IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0438631
(2006-05-22)
|
등록번호 |
US-7425122
(2008-09-16)
|
발명자
/ 주소 |
- Winget,Larry J.
- Preisler,Darius J.
- Murar,Jason T.
|
출원인 / 주소 |
|
대리인 / 주소 |
Harness, Dickey & Pierce, P.L.C.
|
인용정보 |
피인용 횟수 :
2 인용 특허 :
63 |
초록
▼
A method is provided for manufacturing a painted plastic component such as painted air bag covers, side cladding or exterior bumpers, which includes a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contac
A method is provided for manufacturing a painted plastic component such as painted air bag covers, side cladding or exterior bumpers, which includes a painted film sheet and a one-piece thermoplastic elastomeric structural carrier. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the mold cavity of a vacuum mold which is utilized to vacuum-mold the film sheet to form the desired painted plastic component.
대표청구항
▼
What is claimed is: 1. A system for manufacturing a molded plastic component, the system comprising: a pre-painted film laminate sheet including a film sheet selected from the group consisting of polyester, polycarbonate, and polyurethane, said pre-painted film laminate sheet further including a la
What is claimed is: 1. A system for manufacturing a molded plastic component, the system comprising: a pre-painted film laminate sheet including a film sheet selected from the group consisting of polyester, polycarbonate, and polyurethane, said pre-painted film laminate sheet further including a layer of acrylic color, a layer of polyvinylidine fluoride and an acrylic clear coat; and an injection mold configured to accept the pre-painted film laminate sheet vacuum molded to define a pre-form, the injection mold further configured to receive a thermoplastic elastomer injected, at a pressure of 50 psi to 15,000 psi, into a mold cavity of the injection mold to generate a structural carrier for the pre-form, the generation of the structural carrier creating sufficient pressure and heat to bond the structural carrier to a bottom surface of the pre-form to form the molded plastic component. 2. The system of claim 1, wherein the thermoplastic elastomer is selected from the group consisting of a thermoplastic polyolefin, thermoplastic urethane, polyester, polycarbonate, acrylonitrile/butadiene/styrene, polypropylene, copolymer based thermoplastic elastomer, polyolefin ionomer alloy, a mixture of acrylonitrile/butadiene/styrene and polycarbonate, and mixtures thereof. 3. The system of claim 1 wherein the pre-painted film laminate sheet has a total thickness of 0.2 millimeters. 4. The system of claim 1 wherein the structural carrier has a flexural modulus in the range of 15,000 to 400,000 psi. 5. The system of claim 1 wherein the structural carrier has a durometer in the range of 15 Shore D to 100 Shore D. 6. The system of claim 1 wherein the polyvinylidine fluoride comprises more than fifty percent of the total thickness of the pre-painted film sheet. 7. The system of claim 1 wherein the structural carrier is bonded to the bottom surface of the pre-form by diffusion. 8. An injection molding system for manufacturing a molded plastic component, the injection molding system comprising: a pre-painted film laminate sheet including a film sheet selected from the group consisting of polyester, polycarbonate, and polyurethane, said pre-painted film laminate sheet further including a layer of acrylic color, a layer of polyvinylidine fluoride and an acrylic clear coat; an injection mold having an upper mold half and a lower mold half, the upper and lower mold halves cooperating to define a mold cavity of the injection mold, the mold cavity configured to accept the pre-painted film laminate sheet vacuum molded to define a pre-form; and a nozzle for injecting, at a pressure of 50 psi to 15,000 psi, a thermoplastic elastomer into the mold cavity to generate a structural carrier for the pre-form, the generation of the structural carrier creating sufficient pressure and heat such that the structural carrier is bonded to a bottom surface of the pre-form to form the molded plastic component. 9. The injection molding system of claim 8, wherein the thermoplastic elastomer is selected from the group consisting of a thermoplastic polyolefin, thermoplastic urethane, polyester, polycarbonate, acrylonitrile/butadiene/styrene, polypropylene, copolymer based thermoplastic elastomer, polyolefin ionomer alloy, a mixture of acrylonitrile/butadiene/styrene and polycarbonate, and mixtures thereof. 10. The injection molding system of claim 8 wherein the mold cavity is configured to accept a pre-painted film sheet having a total thickness of 0.2 millimeters. 11. The injection molding system of claim 8 wherein the structural carrier has a flexural modulus in the range of 15,000 to 400,000 psi. 12. The injection molding system of claim 8 wherein the structural carrier has a durometer in the range of 15 Shore D to 100 Shore D. 13. The injection molding system of claim 8 wherein the polyvinylidine fluoride comprises more than fifty percent of the total thickness of the pre-painted film sheet. 14. The injection molding system of claim 8 wherein the structural carrier is bonded to the bottom surface of the pre-form by diffusion. 15. An injection molding system for manufacturing an embossed molded plastic component, the injection molding system comprising: a pre-painted film laminate sheet including a film sheet selected from the group consisting of polyester, polycarbonate, and polyurethane, said pre-painted film laminate sheet further including a layer of acrylic color, a layer of polyvinylidine fluoride and an acrylic clear coat; an injection mold having an upper mold half and a lower mold half, the upper and lower mold halves cooperating to define a mold cavity of the injection mold, the mold cavity configured to accept a pre-painted film sheet vacuum molded to define a pre-form, at least one of the upper and lower mold halves being etched with at least one of a letter having at least a 0.5 millimeter radius on edge and a pattern; and a nozzle for injecting, at a pressure of 50 psi to 15,000 psi, a thermoplastic elastomer into the mold cavity to generate a structural carrier for the pre-form, the generation of the structural carrier creating sufficient pressure and heat such that the structural carrier is bonded to a bottom surface of the pre-form to form the embossed molded plastic component. 16. The injection molding system of claim 15, wherein the thermoplastic elastomer is selected from the group consisting of a thermoplastic polyolefin, thermoplastic urethane, polyester, polycarbonate, acrylonitrile/butadiene/styrene, polypropylene, copolymer based thermoplastic elastomer, polyolefin ionomer alloy, a mixture of acrylonitrile/butadiene/styrene and polycarbonate, and mixtures thereof. 17. The injection molding system of claim 15 wherein the mold cavity is configured to accept a pre-painted film sheet having a total thickness of 0.2 millimeters. 18. The injection molding system of claim 15 wherein the structural carrier has a flexural modulus in the range of 15,000 to 400,000 psi. 19. The injection molding system of claim 15 wherein the structural carrier has a durometer in the range of 15 Shore D to 100 Shore D. 20. The injection molding system of claim 15 wherein the structural carrier is bonded to the bottom surface of the pre-form by diffusion.
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