JP2003529471A - Molded finished part and method of manufacturing the same - Google Patents

Molded finished part and method of manufacturing the same

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Publication number
JP2003529471A
JP2003529471A JP2001572300A JP2001572300A JP2003529471A JP 2003529471 A JP2003529471 A JP 2003529471A JP 2001572300 A JP2001572300 A JP 2001572300A JP 2001572300 A JP2001572300 A JP 2001572300A JP 2003529471 A JP2003529471 A JP 2003529471A
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JP
Japan
Prior art keywords
insert
molding
mold
cavity
finish
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.)
Pending
Application number
JP2001572300A
Other languages
Japanese (ja)
Inventor
アシンク、ケネス
キンディグ、アラン・エル
クラーク、ラッセル・エル
ドネイ・ヘガー、テレサ・エム
ベアード、デニス・ジェイ
ヘリントン、カート・エイ
ボエルマ、トーマス・エル
Original Assignee
クラリオン・テクノロジーズ・インコーポレイテッド
トータル・イノヴェイティヴ・マニュファクチャリング・エルエルシー
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
Priority to US19319600P priority Critical
Priority to US60/193,196 priority
Application filed by クラリオン・テクノロジーズ・インコーポレイテッド, トータル・イノヴェイティヴ・マニュファクチャリング・エルエルシー filed Critical クラリオン・テクノロジーズ・インコーポレイテッド
Priority to PCT/US2001/010262 priority patent/WO2001074583A1/en
Publication of JP2003529471A publication Critical patent/JP2003529471A/en
Pending legal-status Critical Current

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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
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • 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
    • B29C45/00Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29KINDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0809Fabrics
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/30Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005Body finishings
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29LINDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00Other particular articles
    • B29L2031/30Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3005Body finishings
    • B29L2031/3041Trim panels

Abstract

(57) [Summary] The molded finish part includes a finish insert in which a finishing material is arranged on a side of the front insert, and a main body of the molded part. The insert has a substantially rigid but elastic layer of molding material. The layers have opposing front and rear insert sides. The component body has a body surface corresponding to the rear insert side. The main body is also formed of a molding material. Furthermore, the body surface and the rear insert sides melt together, resulting in an almost indistinguishable joint surface. Forming the finished part, preparing the mold, preparing the insert, placing the insert in the mold, closing the mold, injecting the molding material into the molding cavity, It can be formed by a method including a step of opening a mold and a step of removing a molded part. The insert is an elastic member and has opposed insert front and rear sides. The molding cavity has at least one first cavity surface, and the insert front side has a front insert surface corresponding to the first cavity surface. When the finishing insert is placed in the molding cavity, the front surface of the insert engages the first cavity surface. Further, the molding material flows while pressing the rear side of the insert, and the front surface of the insert is pressed against the first cavity surface.

Description

Detailed Description of the Invention

BACKGROUND OF THE INVENTION The present invention relates to the molding of finished or ready-to-assemble parts with at least one side covered with a finish. The finishing material is generally, for example, a cloth material. The fabric material can include, but is not limited to, woven or non-woven fabrics. The finish may also include, for example, a film material. Membrane materials can include, but are not limited to, plastic or metal films.

CROSS-REFERENCE TO RELATED APPLICATIONS This application is co-pending US Provisional Patent Application No. 60 / 193,196, entitled “Molded Finished Parts and Method of Manufacturing Same,” filed March 30, 2000. Is a non-provisional continuation application of the present application, the disclosure content of which is incorporated herein by reference.

Fabrics commonly known to those skilled in the art as back moldling, reverse molding, in mold lamination and hinterspritzen. It will be appreciated that various attempts have been made and sold to form parts having other decorative finish surfaces. These conventional attempts to back mold parts have met with varying degrees of success with various sheet good finish materials. In general, these conventional trials of back-molding basically include applying a flexible sheet-like finish to the mold die, closing the die, and injection molding the part. The finish has two opposite sides, one side of which is preselected to provide an exposed finish surface. On the other or rear side of the finish, the molten molding material is poured into the closed mold.

The use of fabrics generally causes leakage problems. That is, the molten molding material injected behind the fabric penetrates the fabric finish and leaks from that material to the exposed finish surface, which is unacceptable. Alternatively, the membrane material generally undergoes thermal destruction. The heat of the molten material injected behind the membrane will cause it to melt. It will be appreciated that both of these issues are related to the flow control of the poured melt material and the temperature control of both the poured melt material and the mold.

In addition to leakage and heat problems, it would be considered that the back molding method is accompanied by strain problems. If the finish has a pattern on the finished side, the pattern will stretch and move as the finish is pressed into the mold as it flows behind the finish into the molding cavity.

[0006] Thus, while back molding has the very attractive potential of improving the production of finished part molding, it has serious limitations as briefly mentioned above.

SUMMARY OF THE INVENTION Accordingly, the molded finished parts and methods of making the same of the present invention address the drawbacks previously known in backmolding. More specifically, the present invention provides a back molding insert or finish insert that substantially lines at least a portion of a component mold with the finish surface substantially abutting the molding cavity surface. Therefore, the finished surface is initially placed in the approximately final position. Also, because the finishing inserts preferably have a back surface on the opposite side of the finishing surface that is compatible with the molding material used to form the part, the back molding inserts naturally or by necessity part. Integrated with. The insert can also provide a barrier to the molding material that penetrates the finish surface.

The molded finish part preferably includes a finish insert having a finish placed on the front insert side and a body portion of the molded part. The insert has a fairly rigid but elastic layer of molding material. This layer has opposite front and back insert sides. The component body portion has a body surface corresponding to the rear insert side portion. The body portion is also made of a molding material. In addition, the body surface and the rear insert sides melt together into a nearly indistinguishable interface.

The mold finishing part includes preparing a mold, preparing an insert, placing the insert in the mold, closing the mold, and injecting molding material into the molding cavity. It can be formed by a method including steps, opening a mold, and removing a molded part. The insert is an elastic member and has opposing front and rear side parts. The molding cavity has at least one first cavity surface and the insert front side has an insert front surface corresponding to the first cavity surface. The front surface of the insert engages the surface of the first cavity when the finishing insert is placed in the molding cavity. Further, the molding material flows while pressing the rear side portion of the insert, and the front surface of the insert is pressed against the surface of the first cavity.

The above and other features, objects and advantages of the invention will be appreciated by those skilled in the art and those who practice the invention from this disclosure, including the specification, claims and drawings. .

DETAILED DESCRIPTION OF THE INVENTION The shaped finished part of the present invention is a shaped article having an exposed finish as at least a portion of the exterior exterior surface of the exterior. Molded finished parts of the present invention, for example,
As will be appreciated by those skilled in the art, many configurations can be formed in a variety of shapes depending on the requirements specified for the part or the preferences of the user or manufacturer. The finish may generally be a fabric or flexible membrane, and may include, for example, without limitation, woven or non-woven fabrics. Alternatively, the finishing material is
Membrane materials can also be included, including, but not limited to, plastic or metal films and the like.

The molded finished part of the present invention is formed by finishing, insert molding 172 (FIGS. 7-16) by back molding, reverse molding, molding laminating or Hintersplitzen as is known to those skilled in the art. It The insert 172 is also a molded member, most preferably a fairly rigid but elastic member. Being a rigid member, the insert 172 does not undergo significant deformation or displacement during the back molding process. In a preferred embodiment, the back molding insert 172 is made of molding material 1
2 and a layer of finish 16 and may be a unitary piece that may optionally include a layer of filler material 14 (FIG. 2). The molding material layer 12 has two opposing surfaces, a finishing surface or a front insert side and a rear surface. The finish 16 is at least partially embedded within the finish surface and defines the finish side of the back molding insert 172. The front insert side is a fully finished surface as shown, but for certain applications of the invention, inserts where the finished surface is only a portion of the front insert side would be required. In addition, a layer of the filler material 14 may be optionally embedded in the molding material layer 12, as described later.

The molding material layer 12 can be made of a single material or a mixture of constituent materials.
A suitable material for the molding material layer 12 can be a thermoplastic such as, but not limited to, polyester, copolyester, polypropylene, nylon, polyethylene, or mixtures thereof. When using a mixed material, one of the constituent materials may have a higher melting point than the other material so that the low melting material adheres to the matrix it forms. The matrix material may also include the thermoplastics described above, but may also include natural materials such as sisal, cotton, flax, hemp, ceramic filaments and metal filaments. A person skilled in the art can obtain a base material having a relatively high free-flowing property that matches the shape of a mold member having a small roundness by using a composition of 100% polyester (all polyester). It will be appreciated that the other insert properties obtained can be preselected according to the composition of the molding compound layer.

Layer 12 may preferably be provided as a non-woven mat. For example, shreds of recycled or virgin polyester or polypropylene or mixtures thereof,
Crushing, fluffing, mixing and lofting into a non-woven sheet,
Sheets can be collected on rolls for storage and processing as is known. The mixing process can provide a uniform mixture of materials according to the desired final properties.

As will be appreciated by those skilled in the art, the finishing insert 172 can be successfully constructed and used in a single mat of material. It will also be appreciated that certain combinations of multi-component mats having different predetermined compositions can result in inserts 172 having custom structural properties that meet user requirements. Thus, for example, a second mat 18 consisting of a mixture including filler material 14 can be used with mat 12 to incorporate and position filler material layer 14 into the final integrated finishing insert 172 of the present invention (FIG. 2 and FIG.
). This can be conveniently accomplished by the same methods used to prepare the molding material layer 12 above, except that the fibers of the filler material are included in the mixture. Thus, a second mat 18 consisting of a homogeneous mixture of molding material and filler material 14 is also provided, according to the desired final properties. The filler material can include any of a variety of materials that preferably have a higher melting point temperature than the molding material used to mold the finish insert 172. Some examples of materials that can be used as fillers include, but are not limited to, polyester, polypropylene, nylon, polyethylene, ceramics, metals, sisal, cotton, flax and hemp.

As can be seen in FIG. 1, the production line configured to produce the finished insert of the present invention comprises a loading section 22, an uncoiler 24, a shears 26,
A high intensity oven 28, a bonding press 30 and a cloth rotary conveyor 32 may be provided. The press machine 30 has a molding cavity 1 having a predetermined shape.
Cooperating mold members or dies 162 and 164 (FIGS. 7-10) defining 66 are provided to allow the press to form the desired predetermined finishing insert 172 when the mold members 162 and 164 are mated.

The first conveyor section 42 includes the loading section 22, the uncoiler 24, and the shearing machine 2.
6. High strength furnace 28 and bonding press 30 can be interconnected (FIG. 1)
. A second conveyor section may interconnect the cloth carousel 32 and the splicing press 30. In addition, an automatic unloader 46 can be provided to remove the insert 172 from the bonding press 30 and stack it on a pallet or transfer it to another conveyor, for example.

The first mat 12 of the molding material and the second mat 18 containing the filler 14 may be provided by the individual rolls 50 of the loading section 22, but they may be wound concentrically on the same roll. In any case, when trying to construct the finishing insert 172 with the buried layer, the two mats 12 and 18 are aligned and fed into the shears 26 at the same time. The mats 12 and 18 are cut to length by a shearing machine 26 and fed into a furnace 28 by a conveyor section 42. Of course, only a single mixed material mat 12 may be used when attempting to configure the insert 172 to have a uniform structure, rather than disposing the material layers inside a unitary member. In addition, each mat 1 may have desired characteristics depending on the materials mixed in the mat.
2 and 18 may be configured, but the final finished insert may be configured to provide the desired properties by mixing mats of different composition in a given array.

The molding material of the mat 12, and optionally of the mat 18, is preferably a furnace 28.
It is heated to a point where it changes from a solid state to a moldable state which is gel-like or partly liquid. Some of the fibers of the molding material will liquefy in the oven, while another will remain solid and another will be in the transient or gel state. As mentioned above, a matrix material having a relatively high melting point can also be included. Thus, the material becomes very flexible, but it is still handleable because it retains the mat structure. The hot mats 12 and 18 are further conveyed by the conveyor section 42 to the furnace 2
8 is transferred to the bonding press 30.

At about the same time or in advance, the corresponding finish or fabric 16 is transferred from the fabric rotary conveyor 32 to the splicing press 30 by the second conveyor section, where the fabric is mated with the hot mats 12 and 18. The finish or cloth 16 is typically
Fabric materials including, but not limited to, woven or non-woven fabrics can be used. Finishing material 16 can also include membrane materials including, but not limited to, plastic or metal films.

When the cloth 16 and the high temperature mats 12 and 18 are aligned with each other and further in the mold and the press 30 is closed, the finishing cloth 16 and the mats 12 and 18 are moved to the mold member 162.
And 164 are captured and compressed. Due to the pressure applied by the press 30, the hot molding material will transform completely into the liquid state in the mold. Regardless, the hot molding material moves or flows in the mold of the press 30. Therefore,
The two mats 12 and 18 become a single layer with the filler layer 14 embedded in the molding material according to the arrangement of the mats. Through almost the entire molding cavity, the molten molding material is forced to flow and adhere to the non-molten material. The molten material is also pushed into the finish cloth 16 so that the cloth is at least partially embedded in the molding material.

The mold members or dies 162 and 164 are most preferably controlled at a temperature below the melting temperature of the molding material. Thus, the furnace heats the molding material and the pressure of the closed mold in the press molds the material before heat is transferred from the material to the die and the material solidifies into a solid state.

The structural characteristics of the final finish insert will be influenced by the composition of the materials described above and the method of construction, including factors such as the temperature and pressure of the closed mold and, above all, material density. More specifically, for a given amount of material, a given mold cavity volume will result in a particular material density. Increasing the amount of material by holding the mold cavity volume constant will increase the final material density. A final finished insert with a relatively high final material density would be a relatively tough insert that is difficult to penetrate, including insertions such as pins. Alternatively, reducing the amount of material will result in a finished insert having a relatively low material density and less toughness, ie easier pin insertion, resulting in a finished insert that can be pinned if desired. .

Thus, the finish insert 172 of the present invention can be made fully pinnable, for example, by properly adjusting the final material density. That is, the finish insert 172 can be configured such that paper or the like can be affixed or pinned anywhere on the insert with pushpins or tacks or the like. As a matter of geometry, as will be appreciated by those skilled in the art, the pinnable finish insert 172 will have at least about 10 mm (= 3/8 inch) to support the weighted pushpin. Preferably has a thickness of.

It should be noted that when the molding material is heated to the liquid state, the material will generally be very viscous and will not be able to freely flow and flow throughout the molding cavity. Rather, the molten molding material will cause some migration or leakage due to local molding pressure, but tends to stay where it was when the press closed the mold. Thus, the finished insert will have a localized area of relatively high material density and therefore higher toughness of the material, at which location, for example, the molding cavity and final insert 172 will have a reduced cross-sectional thickness.

Further, depending on the requirements of the particular molded finished part, a fire barrier layer within the finish insert 172 may be desired. This can be achieved, for example, with the glass fiber layer 14 or foil layer under the finishing fabric 16. Mat 18 that uses glass fibers as the filler material and has a relatively high mixing ratio of glass fibers to the molding material (FIG. 3)
Will have acceptable levels of fire barrier properties. Alternatively, the foil may be laid on the underside of the finishing fabric, like another mat.

As previously mentioned, those skilled in the art will appreciate that various modified “lay-up” arrangements of multi-mats can be formed prior to molding in the bonding press into the integrated finish insert 172 of the present invention. It will be appreciated that the finishing insert 172 of the present invention can be constructed with. By selecting a different number of mats, and by varying the thickness and content of each mat, that is, by preselecting a particular array of mats, the final integrated finishing insert 172 of the present invention.
The stiffness, toughness, sound and other properties of the can be modified.

The layup of the fabric 16, the filler-mixing mat 18 and the molding compound mat 12 (FIG. 3) will, for example, result in an integral finishing insert 172 with the embedded filler layer 14 adjacent the fabric 16 (FIG. 2). Let's do it. Alternatively, if desired, the embedded filler layer 14 can be separated from the fabric 16 by using, for example, an additional molding material mat 12 (FIG. 4) or by reversing the positions of the mats 12 and 18. Alternatively, strength and other properties can be increased, for example, by using metal or ceramic fibers. Further, including but not limited to a rigid structure including the metal mesh 20 in the structure within the mat array (FIGS. 5 and 6).
) Can be embedded in the integral insert 172.

More specifically, finishing insert 172 can be molded with mold 160 of various known constructions. A suitable mold structure is shown generally in Figures 7-10. The mold has an upper mold member 162 and a lower mold member 164.
The upper mold member 162 is generally shown as a female mold member having a molding cavity 166 having a predetermined shape, as described above. Lower mold member 164 includes silicone core 168 and soft compression member 17 as will be appreciated by those skilled in the art.
Shown generally as a male member having zero. When the mold 160 is closed, a combination of the finish 16 and a high temperature mat comprising, for example, layers 12 or 12 and 14 of molding material, generally referred to as the finish insert 172, forms a mold member 162. And 164. More specifically, the outer peripheral edge portion of the finishing insert 172 is caught and fixed between the upper mold member 162 and the soft member 170.

A plate-shaped member 174 extends substantially inward from the lower edge of the upper mold member 162. When the mold 160 is completely closed, the core 168 advances into and fills the cavity 166, forcing the compound 172 into the cavity 166 for alignment. Additionally, the core 168 presses the member 174 substantially outwardly to form an inwardly extending flange 176 at the outer periphery of the finishing insert 172. Upper mold member 162
By making the dimensional tolerance between the plate-shaped member 174 and the block-shaped member 178 of the lower mold member 164 extremely narrow, a shear portion is formed in the mold 160 along the outer peripheral flange 176. Thus, shaping and final trimming of the finished insert is accomplished in one step of the finished insert molding operation. If necessary,
The finishing insert 172 is deflected to move it into the cavity 166 of the upper mold member 162.
Can be taken from. Alternatively, member 174 may be provided with a slide or series of slides that translate laterally to remove finishing insert 172, as known to those skilled in the art.

Various molding methods can be used to form the finish insert 172. The use of the mold 160 described above is the preferred but exemplary method. The back mold insert 172 can also be formed using a more traditional match mold. The preferred method of forming the insert 172 will be affected by a number of factors, including, but not limited to the particular component requirements or specifications, and the manufacturer's preferred technique. Another preferred exemplary molding of a back molding insert is generally shown in FIGS. 11-13, in which reference numbers in the 200 series are used to refer to the second embodiment. Thus, while the first embodiment of the insert described above is designated by the reference numeral 172, the second embodiment of the insert described below is designated by the reference numeral 272 and the different numbers mainly refer to the two moldings. Show the difference in the method.

The back molding insert 272 is a bladder wrap mold 2
00 (FIG. 11) and as understood by those skilled in the art, the mold comprises a frame 210, an elastic bladder 202 with a blank 204, a horn 206, and a nest 208. ing. Accordingly, the heating mat 12 and finish 16 described above in more detail include the horn 206 and the bladder 20.
It is placed between two or blanks 204. The mold 200 is closed over the green insert 272 by placing the horn 206 against the mat 12 and snapping it into the nest 208 (FIG. 12). This allows the bladder to at least partially
Wrap around 72 and insert 272 is at least partially horn 2
Wrap around 06. As will be appreciated by those skilled in the art, suction is applied to the mold to draw bladder 202 and insert 272 completely around horn 206. Accordingly, insert 272 will be substantially vacuum formed within bladder wrap mold 200.

Finishing insert 272 is peeled off or otherwise removed from horn 206 and placed in trim fixture 220 (FIG. 13). Trim fixture 2
20 includes a trim nest 222, a trim clamp 224, and a trim guide 226.
And a trim knife 228. Also, insert 172 into mold 1
Note that it may be molded without trimming in 60 and then trimmed, such as with trim fixture 220. Therefore, insert 172 as follows
It should be understood that when referring to either or 272, either insert 272 or untrimmed insert 172 is included interchangeably. Insert the insert 172 or 272 into the trim nest 222 to remove the trim clamp 224.
Hold it in place by. The trim guide 226 is positioned or indexed so that the flange 176 of the insert 172 can be trimmed as desired by running the knife device 228 along the trim guide 226. Guide 22
6 can provide additional support for insert 172 during trimming and can heat knife device 228 to facilitate cutting, both of which will be understood by those skilled in the art. . More specifically, the flange is preferably trimmed to a length "L" (FIG. 15) to allow the flange to adhere to the injection mold without sagging, as will be described further below.

Preferably, the trimmed back molding insert 172 is inserted into the injection mold 190 (FIG. 1).
1 to 16). The mold 190 will have an upper mold member 192 and a lower mold member 194. The upper mold member 192 is a female mold member and preferably has a corresponding molding cavity 196 on the finish or front side of the insert 172 so that the insert is mated with the molding cavity 196 in a generally abutting engagement.
That is, to be able to sit down. Thus, the finish insert 172 effectively lines the cavity 196 in line. The lower die member 194 is a male die member (FIGS. 14 and 16 to 19) having a core portion 198. After covering the core 198 with the finishing insert 172, the mold is closed. Alternatively, the finishing insert 172 is fitted into the cavity 196 and then the mold is closed and the core 19
Insert 8 into finishing insert.

Finishing insert 172 is disposed between upper mold member 192 and lower mold member 194, with the mold closed and from the passage or runner 180 to the molding material, as is known to those skilled in the art. 102 can be injected into the molding cavity (FIGS. 18 and 19). The molding material 102 can include, for example, a thermoplastic such as polyester, copolyester, polypropylene, nylon, polyethylene, or mixtures thereof. More specifically, regarding back molding,
The hot molding material 102 is injected on one side of the finishing insert 172, i.e. on the non-finishing rear side. The insert 172 is a molding material, preferably a melt molding material 102.
The insert and the final molded part will be an integral part because they are formed of a material that is compatible with. The backside of the insert and the infused material 102 melt together into a nearly indistinguishable interface.

As shown and described above, the high temperature molding material 102 comprises the finishing insert 1
Injected between 72 and core 198 to become, or indeed be, the body part of the finish molded part. While the molding material 102 is being poured, it flows within the molding cavity 196 between the finishing insert 172 and the core 198, pressing the finishing insert 172 against the surface of the upper mold member 192 and, to some extent, stretching it along the finish. The insert abuts the upper mold member and lines it (FIGS. 14 and 16-19). Therefore, the finishing material 16 can also slowly move along the surface of the upper mold member 192. Depending on the dimensions of the part and factors including the resiliency or extensibility of the finish 16, the finish will not only cover the edges of the finish-formed part,
It is possible to move more slowly to a distance where it can wrap around a portion of the backside of the molded part and overlap.

In many parts, it is desirable for the finishing surface or material to wrap around the edges of the part. Therefore, it may be important that the edges 176 do not form the outer surface of the part and are not embedded in the molten molding material that results in the finished molded part. For at least this reason, the flange 176 is preferably trimmed to length "L" (FIG. 15) to prevent the flange from sagging by the molding core 198, as previously described. Although slight deflection is acceptable, it is preferable that there is no deflection at all because it facilitates avoiding excessive deflection that may occur due to general manufacturing tolerances. Excessive sag may cause the injected molten molding material to pass through the distal edge of the flange 176 and fill the void 182 (FIG. 20) formed behind the sagging flange, and thus the flange 176. Deflection is undesirable. This event will be called blow-by.

As the injected molding material passes through the flange 176 and fills the void 182, the flange is embedded within the body of the molded part and does not provide a finished surface wrapped around the edges of the molded part. A suitable dimension for the length "L" of the flange 176 will depend on the edge thickness of the molded part. More specifically, insert 1
72 abuts one surface of the molding cavity, particularly the inner surface of the upper mold member 192 as shown, while the insert has the other surface 184 (FIG. 17), namely the lower mold member 1
Away from the inner surface of 94. This space defines the thickness of the molded part. Most preferably, at the location of insert flange 176, the part thickness and flange length "L" are the same.

As mentioned above, because the finish insert 172 travels slowly along the surface of the upper mold member 192, the length “L” of the flange 176 is actually less than the thickness of the molded part, but the finished molded part is not. Can be fully covered. For example, when the thickness of the molded part is about 8 mm (= about 5/16 inch), the flange length "L" is about 5 m.
Even as short as m (= about 3/16 inch), it can be pushed slowly by the flow of injected molten material 102 to completely cover the edges of the part.

The final molded part has a finish surface provided by the finish insert 172 and also has a finish trim edge predetermined by the selected trim length of the flange 176 during molding of the finish insert as previously described. . Also, while the molten molding material 102 is injected into the cavity 196 between the finish insert 172 and the core 198 by any suitable thermal control method known to those skilled in the art, the upper mold member 192 and the finish insert finish surface are Note that can be maintained at a predetermined low temperature. Furthermore, the high temperature molding material 102 and the finishing insert 1
The heat transfer to and from the unfinished side of 72 causes the unfinished or rear surface of the insert to soften or melt to some extent, causing the finished insert and injection molding material to melt together, resulting in a final molded finished part being one piece You may make it a single member.

Further, a parting line 186 (FIG. 19) between the upper mold member 192 and the lower mold member 194.
Note that the angles of 286 and 286 (FIG. 20) affect the creep of the finish 16 and thus the wrapping or coating of the finish surrounding the edges of the molded part. When the parting line 186 extends at an angle from the insert 127 to the flange 176, the insert or finish 16 is free to encircle the edge of the finished molded part. If the parting line 286 extends substantially straight from the insert 127 to the flange 176, the insert or finish 16 may be constrained to prevent it from moving slowly to enclose the edges of the finished molded part. Ah

Those skilled in the art and those who practice the present invention will appreciate that various changes and modifications can be made without departing from the spirit of the disclosed concept. Improvements within the scope of the disclosed concept include, but are not limited to, for example:
Embedding various electrical, pneumatic or hydraulic conduits into the integrated finishing inserts of the present invention may be included. For example, various related terms are used in the detailed description and claims of the present invention, including left, right, front and back, and up and down, but only to indicate the relative placement of the various elements of the claimed invention. Is. The scope of protection afforded shall be determined by the scope of the claims and the breadth of interpretation permitted by law.

[Brief description of drawings]

FIG. 1 is a perspective view of a production line adapted to produce a finished insert of the present invention.

[Fig. 2]   FIG. 4 is a schematic cross-sectional view of the finishing insert, broken away.

[Figure 3]   FIG. 3 is a schematic exploded cross-sectional view of a number of material layers for a finishing insert.

[Figure 4]   FIG. 4 is a view of FIG. 3 showing a first modified structure of the finishing insert.

[Figure 5]   FIG. 4 is a view of FIG. 3 showing a second modified structure of the finishing insert including a rigid structure.

[Figure 6]   FIG. 6 is a view of FIG. 2 showing the second modified structure of FIG. 5 incorporated into the finishing insert.

[Figure 7]   It is a cross-sectional schematic diagram of the finishing insert metal mold in the state in the middle of closing.

[Figure 8]   8 is a view of FIG. 7 in a closed position.

[Figure 9]   It is an enlarged view of the IX part of FIG.

[Figure 10]   It is an enlarged view of the X part of FIG.

FIG. 11   It is a schematic perspective view of a finishing insert bladder wrap mold.

[Fig. 12]   It is an expanded fracture schematic diagram showing a mold closed.

[Fig. 13]   FIG. 3 is an enlarged cutaway schematic view showing a trim fixture with a finishing insert in section.

FIG. 14   FIG. 5 is an exploded schematic view of a cross section of a back mold showing the placement of finishing inserts.

FIG. 15   It is an enlarged view of the XV part of FIG.

16 is the view of FIG. 14 showing the finishing insert positioned against one side of the back mold.

FIG. 17   It is an enlarged view of the XVII part of FIG.

FIG. 18 shows finishing inserts placed with the back mold closed (showing the f
FIG. 3 is a schematic view of a cross section of an inish insert positioned with the back mold closed).

FIG. 19   It is an enlarged view of the XIX part of FIG.

FIG. 20   FIG. 18 is a view similar to FIG. 17, showing a first modified mold and insert.

[Explanation of symbols]

102 Melt molding material 172 finishing insert

─────────────────────────────────────────────────── ─── Continued front page    (71) Applicant Total Innovative Manufacture             Kucharing LLC             TOTAL INNOVATIVE MA             NUFACTURING, LLC             Horan, Michigan, United States             De, New Holland Street             12688             12688 New Holland Str             eet, Holland, MI             49424, U.S.S. S. A. (72) Inventor Async, Kenneth             Horan, Michigan, United States             De, New Holland Street             12688 (72) Inventor Baird, Dennis Jay             Horan, Michigan, United States             De, New Holland Street             12688 (72) Inventor Boerma, Thomas El             Geniso, Michigan, United States             Pine Ridge Court 6719 (72) Inventor Clark, Russell El             Geniso, Michigan, United States             Pine Ridge Court 6719 (72) Inventor Donay Hegger, Teresa M             Horan, Michigan, United States             De, New Holland Street             12688 (72) Inventor Herrington, Kurt Aye             Geniso, Michigan, United States             Pine Ridge Court 6719 (72) Inventor Kindig, Alan El             Geniso, Michigan, United States             Pine Ridge Court 6719 F term (reference) 4F100 AK01B AK01C AK04 AK07                       AK41 AK48 AT00A BA03                       BA10A BA10C DD09 DG06                       DG11 DG15 DG16 EC032                       EH362 GB33 GB81 HB00A                 4F206 AD08 AD16 AD20 AG03 JA07                       JB13 JF05 JL02 JM04 JN11                       JQ81 [Continued summary] Flows while pressing the rear part of the insert, before inserting The surface is pressed against the surface of the first cavity.

Claims (5)

[Claims]
1. A molded part having a finished surface, comprising a substantially rigid but elastic layer of a first molding material, said layer having opposing first and second insert sides. A back molding finish insert having a finish disposed on the first insert side and a body portion having at least one first body surface corresponding to the second insert side. And the body portion is formed of a second molding material, the first and second molding materials being compatible with each other, whereby the first body surface and the second insert side melt together. Then, the molded parts that have become almost indistinguishable joint surfaces.
2. A method of making a molded part having a finished surface, the method comprising forming a mold cavity corresponding to a predetermined part shape having at least one first cavity surface corresponding to the finished surface of the molded part. Preparing the mold and finishing insert with a substantially rigid but elastic member having opposite insert front and back sides, the front side of the insert having a finish surface corresponding to the first cavity surface And placing the finishing insert in the mold such that the finishing surface engages the first cavity surface, and with the finishing insert placed in the molding cavity. Closing the mold, injecting molding material into the molding cavity, whereby the molding material pushes the rear side of the insert. Only while flowing, the method comprising whereby the steps to ensure that the insert front portion is pressed against the first cavity surface, a step of opening the mold, and a step of removing the molded part from the mold.
3. The method of claim 2, wherein providing the finish insert further comprises forming the finish insert with a molding material.
4. A method of making a molded part having a finished surface, the method comprising: providing a mold having a molding cavity having at least one first cavity surface to allow a predetermined molded part to be formed. A step of preparing an insert which is an elastic member and has opposite insert front and rear sides, and the insert front side has an insert front surface corresponding to the first cavity surface, and the insert front surface is Arranging the insert in the mold so as to engage the surface of the first cavity, and thus arranging the finishing insert in the molding cavity,
Closing the mold; injecting molding material into the molding cavity so that the molding material flows while pressing against the rear side of the insert, the front surface of the insert pressing against the surface of the first cavity; , Opening the mold and removing the molded part from the mold.
5. The method of claim 2, wherein providing the finishing insert further comprises forming the finishing insert with a molding material.
JP2001572300A 2000-03-30 2001-03-30 Molded finished part and method of manufacturing the same Pending JP2003529471A (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US19319600P true 2000-03-30 2000-03-30
US60/193,196 2000-03-30
PCT/US2001/010262 WO2001074583A1 (en) 2000-03-30 2001-03-30 Molded finished part and method of making same cross-references to related applications

Publications (1)

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JP (1) JP2003529471A (en)
AU (1) AU5114101A (en)
CA (1) CA2399565A1 (en)
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US6926856B2 (en) 2002-07-29 2005-08-09 Dow Global Technologies Inc. Molded parts with fabric surface areas and processes for their production

Family Cites Families (12)

* Cited by examiner, † Cited by third party
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JPS55107441A (en) * 1979-02-13 1980-08-18 Masaaki Kinugawa Double-forming method for product with processed end
JPS6037770B2 (en) * 1980-03-06 1985-08-28 Sanho Jushi Kogyo Kk
JPH0520262B2 (en) * 1987-07-14 1993-03-19 Kasai Kogyo Kk
JP2537668B2 (en) * 1988-09-19 1996-09-25 豊田合成株式会社 Method for manufacturing resin molded products
US5110532A (en) * 1991-03-04 1992-05-05 Siebolt Hettinga Method for molding a laminate
DE4122412A1 (en) * 1991-07-06 1993-01-14 Bayer Ag Moulding prodn. with decorative surface - by inserting decorative material with edge bent inwards in injection moulding tool
DE4127241C2 (en) * 1991-08-17 1994-06-01 Bayer Ag Process for producing molded parts with a surface covered by decorative material by back injection, and molds for carrying out the process
US5328651A (en) * 1993-03-05 1994-07-12 Davidson Textron Inc. Method for manufacturing an automobile trim component by blow molding and injection molding
DE4408446A1 (en) * 1994-03-12 1995-09-14 Otto Deuschle Modell Formenbau Film-covered plastic component prodn. and equipment
AT404690B (en) * 1995-03-08 1999-01-25 Magna Eybl Gmbh Method for producing cladding parts from fiber composite mats, and cladding parts produced by the method
JPH1177739A (en) * 1997-09-10 1999-03-23 Toyo Tire & Rubber Co Ltd Method for integral molding of skin and resin core body
DE19819557C2 (en) * 1998-04-30 2001-05-17 Brocke Kg I B S Process for the production of injection molded plastic parts

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EP1272341A4 (en) 2003-06-25
WO2001074583A1 (en) 2001-10-11
EP1272341A1 (en) 2003-01-08
CA2399565A1 (en) 2001-10-11
AU5114101A (en) 2001-10-15

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