U.S. patent application number 09/253667 was filed with the patent office on 2002-03-14 for method of making fused film plastic parts and parts made by such methods.
Invention is credited to HARDGROVE, WILLIAM H., SWARTZ, MICHAEL A., YAMAMOTO, HIROAKI, YORDE, ANDREW G..
Application Number | 20020031643 09/253667 |
Document ID | / |
Family ID | 22961213 |
Filed Date | 2002-03-14 |
United States Patent
Application |
20020031643 |
Kind Code |
A1 |
HARDGROVE, WILLIAM H. ; et
al. |
March 14, 2002 |
METHOD OF MAKING FUSED FILM PLASTIC PARTS AND PARTS MADE BY SUCH
METHODS
Abstract
Methods for making fused film-plastic parts and parts made
thereby are disclosed. The paint film covered parts include a show
surface section with a paint film laminate overlying the plastic
substrate of this section of the part to provide the desired
aesthetic appeal. An attachment flange section of the part is
provided and is usually hidden from sight when the part is
assembled to the auto or truck body structure. The flange serves as
a location at which clamps, bolts, rivets or the like can support
or attach to the auto to truck structure. A raised portion, such as
a boss section, is provided intermediate the show surface section
and the attachment flange. This boss is adapted for contiguous or
closed spaced positioning adjacent the auto or truck structural
part. The boss is completely covered by the paint film with the
paint film terminating along the attachment flange.
Inventors: |
HARDGROVE, WILLIAM H.;
(ENGLEWOOD, OH) ; YAMAMOTO, HIROAKI; (BROOKVILLE,
OH) ; SWARTZ, MICHAEL A.; (BROOKVILLE, OH) ;
YORDE, ANDREW G.; (BROOKVILLE, OH) |
Correspondence
Address: |
BIEBEL & FRENCH
35 EAST FIRST STREET
DAYTON
OH
45402
|
Family ID: |
22961213 |
Appl. No.: |
09/253667 |
Filed: |
February 19, 1999 |
Current U.S.
Class: |
428/119 ;
264/259 |
Current CPC
Class: |
B29C 2045/14909
20130101; B29C 2045/14901 20130101; B29C 45/1418 20130101; B29L
2031/3044 20130101; B60R 2019/1833 20130101; Y10T 428/24174
20150115 |
Class at
Publication: |
428/119 ;
264/259 |
International
Class: |
B29C 045/14; B32B
003/06 |
Claims
1. In a method of making a film covered plastic part of the type
adapted for snug positioning against an auto or truck body
structure, wherein said film covered part has a show side portion
covered by said film, an attachment flange for connection said part
to said auto or truck body structure, and a boss section connecting
said show side portion to said attachment flange, the improvement
comprising: (a) providing a die cavity for molding said film
covered plastic part, said die cavity including a show face cavity,
an attachment flange cavity, and a boss cavity connecting said show
face cavity and said attachment flange cavity; (b) placing said
film in said die cavity, said film having a first and a second end,
positioning said first end of said film in said show face cavity
and terminating in said attachment flange cavity; and (c) injecting
molten plastic into said die cavity and along said show face
cavity, boss cavity, and said attachment flange cavity, whereby
said film is superposed over said molten plastic and covers at
least a portion of said plastic disposed in said show cavity, all
of said plastic in said boss cavity and at least a portion of said
plastic in said attachment flange cavity.
2. Method as recited in claim 1 wherein said show face cavity, said
attachment flange cavity and said boss cavity are formed between
interfacial surfaces of the three piece die assembly.
3. Method as recited in claim 2 wherein said boss cavity comprises
a pair of mating, curved surfaces, each of said pair of boss
surfaces formed in a different piece of said three piece die
assembly.
4. Method as recited in claim 1 wherein said attachment flange
cavity is formed at a re-entrant angle relative to said boss
cavity.
5. Method as recited in claim 1 wherein said film is a paint film
laminate.
6. Film covered plastic part made by the method of claim 1.
7. Film covered plastic part made by the method of claim 2.
8. Film covered plastic part comprising a show side portion, an
attachment flange adapted for mounting of said part to an auto or
truck structural part, and a boss section connecting said show side
portion and said attachment flange, said film covering at least a
portion of said show side portion, all of said boss section and at
least a portion of said attachment flange.
9. Film covered plastic part as recited in claim 8 wherein said
film is a paint film laminate.
10. Film covered plastic part as recited in claim 9 wherein said
part is a chin-molding.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention pertains to improved methods of insert
molding a plastic film or the like over a plastic substrate and to
fused film-plastic parts made thereby.
[0003] 2. Description of the Prior Art
[0004] A variety of injection molded parts are made and used for
automobile body and trim parts. For example, bumpers, body panels,
doors, filler panels, wheel covers, dashboards, arm rests and other
parts have been made via injection molding techniques.
Additionally, with regard to automobile exteriors, body side
moldings, belt line moldings, roof moldings and window moldings are
made via injection molding of PVC or other thermoplastic
materials.
[0005] In order to provide a painted surface for these parts, film
lamination techniques have been successfully employed. In
accordance with these processes, a paint film laminate is insert
molded with the desired thermoplastic to fuse the film over the
injection molded part. The resulting injection molded part is ready
for assembly without subsequent painting.
[0006] The paint film laminate used in these insert molding
techniques may comprise a backing sheet to which paint layers are
adhered. Typically, the backing sheet comprises an extruded
thermoplastic sheet.
[0007] In such paint film laminates, a paint film, comprising a
cast dried continuous paint coating, is provided over the backing
sheet. The paint film may consist of a monocoat, a clear coat over
a base coat or a clear coat and a base coat with interposed print
or design. The paint film, including base coal, clear coat and
print or design, if desired, may range from about 0.5-4 mil. in
thickness.
[0008] The laminated paint films are available, for example, from
Avery Dennison, Automotive Division, or Rexham Decorative Products,
Charlotte, N.C. The films are typically provided in a roll,
unwound, shaped and trimmed to a proper "preform" size and shape,
ready for insertion into an injection mold.
[0009] The preform is usually placed along the cavity side of the
injection mold with the painted side thereof facing the mold cavity
surface. In some instances, the preform may be placed along the
core side of the mold. The mold is then clamped and the desired
molten resin is injected into the mold cavity. Heat and pressure
conditions in the mold partially melt the backing sheet and a melt
bonding or fusion of the injected resin and film occur. Injection
molds used for these processes are rear or edge gated so that the
molten resin is directed along the backside of the film.
[0010] Techniques for preforming paint film laminates and insert
molding film-plastic parts are disclosed in U.S. Pat. Nos.
5,559,608; 5,746,962; 5,759,477; and 5,783,287. The disclosures of
these patents are incorporated herein by reference.
[0011] In many cases, it is desired to provide a paint file covered
auto or truck part, such as a chin-molding or rocker panel that is
adapted for mounting under or over an associated auto or truck body
structural part such as a bumper or the like. In many of these
structural combinations, a raised portion or boss of the paint film
covered auto or truck part is provided in contiguous or closely
spaced relation with the associated auto structural part. Due to
the close spacing of the boss to the adjacent auto or truck part,
the edge of the paint film laminate, overlying this boss region,
may separate from the underlying plastic substrate, leading to, an
unsightly appearance.
[0012] Accordingly, there is a need for a method of providing such
paint film covered part that will minimize chances of separation of
the paint film from its underlying plastic substrate, especially in
those regions of the part that are adapted for contiguous or
closely spaced position adjacent a mating auto or truck structural
or decorative part.
SUMMARY OF THE INVENTION
[0013] These needs and others are addressed by the instant methods
and fused film-plastic parts made thereby. More specifically, parts
formed by the present method include show sections which are
designed to be visible when the parts are installed on finished
assemblies such as automobiles or trucks.
[0014] The parts include a show surface section with the paint film
laminate overlying the plastic substrate at this section of the
part to provide the desired aesthetic appeal. An attachment flange
section of the part is provided and is usually hidden from sight
when the part is assembled to its associated auto or truck
structural or decorative part. This flange serves as a mounting
location where clamps, bolts, rivets, or other fastening devices
can securely attach the paint film covered part to the auto or
truck structure.
[0015] A raised portion, such as a boss section, is provided
intermediate the show surface and attachment flange. This boss is
adapted for contiguous or closely spaced positioning adjacent the
auto or truck body or structural part. The boss is completely
covered by the paint film with the paint film terminating along the
attachment flange.
[0016] In accordance with the instant methods, the paint film
covered part is generally molded in accordance with conventional
co-molding injection techniques wherein molten plastic is injected
into the die cavity, usually alongside the rear side of the paint
film laminate, forcing the laminate to conform to the desired
surface configuration of the molding cavity. In accordance with the
invention, a specially configured die cavity combined with a novel
positioning of the pain film therein, upon molding, results in the
aforementioned paint film covered plastic part.
[0017] The invention will be further described in conjunction with
the following detailed description and appended drawings.
[0018] In the drawings:
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 is a front end view of an automobile including a
chin-molding, a paint film covered part made in accordance with the
invention;
[0020] FIG. 2 is a cross-sectional view taken along the plane
represented by the lines and arrows 2-2 of FIG. 1;
[0021] FIG. 3 is a schematic, sectional view of a molding apparatus
used in accordance with the invention to make the chin-molding part
shown in FIG. 1;
[0022] FIG. 4 is a schematic sectional view of the molding
apparatus shown in FIG. 3, with the paint film positioned therein
in accordance with the instant methods; and
[0023] FIG. 5 is a schematic sectional view of the molding
apparatus shown in FIG. 4 after injection of the molten plastic
material therein to form the part shown in FIG. 1.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0024] Turning now to FIG. 1, there is shown an automobile 2 with
front end bumper 4 mounted thereon. Immediately below the bumper
and in contiguous relation thereto is a chin-molding member 6 made
in accordance with the invention.
[0025] The chin-molding member is a plastic member comprising a
plastic substrate and overlying paint film laminate. With regard to
FIG. 2, the chin-molding 6 is shown in its position under the front
end bumper 4. The chin-molding, as shown is contiguous to the front
end bumper, but, it will be appreciated, that structural variations
can be made such as a close spacing of the chin-molding member to
the front end bumper.
[0026] The chin-molding 6 comprises plastic material 9 and
overlying paint film 8. The chin-molding is composed a show surface
10 a boss section 12 and an attachment flange 14. The show surface
10 is covered with paint film 8 to provide the desired aesthetic
impression to the viewer. The boss 12 comprises a raised portion of
the chin-molding which is received in a corresponding recess 16
formed in the bumper. The attachment flange 14 is adapted for
direct attachment to attachment flange 18 of the bumper through
conventional means such as clips, rivets, bolts or the like (not
shown). In many of the prior art structural combinations, the end
of the paint film 8 is positioned along the boss section. This, as
mentioned previously, can cause peeling or flaying of the paint
film edge providing an unsightly appearance to the overall
structure.
[0027] Turning now to FIG. 3, there is shown a molding apparatus
adapted to form from convention co-molding injection molding
techniques, the chin-molding 6 as shown in FIG. 1. The molding
members comprise a male molding member 40, a female molding member
42 and a stationary molding member 44. The view shown in FIG. 3 is
somewhat exploded so as to better show the surface configuration
and overall relationship between the three molding members. The
male molding member 40 is adapted for reciprocation along a
horizontal axis as shown in the figure with the female molding
member 42 also shown adapted for reciprocal movement along the
horizontal axis.
[0028] A sprue 46 is provided in the male molding member so that
molten plastic may be injected into the cavity filmed between the
mold members. A convex cavity surface 48 is provided along the male
member and this cooperates with the concave cavity surface 50 of
the female mold member and the concave cavity surface 52 of the
stationary member to provide a mold cavity in which the
chin-molding will be co-molded. A concave curved surface 54 of the
female member cooperates with the concave, curved surface 56 of the
stationary member to, in combination, form a boss portion of the
mold cavity, which, after molding, will result in or correspond to
the boss 12 of the molded, finished part shown in FIG. 2 of the
drawings.
[0029] Turning now to FIG. 4, the members 40, 42, and 44 together
define a show surface cavity 60, a boss cavity 62 and an attachment
flange cavity 64. The boss cavity 62 is formed by the cooperation
of surface members 54, 56 formed respectively in the female and
stationary mold members (see FIG. 3). Paint film 8 is positioned in
the mold cavity with a first end 70 of the paint film positioned in
the show face cavity 60 and with the opposite end 72 of the paint
film extending through the boss cavity 62 and terminating in the
attachment flange cavity 64. The end 72 also extends past the part
line 150 formed between the female and stationary mold members to
thereby minimize pinching of the film that may otherwise occur if
the edge 72 were disposed at or proximate the part line.
[0030] FIG. 5 depicts injection of plastic material 100 into the
mold cavity. The plastic, when injected, will impinge upon the rear
side of the film and force the film to conform to the shape of the
cavity surfaces. As shown, the plastic material extends through the
show face cavity, boss cavity and attachment flange cavity. The
paint film, by reason of co-molding process, thereby covers at
least a portion of the plastic along the show face cavity and all
of the plastic in the boss cavity. The film extends along at least
a portion of the flange cavity 64. In accordance with the process
then, the chin-molding such as that shown in FIGS. 1 and 2 is
provided wherein the paint film extends completely around the boss
section of the chin-molding and terminates in the attachment flange
portion. This attachment flange portion of the chin-molding is
usually hidden from the viewers eye as depicted in FIG. 2 of the
drawings. As can be seen in FIG. 2, it completely covers the boss
and terminates in the attachment flange portion of the
chin-molding, so as to minimize the chance that the edge will
become flayed or the paint film separated from the underlying
plastic substrate during assembly or afterward.
[0031] In an especially preferred embodiment, it can be seen that
the attachment flange (for example in FIG. 4) is formed at an angle
that is re-entrant relative to the vertically shown extremity of
the boss cavity portion as located at the surfaces 54,56.
[0032] Having described the invention in detail and by reference to
the preferred embodiments thereof, it is apparent that
modifications and variations are possible without departing from
the scope of the invention as defined in the appended claims. In
the claims:
* * * * *