WO1996001732A1 - Pare-chocs automobiles co-injectes - Google Patents

Pare-chocs automobiles co-injectes Download PDF

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Publication number
WO1996001732A1
WO1996001732A1 PCT/US1995/008617 US9508617W WO9601732A1 WO 1996001732 A1 WO1996001732 A1 WO 1996001732A1 US 9508617 W US9508617 W US 9508617W WO 9601732 A1 WO9601732 A1 WO 9601732A1
Authority
WO
WIPO (PCT)
Prior art keywords
thermoplastic
core
thermoplastic material
article
polyolefin
Prior art date
Application number
PCT/US1995/008617
Other languages
English (en)
Inventor
Bruce R. Denison
Original Assignee
D & S Plastics International
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 D & S Plastics International filed Critical D & S Plastics International
Priority to AU31255/95A priority Critical patent/AU3125595A/en
Publication of WO1996001732A1 publication Critical patent/WO1996001732A1/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
    • 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
    • B29C45/1642—Making multilayered or multicoloured articles having a "sandwich" structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/03—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by material, e.g. composite
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/18—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by the cross-section; Means within the bumper to absorb impact
    • B60R19/22—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by the cross-section; Means within the bumper to absorb impact containing mainly cellular material, e.g. solid foam
    • 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
    • B29L2031/3044—Bumpers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/18—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by the cross-section; Means within the bumper to absorb impact
    • B60R2019/1806—Structural beams therefor, e.g. shock-absorbing
    • B60R2019/1833—Structural beams therefor, e.g. shock-absorbing made of plastic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/18—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by the cross-section; Means within the bumper to absorb impact
    • B60R2019/1886—Bumper fascias and fastening means therefor

Definitions

  • the present invention relates to plastic articles of manufacture, and to their production by injection molding techniques. More particularly, the present invention relates to articles such as automobile bumpers and fascias that are produced by coinjecting at least two different qualities of thermoplastic resins such as polyolefins into mold shapes that have been designed to utilize the respective qualities of such thermoplastic resins to advantage.
  • Extrusion and coextrusion molding are well known techniques for making articles that may be regarded as essentially "two dimensional" in configuration. Extrusion processes may be used for making long, straight, uniform rods, wires, or complex two- dimensional profiles that may then be cut to length. Extrusion processes are limited by the nature of the shape of the parts that they can form. Running inexpensive core materials in coextrusion is well known, but few automotive parts are manufactured with this process due to shape limitations. In extrusion and coextrusion processes, the plastic flows continuously through the two-dimensional opening and then cools in a water bath and is ultimately cut to length. One can extrude a solid or hollow rod, but it is impossible to cap off the ends in extrusion ⁇ processes.
  • Insert or laminate molding processes tend to have more complex tooling and longer cycle times than coextrusion and coinjection processes. Also, they produce products that are physically more prone to warpage than are the symmetrical skin/core/skin products that can be produced by coinjection molding processes in accordance with the present invention.
  • the present invention provides a means by which relatively large amounts of inferior materials can be used internally in structures in applications never before thought possible without deleterious effects.
  • the present invention provides an article for absorbing and dissipating kinetic energy, which article is formed by coinjection molding of a first thermoplastic material having good appearance and strength properties and of a second thermoplastic material having appearance and/or strength properties significantly inferior to those of the first thermoplastic material.
  • the second thermoplastic material constitutes from 10 to 75 % by volume of the mass of the article.
  • thermoplastic olefin material The unusual internal material that can be used to greatest advantage in accordance with the principles of the present invention is known as "painted regrind” thermoplastic olefin material.
  • Paint regrind refers to articles such as automobile bumpers that had been made of thermoplastic polyolefins and painted and which have subsequently been ground up for use as core material in accordance with the structural configurations of the present invention.
  • Certain properties -- for instance, strength -- may be enhanced by the use of painted regrind in accordance with the present invention. Appearance is the only significant property deriving from the painted regrind core that will generally be inferior to the employment of a comparable core made of virgin material . Where the part in question is intended to be grained or low gloss, relatively rough regrind will generally give acceptable results.
  • the appearance of an article with a painted regrind core may if desired be enhanced by finer grinding of the painted regrind. In this way, one can afford a perfect surface with coinjection for high gloss parts.
  • the articles provided by the present invention are suitable for absorbing and dissipating kinetic energy.
  • thermoplastic material having good appearance properties and of a second thermoplastic material having appearance properties that are significantly inferior to those of the first thermoplastic material.
  • the second thermoplastic material will generally form a core that is entirely surrounded by a skin consisting of the first thermoplastic material, although in some instances a portion of the finished article that may or may not be visible in use may be constituted by exposed core material. Thus, controlled breakthrough of core material may be desirable in some instances.
  • the second thermoplastic material can constitute up to 75 percent by weight of the mass of an article without significantly compromising the strength thereof. Weight-percents at the lower end of the range will often be useful when the core is foamed. Conventional blowing agents may, if desired, be used to reduce the weight of the core.
  • Foaming of the core in this manner has the additional advantage of offsetting sinkmarks, such as those that might be derived from the mold apparatus.
  • the articles will normally be configured as complete or partial automobile bumpers, exterior trim, or energy management fascia, although non-automotive energy management applications may also be appropriate.
  • both of the thermoplastic materials will usually be polyolefins .
  • the first thermoplastic material may advantageously be constituted of a polyolefin formulation that has excellent appearance and paintability attributes, such as ONTEX, which is available from D&S Plastics
  • the second thermoplastic material will generally be constituted of painted regrind.
  • Figure 1 shows a cross-section of a one piece coinjected bumper system in accordance with the invention.
  • Figure 2 shows a cross-section of a foam core coinjected bumper cover, to which an optional beam may be attached by heat, vibration, ultrasonic staking, adhesives, or mechanical attachment.
  • Figure 3a shows a cross-section of a coinjected bumper profile in accordance with the invention.
  • Figure 3b shows a blow-up of a portion of the bumper profile of Fig. 3a, indicating the location of skin and core areas thereof.
  • Figure 4a shows a cross-section of a coinjected energy management fascia profile in accordance with the invention, designed to minimize damage to surrounding body sheet metal.
  • Figure 4b shows a blow-up of a portion of the energy management fascia profile of Fig. 4a, indicating the location and dimensions of skin and core areas thereof.
  • Figure 5 shows a perspective view of a typical mold for coinjection molding a bumper in accordance with the invention.
  • Figure 6 shows a cross-section of a typical mold for coinjection molding a partial or complete automobile fascia in accordance with the invention.
  • Figure 7 shows a cross-section of a generic mold system for coinjection molding an automobile fascia in accordance with the invention.
  • the present invention provides articles for absorbing and dissipating kinetic energy, preferably as components of vehicles such as automobiles.
  • the articles of the present invention are formed by coinjection molding a first thermoplastic material having good appearance properties and a second thermoplastic material having appearance and/or strength properties significantly inferior to those of the first thermoplastic material.
  • the second thermoplastic material will constitute from 10 to 75 % by volume of the mass of the energy management component.
  • thermoplastic material forms a core that is entirely surrounded by a skin consisting of the first thermoplastic material.
  • the core and skin materials should generally be compatible -- that is, adhere to one another -- in order to reduce the danger of delamination failure, although in some instances delamination failure may not be of concern and thus incompatible resins may be appropriate.
  • the present invention relates to any two or more thermoplastic resin systems.
  • Resin systems that may be used in accordance with the present invention, therefore, include polyamides such as nylons (“PA”), thermoplastic elastomers (“TPE”) , polyesters, polycarbonates (“PC”) , polyvinyl chloride (“PVC”) , copolymers such as acrylonitrile-butadiene-styrene (“ABS”) and styrene-acrylonitrile (“SAN”), and polyolefins such as polypropylene (“PP”) .
  • Adhesion is clearly very good between products of the same chemical type, but if one material contains fillers or other foreign matter, there may be a reduction in their adhesion to one another.
  • thermoplastic material that comprises the skin according to the present invention should be substantially free of impurities.
  • substantially free of impurities is meant less than 3 percent of undesired substances that would affect the appearance, impact-resistance, elongation, and similar properties of the resin.
  • the core resin in accordance with the present invention may contain up to 25 percent impurities, in addition to such substances as pigments and fillers as are commonly used in the automotive industry.
  • the core resin may also contain small amounts of "trash” such as road dirt, insect remains, and other such items that may become associated with automotive parts under actual use conditions.
  • the skin/core construction described above enables the use for the second thermoplastic material, or core, of materials that have expense advantages but appearance and/or performance disadvantages, such as painted regrind.
  • the first thermoplastic material, or skin will preferably be composed of polyolefins.
  • Figures 1-4 present schematic representations of typical product configurations for such articles.
  • Figure 1 shows a cross-section of a one piece coinjected bumper system in accordance with the invention having a skin of premium thermoplastic polyolefin such as Ontex, shown by the thick dark lines, and a core of foamed low cost material, shown by the cellular structure.
  • the low cost material can be selected from a variety of products such as inexpensive thermoplastic polymers including various types of polyethylene, scrap, and recycle. Most preferred for the core is recycled plastic automobile bumpers, known generically as "painted regrind" thermoplastic material .
  • the low cost material can be foamed with conventional blowing agents.
  • the mold used to make the bumper of Figure 1 will have a cavity that corresponds in cross-sectional shape to the outside of the structure shown.
  • An important feature of the present invention is the relatively large proportion of the low cost material that can unexpectedly be incorporated into the energy management articles with no significant loss in energy management properties. As depicted in Figure 1, up to approximately two-thirds or even three-quarters of the article by volume may be constituted of the low cost material, with the overall design of the article providing appropriate structural features to ensure an effective mix of energy absorption and energy dissipation.
  • FIG. 2 shows a cross-sectional schematic of a foam core coinjected bumper cover, in which approximately 50% of the article by volume is constituted of low cost foamed material. Due to the manner in which the bumper skin is configured, this bumper configuration will adequately dissipate energy. As indicated in Figure 2, however, this bumper configuration may be reinforced by staking a beam thereto by means of heat, vibration, ultrasound, adhesives, or mechanical attachment.
  • Figure 3 demonstrates the detailing that can be achieved with coinjection molding in the context of a relatively large article such as an automobile bumper.
  • Figure 3b shows a blow-up of a portion of the bumper profile that is highly convoluted. Approximately 60% by volume of the Figure 3 bumper configuration will be constituted of low cost painted regrind.
  • Figure 4 demonstrates the detailing that can be achieved with coinjection molding in the context of a relatively small article such as automobile energy management fascias. As indicated in Figure 4, where the thickness of the article's extremities are less than about 75% of the nominal wall thickness, no core need be present in that locally thin area.
  • a part thickness of 3 millimeters may generally be constituted of about 65% core.
  • a part thickness of 3.5 millimeters may typically be constituted of about 55% core.
  • FIG. 4b shows a blow-up of a portion of the fascia profile that is highly convoluted. Approximately 40% by volume of the Figure 4 fascia configuration will be constituted of low cost painted regrind.
  • the constant for steel is 30,000,000; that for plastic (thermoplastic polyolefin skin/polypropylene core) is typically 500,000. In extreme cases, it may be as high as 800,000, with a gravity of 1.05 for greater weight savings, however.
  • M x (t) 3 is 30, 000, 000 ( .07) 3 or 10,290.
  • a plastic bumper would have to be substantially (although not unusably) thicker than a steel bumper to have the same stiffness as the steel bumper.
  • weight -- 5 since most of the energy used by automobiles goes into moving their weight.
  • the weight savings of a plastic bumper having the same stiffness as a steel bumper may be calculated as follows : t plastic (density plastic) 10 t steel (density steel)
  • Coinjection molding processing in accordance with the present invention can make use of conventional machinery and techniques, such as those described in U.S. Patent No. 5,057,266 and 4,925,100, the entire disclosure of which are hereby expressly incorporated
  • the unexpected benefit of the present invention lies in the application of coinjection molding to the production of energy management articles, the designs of such articles and the shapes of the molds for obtaining and optimizing such
  • thermoplastic resins that can be used to make such articles.
  • Coinjection "sandwich” molding i.e. multi- material molding when only one material is visible, may be synopsized as follows. Material comes from two
  • Figure 7 shows a cross-sectional view of a generic molding system for coinjection molding an automobile fascia in accordance with the invention.
  • 1 is the mold body which has a concave area corresponding in configuration to the exterior surface of the fascia to be produced
  • 2 is the block containing a convex area that interacts with the concave area in 1 to form the mold cavity
  • 3 is the resin injection port
  • 4 is the injection unit that delivers the first material through the resin injection port 3
  • 5 is the injection unit that delivers the second material through port 3.
  • the first unit injects the skin.
  • the second unit injects the core material which forces the skin against the mold wall.
  • the first unit then injects more of the skin material to complete the molding and prepare for the next cycle. This process is explained in greater detail below.
  • Figure 5 shows a perspective view of a typical mold for coinjection molding a bumper in accordance with the invention.
  • the Figure 5 mold is a straight drop injection molding design, in which 1 is the mold body which has a concave area corresponding in configuration to the exterior surface of the bumper to be produced, 2 is the block containing a convex area that interacts with the concave area in 1 to form the mold cavity, and 3 is the resin injection port.
  • 1 is the mold body which has a concave area corresponding in configuration to the exterior surface of the bumper to be produced
  • 2 is the block containing a convex area that interacts with the concave area in 1 to form the mold cavity
  • 3 is the resin injection port.
  • many other types of molds and plastic runners or gating may be employed in accordance with the principles set forth herein.
  • Figure 6 shows a cross-section of a typical mold for coinjection molding a partial or complete automobile fascia in accordance with the invention.
  • 1 is the part cavity
  • 2 is the gate
  • 3 is the sprue bushing
  • 4 is the mold cavity
  • 5 is the mold core
  • A is the area in which an overflow channel may be provided to aid in core distribution.
  • injection takes place at the top of the part to promote the presence of high impact skin along the bottom of the part .
  • Core distribution can be retarded further by necking down wallstock along the bottom of the part .
  • the overflow channel will push excess skin into a "puddle" outside of the part where it may easily be trimmed off.
  • the mold In sandwich molding, the mold is partially filled by the first injection unit, so that material in contact with the wall of the mold forms the skin of the product, leaving a still fluid core.
  • the second material is then injected, pushing the remaining fluid first material further forward, continuing to form the skin, while the second material progressively fills the inside of the component.
  • the second injection unit is stopped before the part is completely filled, and the first injection unit is recommenced from a partially advanced position.
  • This second application of the first material completes the filling of the component, obscures the mold gate, and cleans the machine's injection nozzle downstream of the distribution system ready for the next cycle.
  • the changeover to holding pressure can take place.
  • Advantages of coinjection molding for thick section components include the fact that inferior and less expensive materials can be used for the core material, pigments need only be used with the skin material, all sprues and rejects can be recycled into the core material, core materials with blowing agents eliminate sink marks, leading to improved cooling and shorter cycles, the process temperature of the core material is normally adjusted to the minimum value necessary, leading to less heat to dissipate and hence a reduction in cycle time, automatic separation of the components and sprues within the mold design is possible due to the relatively small gate size requirement when coinjection molding, as opposed to single material injection molding, is being carried out, and high plasticizing rates.
  • a production benefit arises from the fact that the core material never comes into contact with the mold walls. The mold walls, therefore, are not subject to the wear that might otherwise be caused by hard particulate debris in the core material .
  • the distribution of the core material is related to the position of the feed gate, and the obstacles that the flow of material will encounter.
  • the core material is not necessarily used throughout the whole part. For instance, to eliminate shrinkage at ribbed sections it is sufficient to inject a foamed core only at these points.

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

Abstract

La présente invention se rapporte à des articles amortissant et dissipant l'énergie cinétique. Ces articles sont obtenus par moulage par co-injection d'une première matière thermoplastique ayant un bon aspect et une bonne résistance, et d'une seconde matière thermoplastique dont l'aspect et la résistance sont nettement inférieurs à ceux de la première matière. La seconde matière thermoplastique forme généralement une partie centrale qui est entièrement entourée d'une peau constituée par la première matière thermoplastique, bien que, dans certains cas, une partie de l'article fini, qui n'est pas visible lors de l'utilisation ou qui a une fonction spécifique, peut être constituée par la matière de la partie centrale découverte.
PCT/US1995/008617 1994-07-11 1995-07-10 Pare-chocs automobiles co-injectes WO1996001732A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU31255/95A AU3125595A (en) 1994-07-11 1995-07-10 Coinjected automobile bumpers

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US27324194A 1994-07-11 1994-07-11
US273,241 1994-07-11

Publications (1)

Publication Number Publication Date
WO1996001732A1 true WO1996001732A1 (fr) 1996-01-25

Family

ID=23043127

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1995/008617 WO1996001732A1 (fr) 1994-07-11 1995-07-10 Pare-chocs automobiles co-injectes

Country Status (3)

Country Link
AU (1) AU3125595A (fr)
CA (1) CA2194959A1 (fr)
WO (1) WO1996001732A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0823323A1 (fr) * 1996-08-08 1998-02-11 Benetton Sportsystem S.p.A. Procédé de co-injection de produits en matière plastique, notamment pour chaussures
EP1265742A1 (fr) * 2000-02-24 2002-12-18 Conix Corporation Elements de carrosserie de faible densite moules par injection

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3991146A (en) * 1974-04-01 1976-11-09 Imperial Chemical Industries Limited Method of encapsulating an insert in plastics material by injection molding
US5268226A (en) * 1991-07-22 1993-12-07 Diversitech Corporation Composite structure with waste plastic core and method of making same

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3991146A (en) * 1974-04-01 1976-11-09 Imperial Chemical Industries Limited Method of encapsulating an insert in plastics material by injection molding
US5268226A (en) * 1991-07-22 1993-12-07 Diversitech Corporation Composite structure with waste plastic core and method of making same

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0823323A1 (fr) * 1996-08-08 1998-02-11 Benetton Sportsystem S.p.A. Procédé de co-injection de produits en matière plastique, notamment pour chaussures
EP1265742A1 (fr) * 2000-02-24 2002-12-18 Conix Corporation Elements de carrosserie de faible densite moules par injection
EP1265742A4 (fr) * 2000-02-24 2003-05-07 Conix Corp Elements de carrosserie de faible densite moules par injection

Also Published As

Publication number Publication date
CA2194959A1 (fr) 1996-01-25
AU3125595A (en) 1996-02-09

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