U.S. patent application number 10/524167 was filed with the patent office on 2006-07-13 for side sill trim part and method of molding same.
Invention is credited to Renji Maki.
Application Number | 20060154023 10/524167 |
Document ID | / |
Family ID | 31715750 |
Filed Date | 2006-07-13 |
United States Patent
Application |
20060154023 |
Kind Code |
A1 |
Maki; Renji |
July 13, 2006 |
Side sill trim part and method of molding same
Abstract
Improved side sill or rocker panel trim part and methods of
molding same are provided. In the methods, a substantially "C" like
cross-sectional shaped mold cavity (53) is provided having a pair
of terminal cavity portions (56, 58) therein. A living
hinge-forming cavity space (54) is provided between a midpoint of
the cavity and one of the terminal end portions. The part comprises
a longitudinal axis extending therealong and a pair of leg portions
and an intermediate section interconnecting the leg portions. The
part includes a substantially "C" shaped cross-section transverse
to the longitudinal axis with the intermediate section including a
show surface side with the legs extending away from the show
surface side. A hinge joint is provided adjacent one of the legs so
that the part is bendable at the hinge to form a substantially
closed "C" position.
Inventors: |
Maki; Renji; (Brookville,
OH) |
Correspondence
Address: |
WEGMAN, HESSLER & VANDERBURG
6055 ROCKSIDE WOODS BOULEVARD
SUITE 200
CLEVELAND
OH
44131
US
|
Family ID: |
31715750 |
Appl. No.: |
10/524167 |
Filed: |
August 1, 2003 |
PCT Filed: |
August 1, 2003 |
PCT NO: |
PCT/US03/24157 |
371 Date: |
September 14, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60401873 |
Aug 8, 2002 |
|
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|
Current U.S.
Class: |
428/122 ;
264/242; 264/255; 428/156 |
Current CPC
Class: |
Y10T 428/24479 20150115;
B29C 45/14778 20130101; B29C 45/14688 20130101; B60R 13/04
20130101; B29C 45/0055 20130101; B29L 2031/22 20130101; B60R
2013/046 20130101; B29L 2009/006 20130101; B29L 2031/3005 20130101;
B29C 2045/0093 20130101; Y10T 428/24198 20150115; B29C 2045/14901
20130101; B29C 45/0081 20130101 |
Class at
Publication: |
428/122 ;
264/242; 264/255; 428/156 |
International
Class: |
B29C 45/14 20060101
B29C045/14; B32B 3/04 20060101 B32B003/04 |
Claims
1. Method of making a side sill or rocker panel part of the type
having a substantially "C" like cross-sectional shape oriented
transverse to a longitudinal axis of the part, comprising,
providing a mold cavity defining a space congruent with said
cross-sectional shape and having a opposing terminal portions of
said space with each terminal portion being disposed adjacent a
mold part line, determining an approximate midpoint of the space
located between said terminal portions, and providing a living
hinge forming cavity space between said midpoint and one of said
terminal portions, injecting a mass of molten resin into said
cavity over said hinge forming cavity space and into said terminal
portions, allowing said molten resin to harden, ejecting said resin
from said mold cavity thereby forming a substantially "C"
cross-sectional part with a hinged attachment leg formed adjacent
one terminal portion of said part.
2. Method as recited in claim 1 further comprising co-molding a
paint film over said part.
3. Method as recited in claim 2 wherein said paint film is inserted
into said cavity prior to injection of said mass of molten resin
into said cavity.
4. Method as recited in claim 1 further comprising positioning said
part adjacent an automotive frame member, pivotally moving said
attachment leg toward said frame member and securing said
attachment leg member to said frame member.
5. Method of making a side sill or rocker panel automotive part
having a longitudinal axis extending therealong, said part
including a "C" configuration when viewed in a cross-sectional
plane taken transverse to said longitudinal axis and having spaced
top and bottom legs and an intermediate portion connecting said top
and bottom legs and having an inside surface and a show side
surface with both of said legs extending away from said inside
surface, said method comprising providing a mold cavity defining a
space congruent with said configuration and having opposing
terminal portions of said space, said terminal portions of said
space being disposed relative to each other at an angle of less
than 180.degree., providing a living hinge-forming space in said
space proximate to one of said opposing terminal portions,
injecting a mass of molten resin into said cavity substantially
filling said space and flowing over said hinge-forming space,
allowing said molten resin to harden, ejecting said resin from said
cavity thereby forming a side sill or rocker panel with one of said
legs defining a hinged attachment leg formed along one end of said
part and adapted for pivotal movement so that said legs can be
disposed relative to each other in a substantially closed "C"
position.
6. Method as recited in claim 5 wherein said legs can be disposed
relative to each other at an angle of between about
180.degree.-270.degree..
7. Method as recited in claim 6 wherein said end portions of said
legs can be disposed relative to each other at an angle of between
about 225.degree. and 270.degree..
8. Side sill or rocker panel automotive part having a longitudinal
axis extending therealong, said part comprising a pair of leg
portions and an intermediate section interconnecting said leg
portions, said part having a substantial "C" shaped cross section
transverse to said longitudinal axis, said intermediate section
including a show surface side with said legs extending away from
said show surface side, a hinged joint provided adjacent one of
said legs, said part being bendable at said hinge to form a
substantially closed "C" position.
9. Automotive part as recited in claim 8 wherein said legs are
disposed relative to each other at an angle of between about
180.degree. and 270.degree..
10. Automotive part as recited in claim 9 wherein said legs are
disposed relative to each other at an angle of between about
225.degree. to about 270.degree..
11. Side sill automotive part as recited in claim 8 further
including a paint film laminate covering said show surface.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Patent Application Ser. No. 60/401,873 filed Aug. 8, 2002.
BACKGROUND OF THE INVENTION
[0002] Automotive trim parts and protective molding are often
prepared via injection molding techniques with the manufacture of
elongated moldings being greatly aided by gas assisted injection
molding techniques. For some applications, it is desirable to form
deep drawn molded parts wherein the transverse cross section of the
elongated part approximates the letter "C".
[0003] For example, it is desirable to provide deep drawn side sill
and rocker panel moldings wherein the exterior, show surface of the
part (i.e., the outer part surface between the opposed generally
horizontal ends of the "C") has an increased height dimension
measured transverse to the longitudinal axis of the part so that
the part will extend closely to the road surface exhibiting minimum
ground clearance. This effect is not only popular from an aesthetic
perspective, but the low disposition of the part also helps to
serve an air damming effect helping to promote aerodynamic
stability of the vehicle during driving.
[0004] Molding of deep drawn substantially "C" cross sectioned
plastic parts is difficult. If the opposing longitudinally disposed
edges converge toward each other, it is difficult to remove the
part from the mold in the absence of elaborate sliding
mechanisms.
SUMMARY OF THE INVENTION
[0005] A method of making a side sill or rocker panel part of the
type having a substantially "C" like cross-sectional shape is
disclosed. This "C" like shape is oriented transverse to a
longitudinal axis of the part. A mold cavity is provided and
defines a space congruent with the desired cross-sectional shape.
The mold cavity space has opposing terminal portions with each
terminal portion disposed adjacent to the mold part line. An
approximate midpoint of the space located between the terminal
portions is determined, and a living hinge forming cavity space is
provided between that midpoint and one of the terminal end
portions.
[0006] Molten resin is injected into the cavity over the
hinge-forming cavity space and into the terminal portion. The resin
is allowed to harden, and the part is then ejected from the mold
cavity to form a substantially "C" cross section part with a hinged
attachment leg formed adjacent one terminal portion of the part.
The hinged attachment leg may be pivoted so that the part forms a
substantially closed "C" position. The pivoted attachment leg can
then be used as a situs for securing the part to the automotive
frame member.
[0007] The part itself has a longitudinal axis extending therealong
and comprises a pair of leg portions and an intermediate section
interconnecting the leg portions so that the part has a substantial
"C" shaped cross-sectional configuration when viewed transverse to
the longitudinal axis. The intermediate section of the part
includes a show surface side with the legs extending away from the
show surface side. A hinge joint is provided adjacent one of the
legs, and the part is bendable at the hinge to form a substantially
closed "C" position.
[0008] Other objects and advantages of the invention will be
apparent from the following description, the accompanying drawings
and the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] FIG. 1 is a perspective view of an automobile showing a
front and back side sill part;
[0010] FIG. 2 is a cross section of a side sill part in accordance
with the invention taken along a plane that is transverse to the
longitudinal axis of the part;
[0011] FIG. 3 is a sectional view taken along the plane indicated
by the lines and arrows 3-3 of FIG. 1, showing, in phantom,
attachment of the part to the frame by pivotal movement of the
attachment leg;
[0012] FIG. 4 is a schematic cross section of a mold used to
produce the side sill part;
[0013] FIG. 5 is an orthogonal side projection of a side sill in
accordance with the invention showing the attachment side of the
part; and
[0014] FIG. 6 is a diagram showing the angular relation between
longitudinally extending ends or edges of the part.
DETAILED DESCRIPTION
[0015] Turning first to FIG. 1, there is shown an automotive
vehicle 2 of the type including a front side sill 4 and rear side
sill 6 trim parts. In some instances, these side sill members are
referred to as rocker panels. These members are attached below the
framing member of the vehicle and help to create an aerodynamic air
damming effect as noted above.
[0016] Referring now to FIG. 5, there is shown the inside portion
of a finished side sill 500. The inside surface 526 is provided
with anchoring means such as cliphouse 504 and associated mounting
studs 516 which together with hinged legs 522 serve to mount the
side sill member beneath and adjacent the desired frame member. As
shown, the side sill member comprises a longitudinal axis 524
extending therealong, and as is common in the art for molding these
products, a gas assist channel 502 can be provided in the part. The
show surface (not shown in this drawing) may be provided with a
paint film or the like to provide a pleasing aesthetic
appearance.
[0017] Turning now to FIG. 2, there is shown a transverse
cross-sectional view of a side sill made in accordance with the
invention. Here, side sill 10 comprises a top leg member 12 and
bottom attachment leg 14 with an intermediate member
interconnecting the legs and comprising a show surface 20 and an
inside surface 22. A hinge 16 is provided along the attachment leg
portion of the rocker panel so as to provide a fulcrum or pivot
site by which the attachment leg 14 may be pivoted upwardly with
regard to the FIG. 2 drawing. An aperture 18 may be provided in the
attachment leg 14 so as to serve as an anchor site for bolts or
other connectors to facilitate connection of the side sill 10 to
the required framing structure. The longitudinal axis of the rocker
panel is shown as reference numeral 24 in this drawing, and it is
to be understood that this axis extends perpendicularly above and
below the plane of the FIG. 2 drawing. As shown, an aesthetically
appealing paint film laminate layer 27 is provided over the show
side 20 of the part.
[0018] FIG. 3 is a sectional view taken along the lines and arrows
3-3 in FIG. 1 and shows, in phantom, attachment of the rocker panel
to the requisite car framing member 26. Here, the top leg 12 of the
rocker panel fits snugly in the indentation 28 provided on the car
frame, and the upward pivoting position of the attachment leg 14 is
shown in phantom by reference numeral 30. A bolt or the like will
then be placed through the opening in the frame and the attachment
leg 14.
[0019] Turning now to FIG. 4, there is shown a mold structure for
forming the side sill in accordance with the invention. Although a
three-part mold is shown herein, the same part can be made with a
traditional two-part mold. As shown, the mold structure comprises
male part 32, female part 34, and slide member 36. As shown, the
male and female parts will separate from each other as one or both
of these members will be reciprocally moveable along a horizontal
plane with the slider 36, upon completion of the mold cycle,
sliding downwardly with regard to the view shown in the figure, so
that the part may be ejected. Part line 50 is provided in the mold,
and a gate 52 is positioned through the male part so as to provide
for entry of molten plastic into the mold cavity 53. The mold
cavity 53 comprises top and bottom terminal portions 56, 58 which
extend away from the intermediate portion 60 of the cavity. A
hinge-forming member 54 is provided in one of the mold parts so as
to provide for a hinge score line or the like in the finished
plastic part to form a living hinge by which the attachment leg of
the finished part may be pivoted into engagement with the requisite
frame member as shown in FIG. 3.
[0020] As is apparent, the terminal portions 56, 58 of the cavity,
upon completion of the molding cycle, correspond to and will form
the opposing longitudinally extending edges of the finished
part.
[0021] In accordance with the invention, a method of molding a side
sill or rocker panel is provided in which the side sill will have,
in transverse cross section, a substantial "C" configuration
oriented transverse to the longitudinal axis passing through the
part. In the molding method, the mold cavity 53 defines a space
that is congruent with the intended cross-sectional shape of the
part.
[0022] As can be seen in FIG. 4, the mold cavity has opposing
terminal portions 56, 58, and a hinge-forming member is provided
along one of the terminal portions. After the plastic is injected
into the mold and allowed to set, the part is ejected and conforms
to the desired substantially "C" cross-sectional shape. A hinge
detachment leg is provided along one of the end portions of the
part. The part may then be positioned adjacent an automotive
framing member with the attachment leg being pivoted to secure
fastening thereof to the frame.
[0023] Turning to FIG. 6, there is shown a diagram showing the
angular relationship between the top leg 12 and bottom attachment
leg 14 of the part. Here, the top leg 12 is shown on the chart as
position a with b1 on the chart corresponding to the position of
the attachment leg 14 as it is molded (i.e., in the mold). Here, it
can be seen that the angle between the legs a, b1 while in the
mold, is slightly less than 180.degree.. However, due to the
provision of the hinge member, when the part is finished and the
attachment leg pivoted to its desired attachment position, the
angle between the top leg and bottom attachment leg can be greatly
increased so as to provide almost a closed circular cross section.
More specifically, this relationship is shown by the angular
position between point a and b2 with b2 representing the angular
position of the bottom attachment leg 14 after its pivotal
movement, for example, to the phantom position illustrated in FIG.
3. Here, it can be seen that this angle is greater than
180.degree., and as shown, is approximately between 225.degree. and
270.degree.. This is important in that this particular
substantially "C" or circular cross section could not be directly
molded without the use of complicated mechanisms. Traditional molds
could not be used since the part would not be capable of being
removed from the mold cavity, in the absence of elaborate
machinery, due to this almost substantially circular configuration.
Accordingly, as used herein, the phrase "substantially closed `C`
position" means that the edges a and b will have an angular
relationship of at least 180.degree..
[0024] With regard to the molten resins that may be utilized to
form the side sill, a host of thermoplastic polymers may be
mentioned. These include injection moldable thermoplastic resins
such as acrylonitrile-butadiene-styrene, acetals, acrylics,
phenolic, polyamides, polycarbonates, copolyesters, polyethylene,
polypropylene, polystyrene, polyurethane, polyvinyl chloride,
styrene/acrylonitrile blends, acrylonitrile-butadiene
styrene/polycarbonate blends,
acrylonitrile-butadiene-styrene/thermoplastic polyurethane blends,
polybutylene terephthalate/polycarbonate alloys, olefins,
thermoplastic poiyolefins, thermoplastic polyesters, vinyls,
polybutylene terephthalates, glass filled polybutylene
terephthalates, polyphenylene oxides, blends and alloys of
polycarbonate and polybutylene terephthalate, polyphenylene esters,
blends of polyamides and polyphenylene esters and oxides, and
blends of polyolefin and rubber and/or ethylene-propylene-diene
monomer. At present, polypropylene is preferred.
[0025] As above indicated, the show side surface of the part can be
desirably covered with a thin paint film. This is accomplished via
conventional co-molding techniques wherein the film is first
supplied to the mold cavity followed by injection of a molten
polymer. The polymer fuses along one side of the film member with
the outer show side of the film then presented along the finished
surface of the part.
[0026] The paint film laminate used in these co-molding or insert
molding techniques may comprise a backing sheet of about 0.020'' in
thickness to which paint layers are adhered to form a colored side
of the laminate. Typically, the backing sheet comprises an extruded
thermoplastic sheet.
[0027] 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 coat, clear coat and
print or design, if desired, may range from about 0.5-4mil. in
thickness.
[0028] The laminated paint films are commercially available. The
films are typically provided in a roll, unwound, then trimmed to a
proper "preform" size and shape, ready for insertion into the
injection mold. The preform is usually placed along the cavity side
of the 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.
[0029] Techniques for preforming paint film laminates and insert or
co-molding of the laminate and substrate are disclosed, for
example, in U.S. Pat. No. 5,599,608 (Yamamoto et al.); U.S. Pat.
No. 5,746,962 (Yamamoto); U.S. Pat. No. 5,759,477 (Yamamoto); U.S.
Pat. No. 5,783,287 (Yamamoto et al.); U.S. Pat. No. 5,968,444
(Yamamoto); U.S. Pat. No. 6,168,742 (Yamamoto); and U.S. Pat. No.
6,227,319 (Hardgrove et al.). The disclosures of these patents are
incorporated by reference herein.
[0030] While the methods and trim part herein described constitute
preferred embodiments of this invention, it is to be understood
that the invention is not limited to these specifically disclosed
embodiments and that changes may be made without departing from the
scope of the invention, which is defined in the appended
claims.
* * * * *