US20040170788A1 - Double-cast slush molding method and apparatus - Google Patents
Double-cast slush molding method and apparatus Download PDFInfo
- Publication number
- US20040170788A1 US20040170788A1 US10/797,247 US79724704A US2004170788A1 US 20040170788 A1 US20040170788 A1 US 20040170788A1 US 79724704 A US79724704 A US 79724704A US 2004170788 A1 US2004170788 A1 US 2004170788A1
- Authority
- US
- United States
- Prior art keywords
- tub
- polymer material
- tubs
- polymer
- mold
- 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.)
- Abandoned
Links
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
- B29C41/04—Rotational or centrifugal casting, i.e. coating the inside of a mould by rotating the mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
- B29C41/18—Slush casting, i.e. pouring moulding material into a hollow mould with excess material being poured off
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
- B29C41/22—Making multilayered or multicoloured articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/34—Component parts, details or accessories; Auxiliary operations
- B29C41/36—Feeding the material on to the mould, core or other substrate
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S264/00—Plastic and nonmetallic article shaping or treating: processes
- Y10S264/60—Processes of molding plastisols
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
- Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Moulding By Coating Moulds (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Medicines That Contain Protein Lipid Enzymes And Other Medicines (AREA)
- Image Analysis (AREA)
- Die Bonding (AREA)
Abstract
An apparatus for slush molding a thin shell having an outer layer and an inner layer. The apparatus includes two tubs alternately movable to a cast position for dispensing their respective material contents into a mold cavity. According to another embodiment of the invention, the apparatus includes a diverter valve configured to alternately open a passage from each of two tubs to the mold cavity to selectively dispense charge materials from the respective tubs into the mold cavity. In addition, a method is provided for forming a thin shell having an outer layer and an inner layer. A first polymer material is cast and allowed to melt on a heated mold surface to form an outer layer. A second polymer material is then cast and allowed to melt and form an inner layer on the inner surface of the outer layer. The shell is then removed from the mold.
Description
- This invention relates generally to a method and apparatus for slush molding a thin shell, and, more particularly, for slush molding a thin shell having an outer layer and an inner layer.
- The prior art includes a number of different methods for forming thin, resilient multi-layer trim component shells such as automotive instrument panel skins. It is often desirable, particularly in automotive interior trim applications, for the exterior “class A” surfaces of such shells to have an appealing appearance and feel to automobile passenger compartment occupants. To provide an aesthetically pleasing outer class A surface, at least the outer layer of such multi-layered shells is often formed by slush molding methods. Slush molding involves casting a charge of polymer material against a heated mold surface that is shaped to form the desired shape and texture of the outer surface of a thin shell to be cast within the mold. The casting may be accomplished by attaching and sealing an open upper end of a charge box to an outer rim of an open end of the mold. The charge box is then inverted to allow the polymer material within the charge box to fall by gravity from the charge box and onto the heated mold surface. Once polymer material is applied to the heated mold surface, the charge box returns to its upright position and excess casting material returns to the charge box. The cast material is then allowed to melt on the heated surface, the mold surface is cooled, and the material is allowed to harden before removing it from the mold surface. The thin shell layers may be cast in a hot air module using a dry blend, usually in the form of powder or microspheres, of polymer such as polyvinyl chloride (PVC). The dry blend may include material for imparting a predetermined color to the shell.
- Current slush molding methods include a “double-cast” method that includes the casting of a first charge of polymer material on a heated mold surface as described above, then casting a second charge of polymer material on the inner surface of the layer formed by the first casting. Sufficient heat is transferred from the heated mold surface through the first layer to melt the second charge layer. The mold surface is then cooled to allow both layers to harden and bond to one another.
- Double-cast slush molding processes are disclosed, for example, in U.S. Pat. No. 5,344,183, which issued Sep. 6, 1994 to Hersman et al.; U.S. Pat. No. 4,769,278, which issued Sep. 6, 1988 to Kamimura et al.; and U.S. Pat. No. 5,580,501, which issued Dec. 3, 1996 to Gallagher et al. Both Gallagher et al. and Kamimura et al. disclose the casting of a second charge comprising an expandable or foamable polymer powder. Hersman et al. disclose the casting of a second charge comprising reinforcing fibers impregnating a polymer material.
- In addition, the assignee of the present invention has constructed and used a rotational apparatus for manufacturing thin walled hollow parts using a double-cast process. The apparatus is a modification of the apparatus disclosed in U.S. Pat. No. 4,722,678 issued Feb. 2, 1988 to Wersosky and assigned to the assignee of the present invention. The apparatus includes a charge box supported on a movable cart that tracks with a guide mechanism. An electromechanical device shuttles the cart and charge box with the aid of the guide mechanism between a position directly below an open-ended mold for attachment to the mold and a position laterally displaced from the mold (i.e. perpendicular from the axis of rotation) for re-filling with polymer powder. The mold is mounted separately from the cart for rotation about trunnions on a support structure. The cart includes an elevator system that lifts the charge box into engagement with the open end of the mold when the cart is positioned below the mold. Once attached, the charge box is then inverted with the mold to a position over the mold to dispense its contents into the mold. The apparatus also includes a second cart and charge box that are sequentially shuttled into a position below the mold from a direction opposite the first cart and charge box and attached to the mold after the first charge box has been removed and displaced from the mold. From such equipment, two-layer slush molded shells have been manufactured from powdered polyvinyl chloride (PVC). The two-layer slush molded shells comprise a solid PVC outer layer and a foamed PVC inner layer made from virgin materials (i.e. has not been subjected to use other than required for its original manufacture). The materials further comprise the same PVC formulation with the same levels of ultraviolet stabilization except that the PVC foam comprises a lower concentration of pigment resulting in a different color and a blowing agent to produce the foam, which makes the material unsuitable for use as the outer layer. The two layer slush molded shells further comprise an outer layer average thickness of 0.020 inches and an inner layer average thickness of 0.030 inches.
- What is needed is an apparatus configured to execute a double cast slush molding method without the expense of multiple charge boxes and associated expense of added carts, rails and elevator systems. What is also needed is a method for slush molding a double-layer shell or skin using at least a proportion of less expensive materials without compromising the high-quality appearance of an outer class-A surface of the shell or skin.
- In accordance with this invention, an apparatus for molding a thin shell having an outer layer and an inner layer is provided that includes at least two tubs configured to hold charge materials for delivery to a mold cavity. The tubs are simultaneously rotatable around a horizontal axis to an orientation where the charge materials will dispense from the tubs. The tubs have openings configured to be alternately blockable to allow the tubs to alternately dispense charge material into the mold cavity.
- According to another aspect of the invention, the apparatus includes a support structure supported for rotation around a horizontal axis with at least two tubs supported on the support structure and configured to hold charge materials for delivery to a mold cavity. The tubs are rotatable with the support structure around the horizontal axis to an orientation where the charge materials will dispense from the tubs. The tubs are also alternately movable on the support structure to a dispensing position. The support structure is configured to block the opening of a tub not in the dispensing position and to unblock the opening of a tub in the dispensing position. This allows the tubs to alternately dispense their charge material into the mold cavity.
- According to another aspect of the invention, the first one of the two tubs is movable between a first outer position and the dispensing position while the second one of the two tubs is movable between a second outer position and the dispensing position. The support structure is configured to block the tub opening of the first tub in the first outer position and block the tub opening of the second tub in the second outer position. The support structure is also configured to allow charge materials to flow from the tub in the dispensing position.
- According to another aspect of the invention, a diverter valve connectable between the tubs and the mold cavity. The diverter valve is configured to alternately open a passage from each of the tubs to the mold cavity to allow charge materials from the respective tubs to be selectively dispensed into the mold cavity.
- According to another aspect of the invention, the diverter valve includes a separator blade pivotally mounted within a chute that extends between the mold cavity and the two tubs. The separator blade is pivotally movable between a first position and a second position within the chute. In the first position the separator blade is positioned to admit the flow of material from the first tub through the chute and to block the flow of material from the second tub through the chute. In the second position the separator blade is positioned to admit the flow of material from the second tub through the chute and to block the flow of material from the first tub through the chute.
- According to another aspect of the invention, a method for molding a thin shell having an outer layer and an inner layer is provided. The method includes providing a mold having a mold surface configured to complement the desired shape of the shell to be molded and heating the mold surface. A first polymer material is provided in a first tub having a first tub opening and a second polymer material is provided in a second tub having a second tub opening. The second tub opening is blocked and the tubs and the mold are tipped until at least a portion of the first polymer material dispenses from the first tub onto the mold surface to form an outer layer. The tubs and the molds are then righted and the second tub opening is opened while the first tub opening is blocked. The tubs and the mold are then tipped until at least a portion of the second polymer material dispenses from the second tub onto at least a portion of the outer layer to form an inner layer. The mold surface is then cooled, the inner and outer layers are bond together and the shell is removed from the mold.
- According to another aspect of the invention, the method for molding a thin shell having an outer layer and an inner layer including the step of providing a first polymer material in a first tub includes the steps of moving the first tub to a filling position on a support structure and filling the first tub with the first polymer material and the step of providing a second polymer material in a second tub includes the steps of moving the second tub to a filling position and filling the second tub with the second polymer material.
- According to another aspect of the invention, the method for molding a thin shell having an outer layer and an inner layer including the steps of providing a first polymer material in a first tub and providing second polymer material in a second tub includes the steps of connecting the tubs to a diverter valve to provide a polymer material flow path from one of the tubs while blocking polymer material from flowing from the other of the tubs, operating the diverter valve to provide a flow path for the first polymer material from the first tub while blocking the flow of the second polymer material from the second tub and operating the diverter valve to provide a flow path for the second polymer material out of the second tub while blocking the flow of the first polymer material from the first tub.
- According to another aspect of the invention, the method for molding a thin shell having an outer layer and an inner layer including the step of connecting the tubs to a diverter valve is preceded by an additional step of providing a diverter valve comprising a separator blade pivotally mounted within a chute. The chute is configured to releasably connect a mold cavity to the two tubs and to provide a polymer material flow path from the tubs to the mold cavity. The separator blade is pivotally movable between a first position and a second position within the chute. The separator blade in the first position admits the flow of material from the first tub through the chute and blocks the flow of material from the second tub through the chute. The separator blade in the second position admits the flow of material from the second tub through the chute and blocks the flow of material from the first tub through the chute.
- According to another aspect of the invention, the method for molding a thin shell having an outer layer and an inner layer including the steps of operating the diverter valve to provide a flow path for the first polymer material includes the step of pivoting the separator blade to the first position, and the step of providing a layer of the second polymer material on the layer of the first polymer material by operating the diverter valve includes the step of pivoting the separator blade to the second position.
- According to another aspect of the invention, a thin shell for an automotive trim panel having an outer layer and an inner layer is disclosed, where the outer layer comprises a first polymer material and an inner layer comprising a second polymer material. The inner layer at least partially covers the inner surface of the outer layer and is concealed from view by vehicle occupants.
- According to another aspect of the invention, a thin shell for an automotive trim panel is disclosed, said shell having an outer layer and an inner layer, the shell comprising an outer layer comprising a first polymer material and an inner layer comprising a second polymer material, the second polymer material further comprising a polymer material at least a portion of which comprises a formed article prior to its use as the second polymer material, and the inner layer at least partially covering the inner surface of the outer layer and concealed from view by vehicle occupants.
- According to another aspect of the invention, a thin shell for an automotive trim panel is disclosed, said shell having an outer layer and an inner layer, the shell comprising an outer layer comprising a first polymer material, an inner layer comprising a second polymer material, the second polymer material further comprising a mixture of two or more different polymer formulations, and the inner layer at least partially covering the inner surface of the outer layer and concealed from view by vehicle occupants.
- According to another aspect of the invention, a thin shell for an automotive trim panel is disclosed, said shell having an outer layer and an inner layer, the shell comprising an outer layer comprising a first polymer material, an inner layer comprising a second polymer material, the second polymer material further comprising a polymer formulation which is more susceptible to ultraviolet degradation than the first polymer material, and the inner layer at least partially covering the inner surface of the outer layer and concealed from view by vehicle occupants.
- According to another aspect of the invention, a thin shell for an automotive trim panel is disclosed having an outer layer and an inner layer wherein the outer layer comprises an average thickness in a range between and including 0.005 inches to 0.025 inches.
- To better understand and appreciate the invention, refer to the following detailed description in connection with the accompanying drawings:
- FIG. 1 is a partial cross-sectional front view of a slush molding apparatus constructed according to the present invention and showing two tubs in an upright position under the mold with a first of the two tubs disposed in the central unsealed position;
- FIG. 2 is a partial cross-sectional front view of the slush molding apparatus of FIG. 1 showing the apparatus supporting the tubs in an upright and sealed position under the mold with the first tub disposed in a central sealed position;
- FIG. 3 is a partial cross-sectional front view of the slush molding apparatus of FIG. 1 showing the apparatus supporting the tubs in the inverted and sealed position over the mold with the first tub casting material into the mold from the central sealed cast position;
- FIG. 4 is partial cross-sectional front view of the slush molding apparatus of FIG. 1 showing two tubs in an upright position under the mold with a second of the two tubs disposed in the central unsealed position;
- FIG. 5 is a partial cross-sectional front view of the slush molding apparatus of FIG. 4 showing the apparatus supporting the tubs in the inverted and sealed position over the mold with the second tub casting material into the mold from the central sealed cast position;
- FIG. 6 is a partial cross-sectional front view of an alternative slush molding apparatus embodiment constructed according to the invention and showing two tubs supported in an upright position;
- FIG. 7 is a top view of a chute of the alternative slush molding apparatus of FIG. 6;
- FIG. 8 is a side view of the chute of FIG. 7; and
- FIG. 9 is a cross-sectional front view of the chute of FIG. 8 taken along line9-9 of FIG. 8 and showing a diverter valve disposed within the chute.
- A first embodiment of an
apparatus 10 for slush molding a thin shell having an outer layer and an inner layer is generally shown at 10 in FIGS. 1-5. A second embodiment of theapparatus 10 is generally indicated at 10′ in FIGS. 6-9. Reference numerals with the designation prime (′) in FIGS. 6-9 indicate alternative configurations of elements that also appear in the first embodiment. Unless indicated otherwise, where a portion of the following description uses a reference numeral to refer to the figures, we intend that portion of the description to apply equally to elements designated by primed numerals in FIGS. 6-9. - The
apparatus 10 comprises a support structure generally indicated at 12 in FIGS. 1-5 and supported for rotation around ahorizontal axis 13. Theapparatus 10 also comprises at least two tubs shown at 14 and 16, respectively, in FIGS. 1-5. Thetubs tub openings respective tubs common tub base 18. Thetubs support structure 12. Eachtub charge materials slush mold cavity 28 in a slush mold that is generally indicated at 29 in FIGS. 1-5. A first one of the twotubs first polymer material 24 and is movable between a first outer position and a central cast position within thesupport structure 12. Thefirst tub 14 is shown in the first outer position in FIGS. 4 and 5 and in the central cast position in FIGS. 1, 2 and 3. In FIG. 1 thefirst tub 14 is shown in a central position on thesupport structure 12 but is not fully in the cast position because it is not sealed against thesupport structure 12. - A
second one 16 of the twotubs second polymer material 26 and is movable between a second outer position and the central cast position within thesupport structure 12. Thesecond tub 16 is shown in the second outer position in FIGS. 1, 2 and 3 and in the central cast position in FIGS. 4 and 5. In FIG. 4 thesecond tub 16 is shown in a central position on thesupport structure 12 but is not fully in the cast position because it is not sealed against thesupport structure 12. - The two
tubs polymer material contents mold cavity 28. Because the first andsecond tubs support structure 12. As shown in FIGS. 1, 2 and 3, when thefirst tub 14 is in the central position and the central cast position thesecond tub 16 is in the second outer position. As shown in FIGS. 4 and 5, when thesecond tub 16 is in the central and central cast positions thefirst tub 14 is in the first outer position. Thetubs support structure 12 around thehorizontal axis 13 to an inverted cast orientation shown in FIGS. 3 and 5 in which the charge materials will dispense from thetubs tub openings - The
support structure 12 is configured to block thetub opening 20 of thefirst tub 14 when thefirst tub 14 is in the first outer position and thesecond tub 16 is in the central cast position as shown in FIGS. 4 and 5. Thesupport structure 12 is also configured to block thetub opening 22 of thesecond tub 16 when thesecond tub 16 is in the second outer position and thefirst tub 14 is in the central cast position as shown in FIGS. 1, 2 and 3. Thesupport structure 12 is so configured to keep thecharge materials tub other tub support structure 12 is also configured to allowcharge materials tub opening tub support structure 12 is configured to unblock thetub opening tub tubs respective charge materials slush mold cavity 28. - Each
tub rectangular rim tub opening tub support structure 12 includes an elongated rectangular sealing plate generally indicated at 34 in FIGS. 1-5. The sealingplate 34 has a central castposition sealing surface 36 disposed in a generally rectangular trough formed into the sealingplate 34. Thesupport structure 12 also includes first and second outer position sealing surfaces 38, 40 disposed on opposite sides of the central castposition sealing surface 36. As with the central castposition sealing surface 36, the first and second outer position sealing surfaces 38, 40 are disposed in respective rectangular troughs formed into the sealingplate 34 of thesupport structure 12. Each of the three troughs has a generally rectangular shape configured to receive therim tubs position sealing surface 36 is disposed around a generallyrectangular aperture 42 formed in the sealingplate 34 to allow the passage of thepolymer materials plate 34 when the tub opening of one of thetubs plate 34. - A hopper, generally indicated at44 in FIGS. 1-5, is supported on the
support structure 12 adjacent the cast position and is connected between thetubs mold cavity 28. Thehopper 44 is defined by anouter wall 46 having the general shape of a hollow trapezoidal prism. Thehopper 44 is disposed between the sealingplate 34 and the mold and is supported on the sealingplate 34. Thehopper 44 has a relatively large generally rectangularupper opening 48 that is attached and sealed to a rectangularouter rim 50 of an open end of themold 29. Thehopper 44 has a relatively small generally rectangularlower opening 52 that is attached and sealed to anupper surface 54 of the sealingplate 34 around the sealingplate aperture 42. - The
apparatus 10 is supported for rotation around thehorizontal axis 13 to allow thetubs support structure 12 and an attachedmold 29 to be inverted to cast thecharge materials tubs mold 29, then to be returned to their original orientations for refilling of thetubs charge materials charge materials - The two
tubs support structure 12 with bothtub openings tubs particulate polymer materials tubs tubs tub base 18 may be supported on a moveable cart that tracks with a guide mechanism. An electromechanical device may shuttle the cart andtub base 18 includingtubs tubs tub base 18 into engagement with the open end of the mold when the cart is positioned below the mold. - The
slush mold apparatus 10′ of the second embodiment comprises at least twotubs 14′, 16′ disposed in fixed positions adjacent one another as shown in FIG. 6. Theapparatus 10′ also includes a diverter valve generally indicated at 58 in FIGS. 6-9. Thediverter valve 58 is connectable between thetubs 14′, 16′ and a mold cavity (not shown). More specifically, thediverter valve 58 is connectable between thelower opening 52′ of thehopper 44′ and thetub openings 20′, 22′. An upper chute opening, shown at 60 in FIGS. 6, 7 and 9, is disposed at an upper end of arectangular chute portion 62 of thediverter valve 58. Theupper chute opening 60 is removably connected to the sealingplate 34′ around therectangular aperture 42′ in the sealingplate 34′. Thechute 62 also includes a lower chute opening shown at 64 in FIGS. 6 and 9. Thelower chute opening 64 is configured to removably connect to thetubs 14′, 16′ by removably attaching to the sealingplate 34′ around the sealingplate aperture 42′. While, in the embodiment of FIG. 6, thechute 62 does not physically contact thetub openings 20′, 22′, thechute 62 andtub openings 20′, 22′ are connected in the sense that they define a common flow path for thecharge materials 24′, 26′ to pass through. - The
diverter valve 58 is configured to alternately open a passage from each of thetubs 14′, 16′ to the mold cavity (not shown) to allow thecharge materials 24′, 26′ from therespective tubs 14′, 16′ to be selectively casted into the mold cavity. In other words, thediverter valve 58 is configured to provide a polymer material flow path out of one of thetubs 14′, 16′ while blocking thepolymer material 24′, 26′ from flowing out of the other of thetubs 14′, 16′. More specifically, thediverter valve 58 is operable to provide a flow path for thefirst polymer material 24′ out of thefirst tub 14′ and through thechute 62 while blocking thesecond polymer material 26′ from flowing out of thesecond tub 16′. Likewise, thediverter valve 58 is operable to provide a flow path for thesecond polymer material 26′ out of thesecond tub 16′ and through thechute 62 while blocking thefirst polymer material 24′ from flowing out of thefirst tub 14′. - To accomplish this, the
diverter valve 58 includes a separator blade shown at 66 in FIGS. 6-9. Theseparator blade 66 is pivotally mounted within thechute 62. Theseparator blade 66 is pivotally movable between a first position and a second position within thechute 62. In the first position, shown in FIG. 6, theseparator blade 66 is positioned to admit the flow of material from thefirst tub 14′ through thechute 62 and to block the flow of polymer material from thesecond tub 16′ through thechute 62. In the second position (not shown) theseparator blade 66 is positioned to admit the flow of material from thesecond tub 16′ through thechute 62 and to block the flow of material from thefirst tub 14′ through thechute 62. Thediverter valve 58 includes first and second gussets shown at 68 in FIG. 9. Thegussets 68 are fixed to respective chute sidewalls 70 and configured to support anouter edge 72 of theseparator blade 66 in its respective first and second positions within thechute 62. - In practice, a thin shell having an outer layer and an inner layer may be formed by first providing a
mold 29 with amold surface 31 configured to complement the desired shape of the shell to be molded. Themold surface 31 is then heated and afirst polymer material 24, preferably in the form of a dry particulate such as powder or microspheres, is cast onto theheated mold surface 31 as shown in FIG. 3. Thefirst polymer material 24 is allowed to melt on theheated mold surface 31 and to form anouter layer 76 on themold surface 31 as shown in FIG. 5. Thislayer 76 is termed the “outer” layer because it will, when installed, be the outer class-A surface of a trim panel, subject to the possible additional application of an outer coating (e.g. paint, clearcoat). Asecond polymer material 26, also preferably in the form of a dry particulate such as powder or microspheres, is cast on theouter layer 76 formed of thefirst polymer material 24 as shown in FIG. 5. Thesecond polymer material 26 is allowed to melt and form an inner layer at least partially, and preferably completely, covering the inner surface of the outer layer 76 (not shown). Sufficient heat is transferred from theheated mold surface 31 through theouter layer 76 to melt the inner layer. Themold surface 31 is then cooled or allowed to cool which allows the inner andouter layers 76 to harden and bond together. Finally, the shell is removed from themold 29. - This method may be implemented using a
slush mold assembly apparatus 10 constructed according to the first embodiment shown in FIGS. 1-5 is employed, thefirst polymer material 24 and thesecond polymer material 26 are cast by first moving thetubs support structure 12 or a position laterally displaced from themold 29 and filling thetubs second polymer materials second polymer materials hopper 44. The trapezoidal prism shape of thehopper 44 helps to guide thematerials respective tubs - The
first tub 14 is then connected to the mold by moving thefirst tub 14 laterally to the central cast position (i.e. parallel to the axis of rotation) on thesupport structure 12 as shown in FIG. 1. Thefirst tub 14 is then moved upward until therim 30 defining itsupper opening 20 is in sealing contact with the central castposition sealing surface 36 on the sealingplate 34 as shown in FIG. 2. Theupper opening 22 of thesecond tub 16 is blocked when thesecond tub 16 is moved upward against the sealingplate 34 along with thefirst tub 14. When thefirst tub 14 is sealed against sealingsurface 36, therim 32 defining theupper opening 22 of thesecond tub 16 seals against the second outerposition sealing surface 40 of the sealingplate 34. The first andsecond tubs mold 29 are then inverted as shown in FIG. 3. When inverted, thefirst tub 14 is positioned over themold 29 allowing thepolymer material 24 within thefirst tub 14 to fall by gravity from thefirst tub 14, through the sealingplate aperture 42 andhopper 44 and onto theheated mold surface 31. Thetubs mold 29 are then righted and thetubs plate 34, respectively. Therims tub openings plate 34. Thetubs first tub 14 out of the central cast position to the first outer position on thesupport structure 12, and thesecond tub 16 into the central cast position as shown in FIG. 4. - The
second tub 16 is then connected to the mold by moving thetubs rim 32 defining the second tub opening 22 is in sealing contact with the central castposition sealing surface 36 of the sealingplate 34 and thefirst tub opening 20 is blocked by sealing therim 30 of thefirst tub 14 against the first outerposition sealing surface 38 of thesupport structure 12. The first andsecond tubs mold 29 are then inverted such that thesecond tub 16 is positioned over themold 29 and thepolymer material 26 within thesecond tub 16 is allowed to fall by gravity from thesecond tub 16, through thehopper 44, and onto the inner surface of the outer layer as shown in FIG. 5. Thetubs mold 29 are then righted and thetubs plate 34, respectively. Therims tub openings plate 34. - In short, the two
tubs support structure 12 for dispensing their respective material contents into amold cavity 28. - The method of the present invention may also be implemented using a slush molding assembly constructed according to the second embodiment of the present invention shown in FIGS. 6-9. To cast the first and
second polymer material 26′ using an assembly of this type, thetubs 14′, 16′ are connected to thelower chute opening 64 of thechute portion 62 of thediverter valve 58 as shown in FIG. 6. As is also shown in FIG. 6, theseparator blade 66 is moved to the first position opening a flow passage from thefirst tub 14′ through thechute 62 and onto themold surface 31′ (not shown) and blocking thesecond tub 16′. Thetubs 14′, 16′,diverter valve 58 and mold are then inverted causing thefirst polymer material 24′ to flow through the flow passage and onto theheated mold surface 31′. The separator blade is then moved to the second position allowing thesecond polymer material 26′ to flow through a flow passage from thesecond tub 16′ through thechute 62 and onto the layer formed by thefirst polymer material 24′. In the second position, the separator blade also blocks the flow of any additional amount of thefirst polymer material 24′ from thefirst tub 14′. - With regards to materials, the first and
second polymer materials second polymer materials second polymer materials second polymer materials second polymer materials - In order to promote more efficient use of material with the two layer shell manufactured with the apparatus and method described herein,
outer layer 76 preferably has an average thickness in a range between and including 0.005 inches to 0.025 inches and more preferably in the range and including 0.010 inches to 0.020 inches and even more preferably in the range between 0.012 inches and 0.018 inches. Furthermore, it should be understood that within the given ranges of thickness identified above, the ranges may be further narrowed by 0.001 inch increments. However, it has been found that as the average thickness of the shell decreases below 0.040 inches, removal from themold surface 31 without permanent deformation of the shell is made more difficult. - While not being bound to a particular theory, a bond is created between the
mold surface 31 and the shell upon casting. This bond must be overcome to remove the shell from themold surface 31. Since the bond results from a surface phenomena (created between themold surface 31 and the outer surface of the shell), the thickness of the shell is believed to be irrelevant as to the strength of the bond. In other words, the strength of the bond remains virtually constant for a given shell material and mold surface regardless of shell thickness. However, shell thickness plays an important role in removal of the shell from the mold surface. As the thickness of the shell increases its tensile load increases and, correspondingly, the load for its elastic limit also increases. Thus, at an average thickness of 0.040 inches a single layer thermoplastic shell has been found to have a sufficient tensile load elastic limit to be removed from theshell mold surface 31 without, or negligible, permanent deformation. On occasion, an average shell thickness may drop to as low as 0.030 inches, but permanent deformation becomes more troublesome. - Given the above, while the inner layer preferably must contribute strength to the outer layer given the preferred thicknesses identified to facilitate shell removal from the
mold surface 31, the invention recognizes that the inner layer need not necessarily contribute to the appearance of the outer layer given the inner layer is applied to the inner or “class B” surface of theouter layer 76 and thus concealed from view by vehicle occupants. - Thus, as a further feature of the invention, preferably the
second polymer material 26 preferably comprises in a first alternative embodiment a polymer material a portion of which comprises a formed article prior to its use as thesecond polymer material 26. - By formed article, it is meant to include polymer material that has, e.g., experienced a prior plastics manufacturing operation, such as slush molding or injection molding, wherein the plastic material has been converted, by heat, or by heat and pressure, into some desired shape, but which has not survived a quality control measure, and has been rejected by the manufacture for commercial release. This would also include materials recovered in manufacture such as trim scrap and faulty parts (a/k/a/regrind or recycle), and materials recovered from discarded post-consumer products (a/k/a/reclaim). Formed article does not include virgin material (i.e., it has not been subjected to use other than required for its original manufacture).
- In a second alternative embodiment the second polymer material may comprise a mixture of two or more different polymer formulations. By different polymer formulations it is meant that the two polymer formulations differ with respect to the polymer, or any additive contained within said polymer formulation. This alternative embodiment therefore may include virgin material. For example, this second alternative embodiment includes a polymer formulation of a first color mixed with a formulation of a second color. This would include, e.g., polymer formulations that cross-over or are commingled between tubs.
- In a third alternative embodiment the second polymer formulation would include a polymer formulation (polymer plus additives) which is more susceptible to ultraviolet degradation than the polymer formulation used for the
first polymer material 24. For example, in this third alternative embodiment, the second polymer formulation would include a formulation that has less UV stabilizer, or is a polymer formulation containing a polymer that itself is less UV stable. In addition, UV stability is conveniently and reliable measured by considering a change in either mechanical properties for a given exposure, and/or a change in average polymer molecular weight, such as the number average or weight average molecular weight. - Because we intend this description to illustrate certain embodiments of the invention rather than to limit the invention, we have used descriptive words rather than limiting words.
- Obviously, it's possible to modify this invention from what the description teaches. Within the scope of the claims, one may practice the invention other than as described.
Claims (35)
1. An apparatus for molding a thin shell having an outer layer and an inner layer, the apparatus comprising:
at least two tubs configured to hold charge materials for delivery to a mold cavity, each tub having a tub opening for dispensing charge materials;
the tubs being simultaneously rotatable around a horizontal axis to an orientation where the charge materials will dispense from the tubs;
the tub openings configured to be alternately blockable to allow the tubs to alternately dispense charge material into the mold cavity.
2. An apparatus for molding a thin shell having an outer layer and an inner layer, the apparatus comprising:
a support structure supported for rotation around a horizontal axis;
at least two tubs supported on the support structure and configured to hold charge materials for delivery to a mold cavity, each tub having a tub opening for dispensing charge materials;
the tubs being rotatable with the support structure around the horizontal axis to an orientation where the charge materials will dispense from the tubs;
the tubs being alternately movable on the support structure to a dispensing position, the support structure configured to unblock the tub opening of each tub in the dispensing position to allow the tubs to alternately dispense charge material into the mold cavity.
3. An apparatus as defined in claim 2 in which the support structure is configured to block the tub openings of tubs not in the dispensing position when a tub is in the dispensing position.
4. An apparatus as defined in claim 3 including two tubs and which:
a first one of the two tubs is movable between a first outer position and the dispensing position;
a second one of the two tubs is movable between a second outer position and the dispensing position;
the support structure is configured to block the tub opening of the first tub in the first outer position;
the support structure is configured to block the tub opening of the second tub in the second outer position; and
the support structure is configured to allow charge materials to flow from the tub opening of a tub in the dispensing position.
5. An apparatus as defined in claim 4 in which the first and second tubs are connected and move together on the support structure.
6. An apparatus as defined in claim 4 in which the mold cavity is removably supportable on the support structure to rotate with the support structure.
7. An apparatus as defined in claim 4 in which a hopper is supported on the support structure adjacent the dispensing position and is connected between the tubs and the mold cavity.
8. An apparatus as defined in claim 4 in which the two tubs may be moved together into a position with both tub openings unblocked.
9. An apparatus for molding a thin shell having an outer layer and an inner layer, the apparatus comprising:
at least two tubs configured to hold charge materials for delivery to a mold cavity; and
a diverter valve connectable between the tubs and the mold cavity, the diverter valve configured to alternately open a passage from each of the tubs to the mold cavity to allow charge materials from the respective tubs to be selectively dispensed into the mold cavity.
10. An apparatus as defined in claim 9 in which the diverter valve includes a separator blade pivotally mounted within a chute that extends between the mold cavity and the two tubs;
the separator blade pivotally movable between a first position and a second position within the chute, in the first position the separator blade positioned to admit the flow of material from the first tub through the chute and to block the flow of material from the second tub through the chute; in the second position the separator blade positioned to admit the flow of material from the second tub through the chute and to block the flow of material from the first tub through the chute.
11. An apparatus as defined in claim 10 in which the chute includes a mold opening configured to removably connect to a mold comprising the mold cavity and a tub opening configured to removably connect to the tubs.
12. An apparatus as defined in claim 10 in which the diverter valve includes first and second gussets fixed to respective chute side walls and configured to support an outer edge of the separator blade in its respective first and second positions within the chute.
13. An apparatus as defined in claim 9 in which the tubs, diverter valve and mold cavity are supported for rotation around a horizontal axis.
14. An apparatus as defined in claim 11 in which a hopper is connected between the chute and the mold cavity and is removably attachable to the mold opening of the chute and to an outer edge of the mold, the hopper configured to guide material from the tubs into the mold.
15. A method for molding a thin shell having an outer layer and an inner layer, the method including the steps of:
providing a mold having a mold surface configured to complement the desired shape of the shell to be molded;
heating the mold surface;
providing a first polymer material in a first tub having a first tub opening;
providing a second polymer material in a second tub having a second tub opening;
blocking the second tub opening;
tipping the tubs and the mold until at least a portion of the first polymer material dispenses from the first tub onto the mold surface to form an outer layer, righting the tubs and the mold;
opening the second tub opening;
blocking the first tub opening;
tipping the tubs and the mold until at least a portion of the second polymer material dispenses from the second tub onto at least a portion of the outer layer to form an inner layer;
cooling the mold surface;
allowing the inner and outer layers to bond together; and
removing the shell from the mold.
16. A method as set forth in claim 15 in which the steps of dispensing a first polymer material and dispensing a second polymer material each include the step of dispensing a polymer particulate.
17. A method as set forth in claim 16 in which the first or second polymer particulate comprises powder.
18. A method as set forth in claim 16 in which the first or second polymer particulate comprises microspheres.
19. A method as set forth in claim 15 in which the step of dispensing a first polymer material includes the step of dispensing a first polymer material including a material for imparting a predetermined color to the shell.
20. A method as set forth in claim 19 in which the step of dispensing a first polymer material including a material for imparting a predetermined color to the shell includes a pigment.
21. A method as set forth in claim 15 in which:
the step of providing a first polymer material in a first tub includes the steps of moving the first tub to a filling position on a support structure and filling the first tub with the first polymer material; and
the step of providing a second polymer material in a second tub includes the steps of moving the second tub to a filling position and filling the second tub with the second polymer material.
22. A method as set forth in claim 21 including the additional step of moving the two tubs together to meet at the filling position before the steps of providing the first and second polymer materials in the respective first and second tubs.
23. A method as set forth in claim 15 in which the steps of providing a first polymer material in a first tub and providing a second polymer material in a second tub includes the steps of:
connecting the tubs to a diverter valve, the diverter valve configured to provide a polymer material flow path from one of the tubs while blocking polymer material from flowing from the other of the tubs;
operating the diverter valve to provide a flow path for the first polymer material from the first tub while blocking the flow of the second polymer material from the second tub; and
operating the diverter valve to provide a flow path for the second polymer material out of the second tub while blocking the flow of the first polymer material from the first tub.
24. A method as set forth in claim 23 in which:
the step of connecting the tubs to a diverter valve is preceded by an additional step of providing a diverter valve comprising a separator blade pivotally mounted within a chute, the chute configured to releasably connect a mold cavity to the two tubs and to provide a polymer material flow path from the tubs to the mold cavity, the separator blade being pivotally movable between a first position and a second position within the chute, the separator blade in the first position admitting the flow of material from the first tub through the chute and blocking the flow of material from the second tub through the chute, the separator blade in the second position admitting the flow of material from the second tub through the chute and blocking the flow of material from the first tub through the chute;
the step of operating the diverter valve to provide a flow path for the first polymer material includes the step of pivoting the separator blade to the first position; and
the step of providing a layer of the second polymer material on the layer of the first polymer material by operating the diverter valve includes the step of pivoting the separator blade to the second position.
25. A thin shell for an automotive trim panel, said shell having an outer layer and an inner layer, the shell comprising:
an outer layer comprising a first polymer material;
an inner layer comprising a second polymer material;
the second polymer material further comprising a polymer material at least a portion of which comprises a formed article prior to its use as the second polymer material; and
the inner layer at least partially covering the inner surface of the outer layer and concealed from view by vehicle occupants.
26. The thin shell for an automotive trim panel of claim 25 , wherein said formed article comprises a polymer material that has been previously been converted by heat into a desired shape.
27. The thin shell of claim for an automotive trim panel of claim 25 wherein said formed article comprises polymer regrind material, recycled polymer material, or reclaimed polymer material.
28. A thin shell for an automotive trim panel, said shell having an outer layer and an inner layer, the shell comprising:
an outer layer comprising a first polymer material;
an inner layer comprising a second polymer material;
the second polymer material further comprising a mixture of two or more different polymer formulations; and
the inner layer at least partially covering the inner surface of the outer layer and concealed from view by vehicle occupants.
29. The inner shell for an automotive trim panel of claim 28 wherein said polymer formulations comprise a polymer combined with one or more additives, and said formulations differ with respect to the polymer component of said polymer formulations.
30. The inner shell for an automotive trim panel of claim 28 wherein said polymer formulations comprise a polymer combined with one or more additives, and said formulations differ with respect to the additive component in said polymer formulations.
31. The inner shell for an automotive trim panel of claim 28 wherein said polymer formulations comprise a polymer combined with one or more additives, and said formulations differ with respect to the additive component in said polymer formulations, and said additive comprises a pigment.
32. A thin shell for an automotive trim panel, said shell having an outer layer and an inner layer, the shell comprising:
an outer layer comprising a first polymer material;
an inner layer comprising a second polymer material;
the second polymer material further comprising a polymer formulation which is more susceptible to ultraviolet degradation than the first polymer material; and
the inner layer at least partially covering the inner surface of the outer layer and concealed from view by vehicle occupants.
33. The thin shell for an automotive trim panel of claim 32 , wherein said polymer formulation which is more susceptible to ultraviolet degradation than the first polymer material comprises a polymer formulation that has less UV stabilizer than the first polymer material of the outer layer.
34. The thin shell for an automotive trim panel of claim 32 , wherein said polymer formulation which is more susceptible to ultraviolet degradation than the first polymer material comprises a polymer formulation that contains a second polymer material that is more unstable to UV light than said first polymer material.
35. A thin shell for an automotive trim panel, said shell having an outer layer and an inner layer, the shell comprising:
an outer layer comprising a first polymer material;
an inner layer comprising a second polymer material;
the second polymer material comprising a composition at least partially different than the first polymer material;
the outer layer comprising an average thickness in a range between and including 0.005 inches to 0.025 inches; and
the inner layer at least partially covering the inner surface of the outer layer and concealed from view by vehicle occupants.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US10/797,247 US20040170788A1 (en) | 2000-03-20 | 2004-03-10 | Double-cast slush molding method and apparatus |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/528,396 US6409493B1 (en) | 2000-03-20 | 2000-03-20 | Double-cast slush molding method and apparatus |
US10/138,630 US6709619B2 (en) | 2000-03-20 | 2002-05-03 | Double-cast slush molding method |
US10/797,247 US20040170788A1 (en) | 2000-03-20 | 2004-03-10 | Double-cast slush molding method and apparatus |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US10/138,630 Division US6709619B2 (en) | 2000-03-20 | 2002-05-03 | Double-cast slush molding method |
Publications (1)
Publication Number | Publication Date |
---|---|
US20040170788A1 true US20040170788A1 (en) | 2004-09-02 |
Family
ID=24105522
Family Applications (3)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/528,396 Expired - Lifetime US6409493B1 (en) | 2000-03-20 | 2000-03-20 | Double-cast slush molding method and apparatus |
US10/138,630 Expired - Fee Related US6709619B2 (en) | 2000-03-20 | 2002-05-03 | Double-cast slush molding method |
US10/797,247 Abandoned US20040170788A1 (en) | 2000-03-20 | 2004-03-10 | Double-cast slush molding method and apparatus |
Family Applications Before (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US09/528,396 Expired - Lifetime US6409493B1 (en) | 2000-03-20 | 2000-03-20 | Double-cast slush molding method and apparatus |
US10/138,630 Expired - Fee Related US6709619B2 (en) | 2000-03-20 | 2002-05-03 | Double-cast slush molding method |
Country Status (10)
Country | Link |
---|---|
US (3) | US6409493B1 (en) |
EP (2) | EP1825983B1 (en) |
JP (1) | JP2004500263A (en) |
KR (1) | KR100798964B1 (en) |
AT (2) | ATE362425T1 (en) |
AU (1) | AU2001245847A1 (en) |
CA (1) | CA2403464C (en) |
DE (1) | DE60128456T2 (en) |
MX (1) | MXPA02009151A (en) |
WO (1) | WO2001070476A2 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20110177344A1 (en) * | 2007-08-10 | 2011-07-21 | Bayer Materialscience Llc | Thermoplastic polyurethane copolymer molding compositions |
Families Citing this family (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US6887065B2 (en) * | 2002-06-06 | 2005-05-03 | Intertec Systems | Polymeric multiform membrane molding |
DE112007003103T5 (en) | 2006-12-20 | 2009-12-17 | Visteon Global Technologies Inc., Van Buren | Compositions for rotational sintering in a two-shot process |
DE102008003153A1 (en) * | 2008-01-03 | 2009-07-09 | Volkswagen Ag | Molded body for interior fitting such as instrument panel of a motor vehicle, comprises a carrier part and a film, which is connected with the carrier part, forms a surface visible for the user and comprises a first- and second layer |
RU2010147566A (en) * | 2008-04-25 | 2012-05-27 | ХЕНКЕЛЬ АГ энд Ко. КГаА (DE) | PASSIVATING SUBSTANCES BASED ON TREVALENT CHROME FOR THE PROCESSING OF ZINC STEEL |
US20090277380A1 (en) * | 2008-05-09 | 2009-11-12 | Schmidt David A | Method and apparatus to coat eps foam cored mouldings |
US8129015B2 (en) * | 2009-05-14 | 2012-03-06 | International Automotive Components North America, Inc. | Modified moldable urethane with tunable haptics |
US20110028625A1 (en) * | 2009-08-03 | 2011-02-03 | International Automotive Components Group North America, Inc. | Low voc and fog, low temperature pvc for seamless air bag doors |
AU2010346962B2 (en) | 2010-02-23 | 2014-01-09 | Grupo Rotoplas, S.A. De C.V. | Rotational molding method and apparatus |
US9475118B2 (en) | 2012-05-01 | 2016-10-25 | United Technologies Corporation | Metal powder casting |
Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4546022A (en) * | 1981-08-19 | 1985-10-08 | Ciro Madonia | Composite molding system |
US4692837A (en) * | 1985-11-13 | 1987-09-08 | Hoechst Aktiengesellschaft | Coextruded, biaxially oriented, multi-layer and capacitor made therefrom |
US5037680A (en) * | 1989-07-10 | 1991-08-06 | Decoma International Inc. | Exterior automotive component with pigmented substrate and clear coating |
US5344183A (en) * | 1993-05-17 | 1994-09-06 | Davidson Textron Inc. | Multi-layer air bag cover with filled reinforced vinyl |
US6013210A (en) * | 1997-04-18 | 2000-01-11 | Magna Interior Systems Inc. | Process for making decorative automotive interior trim articles with cast integral light stable covering |
US6340531B1 (en) * | 1994-07-20 | 2002-01-22 | Kojima Press Industry Co., Ltd. | Interior trim for automobile |
US6572956B1 (en) * | 1999-04-08 | 2003-06-03 | General Electric Company | Weatherable multilayer resinous articles and method for their preparation |
Family Cites Families (33)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1383602A (en) * | 1972-10-12 | 1974-02-12 | Ici Ltd | Moulded articles |
US4019535A (en) * | 1973-05-31 | 1977-04-26 | Globe-Union Inc. | Material selector system |
US4217325A (en) | 1977-04-21 | 1980-08-12 | Mccord Corporation | Method using modular slush molding machine |
US4331626A (en) | 1977-09-12 | 1982-05-25 | Mccord Corporation | Method useful for rotational molding articles where successful runs are of different colors |
GB2050921B (en) * | 1979-06-15 | 1982-12-15 | Sybron Corp | Apparatus for roto-moulding |
US4389177A (en) | 1979-07-12 | 1983-06-21 | Mccord Corporation | Modular slush molding machine |
JPS59156710A (en) * | 1983-02-25 | 1984-09-06 | Inoue Mtp Co Ltd | Method and die for molding multicolored facing material |
US4722678A (en) | 1983-06-03 | 1988-02-02 | Ex-Cell-O Corporation | Rotational mold with valved charge box |
US4562025A (en) | 1984-05-25 | 1985-12-31 | Ex-Cell-O Corporation | Mold method and apparatus for multi-color plastic shells |
JPS61220812A (en) * | 1985-03-27 | 1986-10-01 | Mitsuboshi Belting Ltd | Method and device for manufacturing composite skin of synthetic resin |
JPS61246021A (en) | 1985-04-24 | 1986-11-01 | Tokai Kasei Kogyo Kk | Preparation of surface forming materials of partially-varied quality |
US4755333A (en) | 1985-07-01 | 1988-07-05 | Ex-Cell-O Corporation | Mold method and apparatus for plastic shells |
DE3674487D1 (en) * | 1985-07-01 | 1990-10-31 | Davidson Textron Inc | METHOD AND DEVICE FOR SHAPING PLASTIC SHELLS. |
JPS6225515A (en) * | 1985-07-26 | 1987-02-03 | Hitachi Denshi Ltd | Analog-digital converter |
JPS62256616A (en) * | 1986-04-30 | 1987-11-09 | Mitsuboshi Belting Ltd | Method and device for molding composite skin material |
US4740337A (en) | 1986-05-27 | 1988-04-26 | Sheller-Globe Corporation | Powder slush process for making plastic articles |
JPH0686177B2 (en) | 1986-09-29 | 1994-11-02 | 河西工業株式会社 | Interior parts for automobiles |
DE3913157A1 (en) * | 1988-05-14 | 1990-01-04 | Guenther Troester Fa | METHOD FOR THE PRODUCTION OF ELASTOMER SKINS AS A CLADDING MATERIAL FOR PLASTIC MOLDED BODIES, e.g. MOTOR VEHICLE FITTING PANELS |
US4938906A (en) | 1988-11-04 | 1990-07-03 | Davidson Textron Inc. | Process for molding multi-colored plastic shells |
US4894004A (en) * | 1988-11-04 | 1990-01-16 | Davidson Textron Inc. | Apparatus for molding multi-colored plastic shells |
US5093066A (en) * | 1989-10-13 | 1992-03-03 | Davidson Textron Inc. | Method for molding multicolor thin wall plastic shell |
AT393990B (en) * | 1990-04-06 | 1992-01-10 | Hetzmannseder Bonum Werk | Mixing apparatus with an intake head for at least two pourable materials |
US5395578A (en) * | 1990-09-17 | 1995-03-07 | Industrie Ilpea S.P.A. | Method for slush molding articles, of two or more colors from thermoplastic, thermosetting or elastomeric resins in powder form |
US5316715A (en) * | 1992-05-08 | 1994-05-31 | Davidson Textron Inc. | Method and apparatus for producing multi-color shells utilizing an indexing divider mold |
JPH0752175A (en) * | 1993-08-20 | 1995-02-28 | Sumitomo Chem Co Ltd | Recycling method for skin material made of vinyl chloride resin |
US5580501A (en) | 1994-11-07 | 1996-12-03 | Gallagher; Michael J. | Method of manufacturing an interior trim panel using polyurethane powder |
DE69528625T2 (en) * | 1994-11-10 | 2003-06-26 | Sumitomo Chemical Co | Multi-layer molded parts and process for producing the same |
JPH08267476A (en) * | 1995-04-03 | 1996-10-15 | Nishikawa Kasei Co Ltd | Resin skin material, manufacture thereof and door trim for vehicle using the resin skin material |
JPH1071624A (en) * | 1996-08-29 | 1998-03-17 | Mitsuboshi Belting Ltd | Multilayered powder slush molding method and apparatus therefor |
US5686147A (en) * | 1996-11-18 | 1997-11-11 | The Goodyear Tire & Rubber Company | Plastisol composition |
JPH11227542A (en) * | 1998-02-18 | 1999-08-24 | Tokai Chem Ind Ltd | Skin for vehicular interior trim and airbag door structure |
JPH11300909A (en) * | 1998-04-15 | 1999-11-02 | Nakagawa Chem:Kk | Flame retardant resin molded product and method for molding flame retardant resin molded product |
GB9818316D0 (en) * | 1998-08-21 | 1998-10-14 | Borealis As | Polymer |
-
2000
- 2000-03-20 US US09/528,396 patent/US6409493B1/en not_active Expired - Lifetime
-
2001
- 2001-03-19 JP JP2001568711A patent/JP2004500263A/en active Pending
- 2001-03-19 AU AU2001245847A patent/AU2001245847A1/en not_active Abandoned
- 2001-03-19 DE DE60128456T patent/DE60128456T2/en not_active Expired - Lifetime
- 2001-03-19 EP EP07008919A patent/EP1825983B1/en not_active Expired - Lifetime
- 2001-03-19 EP EP01918810A patent/EP1265735B1/en not_active Expired - Lifetime
- 2001-03-19 AT AT01918810T patent/ATE362425T1/en not_active IP Right Cessation
- 2001-03-19 MX MXPA02009151A patent/MXPA02009151A/en active IP Right Grant
- 2001-03-19 KR KR1020027012567A patent/KR100798964B1/en not_active IP Right Cessation
- 2001-03-19 WO PCT/US2001/008679 patent/WO2001070476A2/en active IP Right Grant
- 2001-03-19 AT AT07008919T patent/ATE548174T1/en active
- 2001-03-19 CA CA002403464A patent/CA2403464C/en not_active Expired - Fee Related
-
2002
- 2002-05-03 US US10/138,630 patent/US6709619B2/en not_active Expired - Fee Related
-
2004
- 2004-03-10 US US10/797,247 patent/US20040170788A1/en not_active Abandoned
Patent Citations (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4546022A (en) * | 1981-08-19 | 1985-10-08 | Ciro Madonia | Composite molding system |
US4692837A (en) * | 1985-11-13 | 1987-09-08 | Hoechst Aktiengesellschaft | Coextruded, biaxially oriented, multi-layer and capacitor made therefrom |
US5037680A (en) * | 1989-07-10 | 1991-08-06 | Decoma International Inc. | Exterior automotive component with pigmented substrate and clear coating |
US5344183A (en) * | 1993-05-17 | 1994-09-06 | Davidson Textron Inc. | Multi-layer air bag cover with filled reinforced vinyl |
US6340531B1 (en) * | 1994-07-20 | 2002-01-22 | Kojima Press Industry Co., Ltd. | Interior trim for automobile |
US6013210A (en) * | 1997-04-18 | 2000-01-11 | Magna Interior Systems Inc. | Process for making decorative automotive interior trim articles with cast integral light stable covering |
US6572956B1 (en) * | 1999-04-08 | 2003-06-03 | General Electric Company | Weatherable multilayer resinous articles and method for their preparation |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20110177344A1 (en) * | 2007-08-10 | 2011-07-21 | Bayer Materialscience Llc | Thermoplastic polyurethane copolymer molding compositions |
US9708438B2 (en) | 2007-08-10 | 2017-07-18 | Covestro Llc | Thermoplastic polyurethane copolymer molding compositions |
Also Published As
Publication number | Publication date |
---|---|
WO2001070476A2 (en) | 2001-09-27 |
ATE548174T1 (en) | 2012-03-15 |
ATE362425T1 (en) | 2007-06-15 |
KR100798964B1 (en) | 2008-01-28 |
WO2001070476A3 (en) | 2002-04-25 |
EP1265735B1 (en) | 2007-05-16 |
CA2403464C (en) | 2009-01-20 |
US6709619B2 (en) | 2004-03-23 |
KR20030007475A (en) | 2003-01-23 |
EP1825983B1 (en) | 2012-03-07 |
JP2004500263A (en) | 2004-01-08 |
DE60128456D1 (en) | 2007-06-28 |
MXPA02009151A (en) | 2003-03-12 |
US20030109601A1 (en) | 2003-06-12 |
EP1265735A2 (en) | 2002-12-18 |
DE60128456T2 (en) | 2008-01-17 |
EP1825983A3 (en) | 2007-11-28 |
EP1825983A2 (en) | 2007-08-29 |
CA2403464A1 (en) | 2001-09-27 |
US6409493B1 (en) | 2002-06-25 |
AU2001245847A1 (en) | 2001-10-03 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
EP1053090B1 (en) | Decorative automotive interior trim articles with cast integral light stable covering containing an invisible tear seam and process for making the same | |
US6958190B2 (en) | Decorative automotive interior trim articles with cast integral light stable covering and process for making the same | |
US6409493B1 (en) | Double-cast slush molding method and apparatus | |
JP3814032B2 (en) | Molding | |
CA1260662A (en) | Mold method and split mold apparatus for multi-color plastic shells | |
US20230356444A1 (en) | Vented Mold | |
DE4030478A1 (en) | Mfg. mouldings and objects for prodn. of vehicle inner linings, etc. | |
CA2215253A1 (en) | Foamed rotationally molded articles | |
US6352659B1 (en) | Vented mold and method for producing a molded article | |
US20040007798A1 (en) | Polymer blends for tip molding process and method of forming a plastic part | |
JPH0471692B2 (en) | ||
JP2001018278A (en) | Production of regenerated synthetic resin molded article | |
JPH02147218A (en) | Manufacture of composite foam | |
JPH02277610A (en) | Molding method of skin material | |
MXPA99011442A (en) | Decorative automotive interior trim articles with cast integral light stable covering containing an invisible tear seam and process for making the same |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
AS | Assignment |
Owner name: VISTEON GLOBAL TECHNOLOGIES, INC., MICHIGAN Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:COLLINS & AIKMAN PRODUCTS CO.;REEL/FRAME:022990/0992 Effective date: 20090723 |
|
STCB | Information on status: application discontinuation |
Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION |