Title: Method of manufacturing multiple levels of automobile trim
Abstract: A method for using a single injection molding apparatus to manufacture at least two and up to four different levels of automobile trim pieces as well as automobile trim level pieces manufactured by the methods of this invention.
Patent Number: 6,841,107 Issued on 01/11/2005 to Peters, et al.
| Inventors:
|
Peters; Arnis E. (Onalaska, WI);
Weinstock; Dan (La Crescent, MN);
Rink; Kevin J. (Onalaska, WI)
|
| Assignee:
|
Northern Engraving Corp. (Sparta, WI)
|
| Appl. No.:
|
288068 |
| Filed:
|
November 5, 2002 |
| Current U.S. Class: |
264/135; 264/132; 264/134; 264/250; 264/257; 264/265; 264/267; 264/275 |
| Intern'l Class: |
B29C 045/14; B29C070/78 |
| Field of Search: |
264/132,134,135,250,254,257,259,263,265,266,267,271.1,275,294,296
428/545,577,98,195.1
|
References Cited [Referenced By]
U.S. Patent Documents
| 4734230 | Mar., 1988 | Rhodes et al. | 264/46.
|
| 4923539 | May., 1990 | Spengler et al. | 156/79.
|
| 5133912 | Jul., 1992 | Hagiwara et al. | 264/46.
|
| 5411688 | May., 1995 | Morrison et al. | 264/45.
|
| 5824251 | Oct., 1998 | Morrison et al. | 264/259.
|
| 5919324 | Jul., 1999 | Moffitt et al. | 156/79.
|
| 5925847 | Jul., 1999 | Rademacher et al.
| |
| 6391232 | May., 2002 | Fritsch | 264/46.
|
| 6422640 | Jul., 2002 | Whitehead et al. | 296/146.
|
| 6447706 | Sep., 2002 | Savonuzzi | 264/266.
|
| 6464917 | Oct., 2002 | Piec et al. | 264/161.
|
| 6479006 | Nov., 2002 | Kaufmann | 264/275.
|
| Foreign Patent Documents |
| 0 376 010 | Jul., 1990 | EP.
| |
| 0 607 968 | Jul., 1994 | EP.
| |
| 0 936 044 | Aug., 1999 | EP.
| |
| 1 044 779 | Oct., 2000 | EP.
| |
| 2 027 636 | Feb., 1980 | GB.
| |
| 57 140114 | Aug., 1982 | JP.
| |
Other References
Yang et al., "Injection Molding of Ribbed Plastic Plates with a
Superplastic Zn-22% A1 Sheet", Advances in Polymer Technology, pp. 216-225
(2001).
Giebauf, et al., "Thin and Also Decorative", KU Kunststoffe, vol. 92, pp.
54-58 (1992) (Translation enclosed).
Knoblauch, et al. "Insert Molding Creates the Perforation",
Fraunnhofer-Innstitut fur Chemische Technologie, Pfinztal, vol. 44, pp.
40-41 (Translation enclosed).
Hella, "Optimales Klima durch Vollautomatisches Regelsystem", ATZ
Automobiltechnische Zeitschrift, vol. 100, p. 879 (Translation enclosed).
Mishcke, et al. "Back-injection of textiles, carpets and foils",
Kinstoffe/Plastics, pp. 199-203 (1991).
|
Primary Examiner: Ortiz; Angela
Attorney, Agent or Firm: McDonnell Boehnen Hulbert & Berghoff LLP
Claims
What we claim is:
1. A method for manufacturing at least two types of trim level pieces
comprising the steps of:
a. preparing a mold having a first piece including a first surface, a
second piece including a second surface, and at least one injection port
located in the second piece wherein the injection port has an outlet
associated with the second surface wherein the mold first piece and second
piece unite to form an internal cavity; and
b. preparing at least two different trim level pieces using the mold each
by a different method wherein the trim level pieces and the associated
method are selected from the group consisting of;
i. a first trim level piece prepared by injecting a resin into the mold and
thereafter removing the cured first level trim piece from the mold and
painting at least one surface of the molded trim piece;
ii. a second trim level piece that is prepared by the further steps
comprising: preparing a preformed skin having a first surface and a second
surface wherein the preformed skin first surface has a shape complementary
to the mold first surface;
placing the preformed skin into the mold such that the preformed skin first
surface contacts the mold first surface;
closing the mold and injecting resin into the mold through the at least one
injection port and into contact with the preformed piece second surface
until the intemal cavity is filled with resin to form a second trim level
piece; and
removing the second trim level piece from the mold;
iii. a third trim level trim piece that is prepared by the further steps
comprising:
preparing a shaped metal piece from flat metal stock wherein the shaped
metal piece has a first surface and a second surface and wherein the
shaped metal piece first surface has a shape complementary to the shape of
the mold first surface;
placing the shaped metal piece into the mold such that the metal sheet
first surface is in contact with the mold first surface;
closing the mold and injecting resin into the mold through the at least one
injection port until the mold cavity is filled with resin to form a third
trim level piece; and
removing the third trim level piece from the mold; and
iv. a fourth trim level piece that is prepared by the further steps
comprising;
preparing a wooden trim piece having a first surface and a second surface
wherein the wooden trim piece first surface has a shape that is
complementary to the shape of the mold first surface;
placing the wooden trim piece into the mold such that the wooden trim piece
first surface is in contact with the mold first surface;
closing the mold and injecting a resin into the mold through the at least
one injection port and into contact with the wood trim piece second
surface until the mold cavity is filled with resin to form a fourth trim
level piece; and
removing the fourth trim level piece from the mold.
2. The method of claim 1 wherein each trim level piece has essentially the
same thicknesses at identical locations on the piece.
3. The method of claim 1 wherein the method is used to manufacture at least
three types of different trim level pieces.
4. The method of claim 1 wherein an adhesive material is applied to the
second surface of the shaped metal piece of the third trim level piece
before the shaped metal piece is placed in the mold.
5. The method of claim 4 wherein the adhesive material is applied to the
second surface before the flat metal sheet is shaped.
6. The method of claim 1 wherein first surfaces of the preformed skin of
the second trim level piece includes a decorated first surface.
7. The method of claim 1 wherein the preformed skin of the second trim
level piece has a thickness of from about 0.008 to about 0.030 inches.
8. The method of claim 1 wherein the shaped metal piece of the third trim
level piece has a thickness of from about 0.012 to about 0.018 inches.
9. The method of claim 1 wherein a glass filled resin is used to
manufacture the third trim level piece.
10. The method of claim 9 wherein a glass filled thermoplastic is used to
manufacture the third trim level piece.
11. The method of claim 1 wherein the preformed skin of the second trim
level piece is a preformed piece further comprising a layer of cloth and a
layer of plastic.
12. A method for manufacturing at least two types of trim level pieces
comprising the steps of:
a. preparing a mold having a first piece including a first surface, a
second piece including a second surface, and at least one injection port
located in the second piece wherein the injection port has an outlet
associated with the second surface wherein the mold first piece and second
piece unite to form an internal cavity; and
b. preparing at least two different trim level pieces using the mold each
by a different method wherein the trim level pieces and the associated
method are selected from the group consisting of;
i. a first trim level piece prepared by injecting a resin into the mold and
thereafter removing the cured first level trim piece from the mold and
painting at least one surface of the molded trim piece;
ii. a second trim level piece that is prepared by the further steps
comprising: preparing a preformed skin having a decorated first surface
and
a second surface wherein the preformed skin first surface has a shape
complementary to the mold first surface;
placing the preformed skin into the mold such that the preformed skin first
surface contacts the mold first surface;
closing the mold and injecting resin into the mold through the at least one
injection port and into contact with the preformed piece second surface
until the internal cavity is filled with resin to form a second trim level
piece; and
removing the second trim level piece from the mold;
iii. a third trim level trim piece that is prepared by the further steps
comprising:
preparing a shaped metal piece from flat metal stock wherein the shaped
metal piece has a first surface and a second surface and wherein the
shaped metal piece first surface has a shape complementary to the shape of
the mold first surface;
placing the shaped metal piece into the mold such that the metal sheet
first surface is in contact with the mold first surface;
closing the mold and injecting resin into the mold through the at least one
injection port until the mold cavity is filled with resin to form a third
trim level piece; and
removing the third trim level piece from the mold; and
iv. a fourth trim level piece that is prepared by the further steps
comprising;
preparing a wooden trim piece having a first surface and a second surface
wherein the wooden trim piece first surface has a shape that is
complementary to the shape of the mold first surface;
placing the wooden trim piece into the mold such that the wooden trim piece
first surface is in contact with the mold first surface;
closing the mold and injecting a resin into the mold through the at least
one injection port and into contact with the wood trim piece second
surface until the mold cavity is filled with resin to form a fourth trim
level piece; and
removing the fourth trim level piece from the mold wherein at least one of
the trim level pieces is a second or third trim level piece and wherein an
insert selected from the preformed skin and the preshaped metal piece
includes a through hole.
Description
BACKGROUND OF THE INVENTION
(1) Field of the Invention
This invention concerns a method for using the same injection molding
apparatus to manufacture at least two and up to four different levels of
automobile trim pieces. This invention also concerns a strong third trim
level piece that is comprised of a thin decorative metal layer and a thin
resin layer. This invention further includes trim level pieces
manufactured from a stable injected molding resin. Another aspect of this
invention are molded plastic and metal parts that include a through
feature on their face through which a transparent, semitransparent or
opaque resin or plastic is injected.
(2) Description of the Art
Automobiles include various "trim levels" depending primarily upon the cost
and luxury level of the automobile in which the trim is being installed.
The trim pieces are interior and exterior trim features and molding that
are applied to the automobiles in various locations such as dashboards,
door handle trim, glove compartment trim, console trim and so forth. The
first and lowest trim level is typically painted molded resin trim pieces.
A second trim level consists of a pre-formed polymer skin to which a resin
backing is applied to give the pre-decorated skin structural integrity. A
third trim level consists of decorated metal sheets that are preformed and
then united with a premolded resin backing. The fourth and highest trim
level consists of real laminated wood to which is applied a metal or
premolded resin backing.
Each trim level piece includes tabs, connectors, an adhesive on the backing
or some equivalent means for attaching each trim level piece to an
automobile structure.
Presently, each level type of trim piece is manufactured using different
processes, machines and molding apparatuses. This means that tools, dies,
stamping machines, injection molds and so forth must be individually
purchased to manufacture each piece for each trim level. Further,
employees must be hired to manufacture the various trim level pieces, and
each trim level piece must be separately designed and engineered. All of
this equipment and labor increases the cost to manufacture each trim level
trim piece.
Moreover some of the trim levels pieces require post molding manufacturing
steps. For example third trim level pieces are made by uniting a premolded
resin backing with a prestamped decorative metal piece. After the parts
are united, further stamping and crimping steps are required to secure the
decorative metal piece to the resin backing. These manufacturing steps
also add significant costs to each manufactured trim piece.
There is a need therefore to reduce the design, machining and manufacturing
costs of automobile trim level pieces. Furthermore, there is a need to
produce third trim pieces that use significantly less materials.
SUMMARY OF THE INVENTION
It is an object of this invention to provide a method for manufacturing at
least two and preferably three or four levels of automobile trim pieces
using the same injection molding apparatus. The methods of this invention
significantly reduce the tooling cost and labor associated with the
production of automobile trim level.
It is another object of this invention to provide third trim level pieces
including a decorative metal surface and a resin backing that is
manufactured of very thin layers of material.
Yet another object of this invention is a plastic or metal part including
through features that are filled with a transparent or semi-transparent or
opaque plastic or resin.
One aspect of this invention includes methods for manufacturing at least
two types of trim level pieces using the same injection mold. The method
includes the steps of: (a) preparing a mold having a first piece including
a first surface, a second piece including a second surface, and at least
one injection port located in the second piece wherein the injection port
has an outlet associated with the second surface wherein the mold first
piece and second piece unite to form an internal cavity; and (b)
manufacturing at least two different trim level pieces using the mold. The
trim level piece are selected from the group including; (i) a first trim
level piece prepared by injecting a resin into the mold and thereafter
removing the cured first level trim piece from the mold and painting at
least one surface of the molded trim piece; (ii) a second trim level piece
that is prepared by the further steps comprising: preparing a preformed
skin having a (decorated) first surface and a second surface wherein the
preformed skin first surface has a shape complementary to the mold first
surface; placing the preformed skin into the mold such that the preformed
skin first surface contacts the mold first surface; closing the mold and
injecting resin into the mold through the at least one injection port and
into contact with the preformed piece second surface until the internal
cavity is filled with resin to form a second trim level piece; and
removing the second trim level piece from the mold; (iii) a third trim
level trim piece that is prepared by the further steps comprising:
preparing a predecorated shaped metal piece from flat metal stock wherein
the shaped metal piece has a first surface and a second surface and
wherein the shaped metal piece first surface has a shape complementary to
the shape of the mold first surface; placing the shaped metal piece into
the mold such that the metal sheet first surface is in "contact" with the
mold first surface; closing the mold and injecting resin into the mold
through the at least one injection port until the mold cavity is "filled
with resin" to form a third trim level piece; and removing the third trim
level piece from the mold; and (iv) a fourth trim level piece that is
prepared by the further steps comprising; preparing a wooden trim piece
having a first surface and a second surface wherein the wooden trim piece
first surface has a shape that is complementary to the shape of the mold
first surface; placing the wooden trim piece into the mold such that the
wooden trim piece first surface is in contact with the mold first surface;
closing the mold and injecting a resin into the mold through the at least
one injection port and into contact with the wood trim piece second
surface until the mold cavity is filled with resin to form a forth trim
level piece; and removing the fourth trim level piece from the mold.
Another aspect of this invention includes decorative automobile trim piece
comprising: a formed metal sheet having decorated first surface and a
second surface wherein the metal sheet has a thickness of no greater than
about 0.025 inches; and a resin layer applied to the formed metal sheet
second surface wherein the resin layer has a thickness of no greater than
2.5 mm.
Yet another aspect of this invention is a second trim level piece that is
prepared by the further steps comprising: adhesively laminating cloth to a
plastic skin and then performing the cloth covered plastic skin to form a
preformed skin having a cloth covered first surface wherein the preformed
skin first surface has a shape complementary to a mold first surface;
placing the preformed skin into a mold so that the preformed skin first
surface contacts the mold first surface; closing the mold and injecting
resin into the mold through at least one injection port and into contact
with a second surface of the preformed skin until the mold internal cavity
is filled with resin to form a second trim level piece; and removing the
second trim level piece from the mold.
Still another aspect of this invention is a trim level piece comprising an
insert having at least one through hole and further including a decorative
surface, and a backing; a resin backing associated with the insert
backing; and at least on resin feature located on the insert decorative
surface.
DESCRIPTION OF THE FIGURES
FIG. 1 is a cross-section of a mold useful in the methods of this invention
including a mold cavity (14);
FIG. 2 is a first level trim piece manufactured by the methods of this
invention;
FIG. 3 is a second level trim piece manufactured by the methods of this
invention;
FIG. 4A is a third level trim piece manufactured by the methods of this
invention;
FIG. 4B is a blow-up view of a cross section of the third level trim piece
of FIG. 4A;
FIG. 5A is a fourth level trim piece manufactured by the methods of this
invention;
FIG. 5B is a blow-up view of a cross section of the fourth trim level piece
of FIG. 5A;
FIGS. 6, 7, 8 and 9 are a cross-section views of a mold of this invention
holding first, second, third and fourth level trim pieces;
FIGS. 10A and 10B are front and side cutaway views of a metal piece
including a through hole in which resin has been injected using methods of
this invention.
FIG. 11A is a cross section of a mold useful for making a trim piece of
this invention and FIGS. 11B and 11C are side and front views of the trim
piece manufactured using the mold of FIG. 11A;
FIG. 12A is a cross section of a mold useful for making a trim piece of
this invention including a preformed skin 22 and FIGS. 12B and 12C are
side and front views of the trim piece manufactured using the mold of FIG.
12A;
FIG. 13A is a cross section of a mold useful for making a trim piece of
this invention including a pre-shaped metal piece, and FIGS. 13B and 13C
are side and front views of a trim piece manufactured using the mold of
FIG. 13A; and
FIGS. 14A and 14B are side and front views of a trim piece 60(d) includes a
metal skin 80, an adhesive layer 36, a preformed skin layer 22, a second
optional adhesive layer 77 and a resin backing 72.
DESCRIPTION OF THE CURRENT EMBODIMENT
The present invention relates to methods for using the same resin injection
molding equipment to manufacture multiple automobile trim level pieces. In
another aspect of this invention is a third trim piece level including a
very thin metal layer and a very thin resin layer that has good strength
and that is highly dent-resistant.
By "multiple automobile trim levels pieces," it is meant that an injection
mold having the same cavity dimensions is used in the process of this
invention to manufacture at least two, preferably three and most
preferably four different levels of automobile trim pieces. Preferably,
the same mold is used to manufacture at least two and preferably three or
more levels of automobile trim pieces.
In the specification and claims certain mold inserts will be described as
being in "contact" with the mold cavity surface. The word contact is used
in its broadest sense to mean that the insert is associated with the mold
surface in a manner that inhibits resin from contacting the surface of the
insert that is associated with the mold surface except in situations where
the insert includes a through hole that expressly allows resin to flow
between the insert and the mold cavity wall.
The four levels of automobile trim that are manufactured using a single
injection mold by the methods of this invention are described below as
"first trim level pieces," "second trim level pieces," "third trim level
pieces," and "fourth trim level pieces." Each of the trim level pieces is
manufactured using an injection mold such as the injection mold of FIG. 1.
Injection mold 10 of FIG. 1 includes a first piece 13 including a first
surface 12 associated with cavity 14 and a second piece 17 including a
second surface 16. Injection mold 10 further includes at least one and
preferably a plurality of resin injection ports 19. When mold first piece
13 is united with mold second piece 17, a cavity 14, in the shape of a
desired trim level piece is formed.
First Trim Level Pieces
First trim level piece 18, shown in FIG. 2 is made of an injected molded
resin that may be painted or unpainted. First trim level piece 18 is
manufactured by injecting a molten resin into injection mold cavity 14 and
thereafter removing the molded part from injection mold 10 once the part
is sufficiently cooled. Thereafter, first trim level piece 18 may be
painted or may remain unpainted to form a first level trim piece 18. First
trim level piece 18 will generally be made entirely of resin and will have
a thickness ranging from about 0.040 to about 0.156 inches.
Second Trim Level Pieces
A second trim level piece 20 is shown in FIG. 3. Second trim level piece 20
comprises a preformed skin 22 that is colored, decorated, or that is a
laminate. Preformed skin 22 is typically preformed by thermalforming. In
one optional embodiment, preformed skin 22 is a laminate of a cloth layer
and a plastic skin layer. In this embodiment, a piece of cloth is
adhesively laminated to a plastic skin and the laminated cloth covered
plastic piece is formed into preformed skin 22. In this alternative
embodiment, the cloth may be located on preformed skin first surface 24 or
second surface 26.
Preformed skin 22 has a first surface 24 and a second surface 26. The skin
first surface 24 is complementary to a first surface 12 of injection mold
10. Second trim level piece 20 is manufactured by placing preformed skin
piece 22 into mold cavity 14 such that first surface 24 of the precoated
preformed skin rests against the first surface 12 of injection mold cavity
14. Next, a resin is injected into the mold such that the resin enters the
mold through mold second surface 16, fills cavity 14, and becomes adhered
to the second surface 26 of preformed skin 22 to form a second trim level
piece 20. After cooling, second trim level piece 20 including preformed
skin 22 and resin layer 25 is removed from injection mold 10. The second
trim level piece will have a total thickness of from about 0.040" to about
0.156" with the plastic inmolded preformed skin 22 having a thickness of
from about 0.008 to about 0.030 inches.
Third Trim Level Pieces
A third trim level piece 30, shown in FIGS. 4A and 4B includes a pre-shaped
metal piece 32 and a resin backing layer 34. A close up cross-section view
of third trim level piece 30 in FIG. 4B shows that third trim level piece
30 further includes an adhesive 36 located between pre-shaped metal piece
32 and the resin backing 34. Third trim level piece 30 is manufactured by
first shaping a sheet of metal having a thickness of from about 0.005 to
about 0.025 inches, and preferably a sheet of aluminum that is decorated
on one surface in stamping and die cutting processes to produce pre-shaped
metal piece 32 having a first surface 37 and a second surface 38. First
surface 37 will have a shape that is complimentary to the shape of the
first surface 12 of mold 10.
Prior to or following shaping of pre-shaped metal piece 32, an adhesive
material is applied in a thin layer to the second surface 38 of the metal
sheet or pre-shaped metal piece 32. The adhesive layer will have a
thickness sufficient to bind the resin to pre-shaped metal piece 32. The
purpose of the adhesive is to aid in bonding the resin to a pre-shaped
metal piece 32. Useful adhesives include thermoplastic adhesives and
thermoset adhesives with thermoset adhesives such as acrylics,
polyeurethanes and combinations thereof being preferred. A preferred
adhesive is a hot melt adhesive such as Ashland Prelam manufactured by
Ashland Chemical.
Shaped metal piece 32 is then placed in mold cavity 14 such that shaped
metal piece first surface 37 abuts first surface 12 of mold cavity 14. The
mold is closed and resin is injected into the mold and against second
surface 38 of shaped metal piece 32. During resin injection, the adhesive
layer facilitates the bonding of the resin to second surface 38 of shaped
metal piece 32 to form a third trim level piece 30 including a resin
backing 34. After cooling, the third trim level piece 30 is removed from
mold 10. Third trim level piece 30 will have a total thickness of from
about 0.040 to about 0.156 inches.
Fourth Trim Level Pieces
A fourth trim level piece 40 is shown in FIG. 5. Fourth trim level piece 40
includes a decorative wooden piece 42 and a resin backing 44. Fourth trim
level piece 40 is manufactured by first preparing decorative wooden piece
42 having a first surface 45 and a second surface 46 as shown in FIG. 5B.
Decorative wooden piece first surface 45 is complimentary in shape to the
shaped first surface 12 of mold cavity 14. Decorative wooden piece 42
typically consists of one or more layers of wood with a very thin wooden
veneer on exposed first surface 45. The wood veneer surface is typically
covered with one or more layers of a protective polymer coating such as a
urethane, polyester, or acrylic coating.
Fourth trim level piece 40 is manufactured by placing decorative wooden
piece 42 into mold cavity 14 so that the decorative wooden piece first
surface 45 is complimentary to and abuts mold cavity first surface 12.
Mold 10 is closed and resin is injected into the mold whereupon the resin
adheres to the second surface 46 of decorative wooden piece 42. The second
surface 46 of decorative wooden piece 42 may include an adhesive or
mechanical structure such as a metal frame or foundation to facilitate the
adherence of resin to second surface 46 of decorative wooden piece 42.
Fourth trim level piece is removed from mold 10 after the resin has
cooled. Fourth level trim piece 40 will have a total thickness of from
about 0.040 inches to about 0.156 inches with veneer portion having a
thickness of from about 0.008 to about 0.100 inches.
The methods of this invention allow for the manufacture of first, second,
third and fourth trim level pieces all having essentially the same overall
thickness. Thus, even though the trim pieces may include decorative metal,
wood, or preformed plastic layers of varying thickness, the overall trim
piece thicknesses are made uniform because the amount of resin that can be
added to the piece is limited by the injection mold cavity dimensions
which is the same for all trim levels. In addition, the methods of the
invention allow for the manufacture of a variety of trim level pieces all
including the same installation tabs and construction thereby facilitating
the assembly of automobiles with different trim levels using the same
assembly techniques.
A benefit of manufacturing third trim level pieces 30 using the methods of
this invention is that the resulting third trim level pieces 30 are
unexpectedly very strong. Therefore, it is possible to decrease the
thickness of the resin and/or metal layers in the third trim level pieces
in comparison to prior art metal clad trim level pieces thereby reducing
the cost of manufacturing third trim level pieces 30 while maintaining its
strength and dent resistant properties. The metal used in third trim level
piece may be any metal that is used to manufacture any thin sheet of metal
that used to manufacture automobile trim. Examples of useful metals
include stainless steel, copper, bronze, aluminum, alloys thereof, nickel
and so forth. Further, the exposed metal surface may be burnished or
polished to form a decorative metal surface. A preferred metal is
aluminum. The metal thickness and preferably aluminum thickness is less
than 0.025 inches and even more preferably ranges between 0.012 and 0.018
inches. The resin layer can be as little as 1.0 mm thick and preferably
ranges between 1.0 and 2.5 mm in thickness.
The selection of the resin is important in order to maintain the strength
of the trim level pieces manufactured according to this invention. It is
preferred that the resin material have a coefficient of expansion that is
similar if not equal to the coefficient of expansion of the material to
which it is associated. Examples of useful resins include, but are not
limited to thermoplastic resins such as nylon, polycarbonate, ABS, PC/ABS,
and combinations thereof. A preferred resin used in the manufacture of
third trim level piece 30 is a glass filled thermoplastic resin such a
glass filled nylon or glass filled PC/ABS wherein the resin includes from
about 10 to about 30 wt % glass fibers and preferably about 25 wt % glass
fibers. A preferred thermoplastic material is a nylon resin manufactured
by Bayer and sold under the trade name Durethan BKV-125.
The methods of this invention use standard injection molding processes and
techniques to manufacture the trim level pieces of this invention. FIGS.
6-10 are side cross section views a of a mold 10 that is used to
manufacture a first trim level piece (FIG. 6), a second trim level piece
(FIG. 7), a third trim level piece (FIG. 8), and a fourth trim level piece
(FIG. 9). In FIGS. 6-9, injection mold 10 is typically a two-piece mold
that includes a first piece 13 having a first surface 12 and a second
piece 17 having a second surface 16. Mold 10 further includes at least one
and preferably a plurality of resin injection ports 19 in second piece 17
that unite the outside of second piece 17 with second surface 16.
In addition to the trim level pieces described above, the methods of
invention are useful for manufacturing automobile buttons, switches, knob
covers and so forth that may optionally include a through hole as a resin
feature associated with the exposed surface of the trim level piece. An
example of such a trim level piece is shown, is side and front view in
FIGS. 10A and 10B. The button 50 shown in FIGS. 10A and 10B includes an
insert 51 that includes a decorative surface 52, a backing 54 and a
through hole 62. When the insert is placed in injection mold 10, resin 55
is applied to backing 54 but some of the resin passes through hole 62 and
fills a feature in the mold having a shape corresponding to decorative
resin feature 56 of button 50. Buttons and trim pieces including a variety
of decorative resin features can be made according to the methods of this
invention. Decorative resin features can include designs, words, emblems,
and they can be made using opaque, transparent, and semi-transparent
resins that have any color.
Another aspect of this invention is, therefore, a resin is injected into a
through hole in a substrate to form a design on the surface of the
substrate or a design that can be back-lit. Referring to FIGS. 11A-11C,
12A-12C and 13A-13C, there is shown trim pieces 60(a), 60(b), and 60(c)
that can be made of any material such as plastic, wood or metal to which a
resin backing can be applied. Trim pieces 60(b) and 60(c) include and
optional through hole 62.
Referring now to FIGS. 11A-11C, there is shown an injection mold 10
including a first piece 13 and a second piece 17 that is combined to form
a mold cavity 14. A resin injection port 19 provides a path for injecting
resin into mold cavity 14 from outside mold 10. Mold cavity 14, as shown
in FIG. 11A, is in the shape of a button or knob that is useful as an
automobile trim piece. Mold cavity 14 further includes a plurality of
features 68. Feature 68 may be an indentation, knob, buttons, writings,
decorations and so forth. FIG. 11B shows trim piece 60(a) that is
manufactured from injection mold 10 shown in FIG. 11A. Trim piece 60(a) is
made entirely of a resin material 70. Trim piece 60(a) includes an exposed
surface 67(a) that includes a plurality of feature 68(a). Expose surface
67(a) and/or feature 68(a) may be painted or printed as desired to form a
decorated trim piece 60(a). FIG. 11C is a front view of a decorated trim
piece 60(a) including a plurality of features 68(a) wherein numerals have
been printed onto feature 68(a). Trim piece 60(a) corresponds to first
level trim pieces described above.
FIGS. 12A-12C depict an alternative trim piece 60(b) that may be
manufactured by the methods of this invention. Injection mold 10 used to
manufacture trim piece 60(b) includes a mold cavity 14 that is identical
in geometry to the mold cavity used to manufacture trim piece 60(a).
However, in FIG. 12A, a preformed skin 22 is placed in injection mold 10
such that first surface 24 of pre-formed skin 22 is associated with first
surface 12 of injection mold 10. Pre-formed skin 22 as shown in FIG. 12A
includes a through hole 62 associated with a feature 68. The pre-formed
skin 22 covers the remaining features 68. Injecting resin into mold 10 of
FIG. 12B, produces trim piece 60(b) shown in FIGS. 12B and 12C. Trim piece
60(b) includes a pre-formed skin layer 22 and a resin backing 72. First
surface 24 of pre-formed skin 22 may be decorated with numerals, writings,
patterns, it may be made of a colored material, or is may included any
known type of decoration that is used to decorate trim piece 60(b). When
resin is injected into the mold of FIG. 12A, the hot resin heats and
forces pre-formed skin 22 into features 68 thereby forming pre-formed skin
covered features 74. In areas where a through hole 62 is associated with a
mold feature 68, the resin fills the feature to form a resin feature 76.
It may be desirable to form resin feature 76 for a variety of reasons. The
resin used to manufacture resin feature 76 may be clear or semi-opaque
thus allowing light to be transmitted from behind trim piece 60(b) to
illuminate resin feature 76. Alternatively, the resin material used to
manufacture trim piece 60(b) may be a colored resin that has a color that
is different than the color of pre-formed skin 22 thereby providing
contrasting colors on the surface of trim piece 60(b). Trim piece 60(b) is
essentially identical in structure to the second level trim pieces
described above.
FIG. 13A depicts a mold that is useful for manufacturing trim piece 60(c)
while FIGS. 13B and 13C depict side and front views of trim pieces 60(c)
manufactured using the mold of FIG. 13A. The injection mold 10 shown in
FIG. 13A is essentially identical to the injection mold shown in FIGS. 12A
and 11A. In addition, mold cavity 14 has the same dimensions as the mold
cavity 14 of FIGS. 11A and 12A. In FIG. 13A, a pre-shaped metal piece 32
is placed in injection mold cavity 14 such that first surface 37 of
pre-shaped metal piece 32 abuts first surface 12 of injection mold 10.
Pre-shaped metal piece 32 does not have to conform identically to the
shape of first surface 12 which includes a plurality of features 68. In
FIG. 13A, pre-shaped metal piece 32 includes an indentation 78 that
corresponds to the shape of a feature 68. Additionally, pre-shaped metal
piece 32 includes a through hole 62 that is located adjacent to a feature
68. Finally, pre-shaped metal piece 32 includes a portion that covers but
does not conform to a feature 68(c). Once injection mold of FIG. 13A is
closed, a heated resin is injected into mold 10 through resin injection
port 19 until cavity 14 is essentially filled with resin to form trim
piece 60(c) shown in FIGS. 13B and 13C. Trim piece 60(c) includes a metal
skin 80 and a resin backing 72. In FIGS. 13B and 13C, two of the features
are formed metal features 82. Formed metal features 82 may be formed as
described above by shaping pre-shaped metal piece 32 to conform with the
mold features or formed metal feature 82 may be formed when pressure
applied by the injected resin forces pre-shaped metal piece 32 into
feature 68(c) of FIG. 13A. In addition, trim piece 60(c) includes a resin
feature 76 formed when the injected resin passed through hole 62 in
pre-shaped metal piece 32 to fill feature 68 in mold first surface 12.
Trim piece 60(c) is essentially identical to the third level trim piece
described above.
FIGS. 14A and 14B are side and front views of yet another embodiment of a
trim piece 60(d) that can be manufactured by the methods of this
invention. Trim piece 60(d) is manufactured using the same mold depicted
in FIGS. 11A, 12A and 13A by placing a pre-shaped metal piece 32 including
an adhesive layer 36 in injection mold cavity 14 such that first surface
37 of pre-shaped metal piece 32 abuts first surface 12 of injection mold
10. Pre-shaped metal piece 32 includes a plurality of through holes 62
that correspond to features 68 in the final trim piece 60(d). After
placing preshaped metal piece 32 into the mold, a preformed and optionally
predecorated skin 22 including a first surface 24 having one or more
features 68 is located in mold 10 so that features 68 protrude through
holes 62 and contact first surface 12 of injection mold 10. Second surface
26 of preformed skin 22 may include an adhesive layer 77. Mold 10 is
closed and heated resin is injected into mold 10 through resin injection
port 19 until cavity 14 is essentially filled with resin to form trim
piece 60(b) shown in FIGS. 14A and 14B. Trim piece 60(d) includes a metal
layer 32, an adhesive layer 36, a preformed skin layer 22, a second
optional adhesive layer 77 and a resin backing 72. In FIGS. 14A and 14B,
each of the features 68 are part of the preformed skin layer 22. Further,
as shown in FIG. 14B, skin layer 22 is predecorated so that the final trim
piece features 68(d) are printed with numerals.
The four levels of trim pieces described above, and trim pieces 60(a),
60(b), 60(c), and 60(d) may all be produced using a single injection mold
having a mold cavity 14 of identical dimensions. One of the primary
differences between the four trim piece levels described above and trim
pieces 60(a), 60(b), 60(c), and 60(d) is the presence of features on the
exposed surface of the trim piece and in particular a feature consisting
partially or entirely of resin material.
The preceding description of this invention is intended to be illustrative
in nature and is not to be considered as limiting the scope of the
invention.
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