

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
CA000541938A CA1278660C (en) 1987-07-13 1987-07-13 Method and apparatus for blow molding automotive component

Publications (1)

Publication Number Publication Date
CA1278660C true CA1278660C (en) 1991-01-08

Family

ID=4136070

Family Applications (1)

Application Number Title Priority Date Filing Date
CA000541938A Expired - Lifetime CA1278660C (en) 1987-07-13 1987-07-13 Method and apparatus for blow molding automotive component

Country Status (1)

Country Link
CA (1) CA1278660C (en)

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