WO1991007289A1 - Methode de fabrication de composants revetus de plastique - Google Patents

Methode de fabrication de composants revetus de plastique Download PDF

Info

Publication number
WO1991007289A1
WO1991007289A1 PCT/US1990/006624 US9006624W WO9107289A1 WO 1991007289 A1 WO1991007289 A1 WO 1991007289A1 US 9006624 W US9006624 W US 9006624W WO 9107289 A1 WO9107289 A1 WO 9107289A1
Authority
WO
WIPO (PCT)
Prior art keywords
fascia
base
wheel
rim
molded
Prior art date
Application number
PCT/US1990/006624
Other languages
English (en)
Inventor
Kenneth L. Todd
Original Assignee
Masco Industries, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Masco Industries, Inc. filed Critical Masco Industries, Inc.
Priority to KR1019910700724A priority Critical patent/KR920700890A/ko
Priority to JP3500566A priority patent/JPH0628878B2/ja
Publication of WO1991007289A1 publication Critical patent/WO1991007289A1/fr

Links

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
    • B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
    • B29C63/26—Lining or sheathing of internal surfaces
    • B29C63/34—Lining or sheathing of internal surfaces using tubular layers or sheathings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B5/00—Wheels, spokes, disc bodies, rims, hubs, wholly or predominantly made of non-metallic material
    • B60B5/02—Wheels, spokes, disc bodies, rims, hubs, wholly or predominantly made of non-metallic material made of synthetic material
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1671—Making multilayered or multicoloured articles with an insert
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
    • B60B7/00—Wheel cover discs, rings, or the like, for ornamenting, protecting, venting, or obscuring, wholly or in part, the wheel body, rim, hub, or tyre sidewall, e.g. wheel cover discs, wheel cover discs with cooling fins
    • 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
    • B29L2031/32—Wheels, pinions, pulleys, castors or rollers, Rims

Definitions

  • This invention relates a method of manufacturing plastic components wherein the plastic overlay coat is mechanically locked over a thermoplastic polymer resin base material and, in particular, to a method of applying a plastic fascia through a low-pressure injection molding process to a polystyrene base which has been molded to the desired configuration of the component.
  • plastics With the increased emphasis on the reduction of vehicle weight for improved performance and fuel savings more vehicle components are being manufactured of lightweight plastics. Additionally, the properties of plastics lends itself in molding ornamental and performance components of motor vehicles. Examples of components which have in the past been molded from plastics include wheel covers, vehicle dams and spoilers, dashboards, etc. However, the pliable nature of thin plastic components requires that a support intrastructure be provided usually by adding metal support structure. Although the ornamental properties of the plastic component are retained, the weight and cost reduction advantages are negated.
  • the present invention overcomes the disadvantages of the prior art by providing components which include a polystyrene base molded in the desired configuration and a thermoplastic fascia coat molded over the base and mechanically locked thereto to prevent separation.
  • the process of the present invention can be utilized to manufacture various vehicle components including ornamental wheels, air dams, spoilers, dashboards and instrument panels as well as various components for the marine industry.
  • the components generally comprise a polystyrene base which is molded into the general configuration of the component. In the case of the vehicle wheel, the polystyrene base is molded against the metal rim. Applied to the molded base is a plastic coating which assumes the configuration of the base. The coating is applied in such a manner as to "mechanically" lock the thermoplastic fascia to the base. As a result, no adhesive is required although the overlay is secured to the base which provides rigidness to the component.
  • the general configuration of the component is first formed by molding a thermoplastic polymer resin in accordance with the final specifications of the product.
  • a thermoplastic polymer resin is a polyphenylene oxide polystyrene developed by G.E. Plastics and marketed under the trademark GECET ®.
  • GECET resin is a high performance expandable foam bead material capable of withstanding high temperatures. During the molding process, the resin will expand to fill the mold.
  • thermoplastic fascia is applied through a low-pressure injection molding process in order to prevent damage to the base material.
  • the thermoplastic fascia is allowed to flow around the base to form a mechanical lock eliminating the need for adhesives.
  • the thermoplastic material flows around the edges of the vent openings engaging the underlying wheel rim to secure the overlay to the rim.
  • FIGURE 1 is a perspective view of a vehicle wheel manufactured using the method of manufacturing of the present invention
  • FIGURE 2 is a perspective view partially in cross-section of the vehicle wheel manufactured using the process of the present invention
  • FIGURE 3 is a flow diagram of the manufacturing process of the present invention.
  • FIGURE 4a is a partial cross-sectional view of the base formation of the manufacturing process of the present invention.
  • FIGURE 4b is a partial cross-sectional view of the fascia molding of the manufacturing process of the present invention.
  • FIG. 1 there is shown a vehicle wheel 10 constructed using the method of manufacture described and defined herein.
  • the method of the present invention will be described in conjunction with a vehicle wheel 10 although it is to be understood that the method may be used to manufacture various components including air dams, spoilers, dashboards, etc.
  • Description of the vehicle wheel 10 will provide a clear understanding of the composition of related vehicle components.
  • the wheel 10 preferably includes a drop center steel rim 12 with a central steel disc 14 provided by a manufacturer and adapted to receive a tire.
  • the central disc 14 is provided with a plurality of bolt holes 16 and a wheel spindle-aperture 18 to facilitate removable attachment of the wheel 10 to a wheel hub and its associated brake assembly.
  • the central disc 14 also includes a plurality of circumferentially spaced vent openings 20.
  • the steel wheel comprising the rim 12 and disc 14 is constructed from a functional standpoint to provide the necessary strength and ventilation.
  • an ornamental cover 22 formed by the process described herein is attached to the rim 12 and disc 14.
  • the ornamental cover 22 generally comprises a base material 24 molded into the desired configuration and a decorative fascia 26 molded over the base material 24 as will be subsequently described.
  • the base 24 is formed from a thermoplastic polymer resin which has a high heat resistance to withstand the heat associated with such wheels 10 and their brakes.
  • a resin is a polyphenylene oxide polystyrene marketed under the product name GECET ® Resin by G.E. Plasti.cs of Pi.ttsfi.eld,
  • the resin is provided in solid beads 0.01 to
  • the resin is a high performance expandable foam bead material with high heat resistance capable of use with temperatures up to
  • thermoplastic fascia 26 is molded over the foam core 24 such that a mechanical lock is formed thereby eliminating the need for adhesives.
  • the fascia 26 and base 24 are molded such that openings
  • the mechanical lock of the fascia 26 around the base 24 and to the rim 12 is formed through the vent openings 20 by molding the thermoplastic around the edges of the openings 20 as will be subsequently described.
  • a flanged lip 32 is formed to secure the fascia 26 to the steel wheel.
  • the lip 32 may also be formed around the bolt holes 16.
  • no adhesive is required.
  • the peripheral edge 34 of the fascia 26 extends to the edge of the wheel. This same securement principal can be used in other components which have spaced openings such as dashboards or instrument panels. In components which do not include openings, the fascia material may be extended completely around the base material 24 to completely enclose the material.
  • a steel wheel 12 is loaded 100 into a tool as half of the mold to which the ornamental cover 22 will be applied.
  • An injection mold 40 is mated with the wheel 12 between which is molded 102 the expandable polystyrene structural base 24.
  • the steel wheel 12 with the integral foam base 24 is transferred to a second station whereat the thermoplastic fascia 26 is applied through a low-pressure injection molding process 104.
  • Low-pressure injection molding 104 is needed to prevent destruction of the base 24 during molding while allowing the thermoplastic material to fill the mold voids including forming the mechanical lock 32 through the vent openings 20.
  • a backing mold 42 is inserted through the back side of the wheel 12 while an injection mold 44 is mated to the front of the wheel 12.
  • the cooperation of the two mold portions 42 and 44 with the wheel 12 forms the ornamental fascia 26 over the base 24 as well as the mechanical locks 32 to the steel wheel itself.
  • the present invention provides an ornamental vehicle wheel which has the ornamental cover attached in such a manner so as to eliminate the retention failure found in conventional wheel covers.
  • the process by which the components are manufactured offers flexibility in styling while maintaining manufacturing costs.
  • the configuration of the plastic cover can be conveniently altered by changing the configuration of the structural core.
  • vehicle components such as spoilers and ground effect components and marine components because of the inherent buoyancy of the materials which make up such parts.
  • alternative structural foam products such as closed cell fiberboards can be utilized to form the base as well as alternate molding methods to form the overlay.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

Méthode de fabrication de composants tels que des roues de véhicule (10) comprenant une base de polystyrène (28) moulée selon la configuration générale de la face ornamentale (22) et un revêtement plastique (26) moulé sur la base et fixé mécaniquement à celle-ci afin d'éviter la séparation. Le recouvrement plastique (26) est moulé sur la base (24) à l'aide d'un procédé de moulage par injection sous basse pression de façon à maintenir l'intégrité de la base moulée (24). Le revêtement plastique (26) passe autour des parties de la base (24) de manière à assurer une fixation sûre entre la base (24) et le recouvrement (26). La méthode peut être employée pour la fabrication de divers composants d'automobile comprenant des disques enjoliveurs, des béquets avant et arrière.
PCT/US1990/006624 1989-11-13 1990-11-13 Methode de fabrication de composants revetus de plastique WO1991007289A1 (fr)

Priority Applications (2)

Application Number Priority Date Filing Date Title
KR1019910700724A KR920700890A (ko) 1989-11-13 1990-11-13 플라스틱 피복된 부품들을 제조하는 방법
JP3500566A JPH0628878B2 (ja) 1989-11-13 1990-11-13 プラスチック被覆部品の製造方法

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US43415589A 1989-11-13 1989-11-13
US434,155 1989-11-13

Publications (1)

Publication Number Publication Date
WO1991007289A1 true WO1991007289A1 (fr) 1991-05-30

Family

ID=23723043

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1990/006624 WO1991007289A1 (fr) 1989-11-13 1990-11-13 Methode de fabrication de composants revetus de plastique

Country Status (5)

Country Link
EP (1) EP0453553A4 (fr)
JP (1) JPH0628878B2 (fr)
KR (1) KR920700890A (fr)
CA (1) CA2044624A1 (fr)
WO (1) WO1991007289A1 (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2678366A1 (fr) * 1991-06-27 1992-12-31 France Etat Armement Dispositif de camouflage multi-spectral d'un galet d'un train de roulement d'un vehicule.
EP0648661A1 (fr) * 1993-10-15 1995-04-19 GERSTEEN exerçant ses activités sous la dénomination ISODELTA Volant de direction pour véhicules automobiles, pièce de montage et colonne de direction adaptées à coopérer avec ce volant, et procédé pour la fabrication de celui-ci
WO1995025019A1 (fr) * 1994-03-17 1995-09-21 Hayes Wheels International, Inc. Roue de vehicule
US5597213A (en) * 1995-06-06 1997-01-28 Lacks Industries, Inc. Wheel and overlay assembly
US5779951A (en) * 1996-05-16 1998-07-14 Hayes Lemmerz International, Inc. Method of forming a vehicle wheel having injection molded annular filler ring in wheel cavity
FR2836865A1 (fr) * 2002-03-11 2003-09-12 Michelin Soc Tech Roue avec jante composite realisee par procede rtm

Citations (30)

* Cited by examiner, † Cited by third party
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US2266432A (en) * 1939-02-28 1941-12-16 Whitchall Patents Corp Method of die casting heads on pins
US2977151A (en) * 1956-06-06 1961-03-28 Jr Frank W Ford Wheel flange protectors
US3062254A (en) * 1959-10-20 1962-11-06 Keefe Arthur Molded wheel having internal reinforcing
US3356421A (en) * 1966-07-28 1967-12-05 Kelsey Hayes Co Wheel and wheel cover assembly
US3517968A (en) * 1968-10-09 1970-06-30 Motor Wheel Corp Wheel rim trim ring
US3567285A (en) * 1969-02-10 1971-03-02 Sheller Globe Corp Simulated magnesium bicycle wheel and method
US3669501A (en) * 1970-03-03 1972-06-13 Motor Wheel Corp Vehicle wheel construction
US3756658A (en) * 1969-09-15 1973-09-04 Motor Wheel Corp Composite styled wheel construction
US3762677A (en) * 1971-10-14 1973-10-02 Motor Wheel Corp Molding apparatus
US3794529A (en) * 1971-12-15 1974-02-26 Goodyear Tire & Rubber Method of making a metal laminate
US3815200A (en) * 1971-10-14 1974-06-11 Motor Wheel Corp Method of making mold
US3823982A (en) * 1973-08-02 1974-07-16 S & S Prod Eng Service Inc Hub cap for molded vehicle wheel
US3891276A (en) * 1973-08-02 1975-06-24 S & S Product Engineering Serv Wheel and wheel trim assembly
US3918762A (en) * 1974-03-29 1975-11-11 Goodyear Tire & Rubber Vehicle wheel cover
US3935291A (en) * 1973-08-28 1976-01-27 The Goodyear Tire & Rubber Company Method of molding polyurethane articles in a mold coated with three mold release agents
US3956451A (en) * 1971-10-14 1976-05-11 Motor Wheel Corporation Method of making an ornamental styled wheel
US4000926A (en) * 1975-10-31 1977-01-04 Wlcox Raymond J Wheel with individually formed ribs
US4017239A (en) * 1976-06-07 1977-04-12 The Goodyear Tire & Rubber Company Molding apparatus
US4076788A (en) * 1976-12-02 1978-02-28 General Motors Corporation Mold coating of freshly molded articles
DE2457907B2 (de) * 1974-12-04 1978-09-28 Kronprinz Ag, 5650 Solingen Fahrzeugrad und Verfahren zu seiner Herstellung
US4153657A (en) * 1976-03-10 1979-05-08 Wilcox Raymond J Method for making a vehicle wheel with a foamed resin core
US4251476A (en) * 1979-03-16 1981-02-17 Motor Wheel Corporation Manufacture of ornamental vehicle wheels
US4397504A (en) * 1980-04-14 1983-08-09 James Connell Wheel cover simulating a wire spoke wheel
US4398770A (en) * 1981-02-23 1983-08-16 Motor Wheel Corporation Wire spoke vehicle wheel and method of manufacture
US4408804A (en) * 1979-11-13 1983-10-11 Rockwell International Corporation Composite wheel cover
US4659148A (en) * 1985-09-23 1987-04-21 Motor Wheel Corporation Vehicle wheel construction
US4682820A (en) * 1985-10-16 1987-07-28 Motor Wheel Corporation Vehicle wheel with an ornamental plastic overlay
US4786027A (en) * 1987-02-17 1988-11-22 Motor Wheel Corporation Apparatus for molding composite metal-elastomer wheels
US4790605A (en) * 1987-02-27 1988-12-13 Motor Wheel Corporation Vehicle wheel with ornamental plastic overlay
US4847030A (en) * 1985-10-16 1989-07-11 Motor Wheel Corporation Method and apparatus for making a composite wheel

Family Cites Families (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3952786A (en) * 1974-07-01 1976-04-27 Plasco, Inc. Unitary wheel and tire assembly
EP0180383A3 (fr) * 1984-10-26 1987-06-03 Aronkasei Co., Limited Méthode de fabrication pour boítiers ayant une structure à deux couches

Patent Citations (30)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2266432A (en) * 1939-02-28 1941-12-16 Whitchall Patents Corp Method of die casting heads on pins
US2977151A (en) * 1956-06-06 1961-03-28 Jr Frank W Ford Wheel flange protectors
US3062254A (en) * 1959-10-20 1962-11-06 Keefe Arthur Molded wheel having internal reinforcing
US3356421A (en) * 1966-07-28 1967-12-05 Kelsey Hayes Co Wheel and wheel cover assembly
US3517968A (en) * 1968-10-09 1970-06-30 Motor Wheel Corp Wheel rim trim ring
US3567285A (en) * 1969-02-10 1971-03-02 Sheller Globe Corp Simulated magnesium bicycle wheel and method
US3756658A (en) * 1969-09-15 1973-09-04 Motor Wheel Corp Composite styled wheel construction
US3669501A (en) * 1970-03-03 1972-06-13 Motor Wheel Corp Vehicle wheel construction
US3762677A (en) * 1971-10-14 1973-10-02 Motor Wheel Corp Molding apparatus
US3815200A (en) * 1971-10-14 1974-06-11 Motor Wheel Corp Method of making mold
US3956451A (en) * 1971-10-14 1976-05-11 Motor Wheel Corporation Method of making an ornamental styled wheel
US3794529A (en) * 1971-12-15 1974-02-26 Goodyear Tire & Rubber Method of making a metal laminate
US3823982A (en) * 1973-08-02 1974-07-16 S & S Prod Eng Service Inc Hub cap for molded vehicle wheel
US3891276A (en) * 1973-08-02 1975-06-24 S & S Product Engineering Serv Wheel and wheel trim assembly
US3935291A (en) * 1973-08-28 1976-01-27 The Goodyear Tire & Rubber Company Method of molding polyurethane articles in a mold coated with three mold release agents
US3918762A (en) * 1974-03-29 1975-11-11 Goodyear Tire & Rubber Vehicle wheel cover
DE2457907B2 (de) * 1974-12-04 1978-09-28 Kronprinz Ag, 5650 Solingen Fahrzeugrad und Verfahren zu seiner Herstellung
US4000926A (en) * 1975-10-31 1977-01-04 Wlcox Raymond J Wheel with individually formed ribs
US4153657A (en) * 1976-03-10 1979-05-08 Wilcox Raymond J Method for making a vehicle wheel with a foamed resin core
US4017239A (en) * 1976-06-07 1977-04-12 The Goodyear Tire & Rubber Company Molding apparatus
US4076788A (en) * 1976-12-02 1978-02-28 General Motors Corporation Mold coating of freshly molded articles
US4251476A (en) * 1979-03-16 1981-02-17 Motor Wheel Corporation Manufacture of ornamental vehicle wheels
US4408804A (en) * 1979-11-13 1983-10-11 Rockwell International Corporation Composite wheel cover
US4397504A (en) * 1980-04-14 1983-08-09 James Connell Wheel cover simulating a wire spoke wheel
US4398770A (en) * 1981-02-23 1983-08-16 Motor Wheel Corporation Wire spoke vehicle wheel and method of manufacture
US4659148A (en) * 1985-09-23 1987-04-21 Motor Wheel Corporation Vehicle wheel construction
US4682820A (en) * 1985-10-16 1987-07-28 Motor Wheel Corporation Vehicle wheel with an ornamental plastic overlay
US4847030A (en) * 1985-10-16 1989-07-11 Motor Wheel Corporation Method and apparatus for making a composite wheel
US4786027A (en) * 1987-02-17 1988-11-22 Motor Wheel Corporation Apparatus for molding composite metal-elastomer wheels
US4790605A (en) * 1987-02-27 1988-12-13 Motor Wheel Corporation Vehicle wheel with ornamental plastic overlay

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP0453553A4 *

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2678366A1 (fr) * 1991-06-27 1992-12-31 France Etat Armement Dispositif de camouflage multi-spectral d'un galet d'un train de roulement d'un vehicule.
EP0648661A1 (fr) * 1993-10-15 1995-04-19 GERSTEEN exerçant ses activités sous la dénomination ISODELTA Volant de direction pour véhicules automobiles, pièce de montage et colonne de direction adaptées à coopérer avec ce volant, et procédé pour la fabrication de celui-ci
WO1995010440A1 (fr) * 1993-10-15 1995-04-20 Gersteen Volant de direction pour vehicules automobiles, piece de montage et colonne de direction adaptees a cooperer avec ce volant, et procede pour la fabrication de celui-ci
WO1995025019A1 (fr) * 1994-03-17 1995-09-21 Hayes Wheels International, Inc. Roue de vehicule
FR2717424A1 (fr) * 1994-03-17 1995-09-22 Hayes Wheel Int Inc Roue de véhicule.
US5591386A (en) * 1994-03-17 1997-01-07 Hayes Wheels International, Inc. Vehicle wheel with filler ring
US5597213A (en) * 1995-06-06 1997-01-28 Lacks Industries, Inc. Wheel and overlay assembly
US5779951A (en) * 1996-05-16 1998-07-14 Hayes Lemmerz International, Inc. Method of forming a vehicle wheel having injection molded annular filler ring in wheel cavity
FR2836865A1 (fr) * 2002-03-11 2003-09-12 Michelin Soc Tech Roue avec jante composite realisee par procede rtm
WO2003076212A1 (fr) * 2002-03-11 2003-09-18 Societe De Technologie Michelin Roue avec jante composite realisee par procede rtm.
US7309110B2 (en) 2002-03-11 2007-12-18 Michelin Recherche Et Technique S.A. Wheel with composite rim produced by resin transfer molding

Also Published As

Publication number Publication date
KR920700890A (ko) 1992-08-10
JPH04503641A (ja) 1992-07-02
JPH0628878B2 (ja) 1994-04-20
EP0453553A4 (en) 1992-04-08
EP0453553A1 (fr) 1991-10-30
CA2044624A1 (fr) 1991-05-14

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