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WO1997016294A1 - Procede de fabrication d'une piece de vehicule peinte - Google Patents

Procede de fabrication d'une piece de vehicule peinte Download PDF

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Publication number
WO1997016294A1
WO1997016294A1 PCT/US1996/017313 US9617313W WO9716294A1 WO 1997016294 A1 WO1997016294 A1 WO 1997016294A1 US 9617313 W US9617313 W US 9617313W WO 9716294 A1 WO9716294 A1 WO 9716294A1
Authority
WO
WIPO (PCT)
Prior art keywords
film carrier
air bag
painted
paint
bag cover
Prior art date
Application number
PCT/US1996/017313
Other languages
English (en)
Inventor
Larry J. Winget
David J. Davis
Original Assignee
Winget Larry J
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 Winget Larry J filed Critical Winget Larry J
Priority to AU74815/96A priority Critical patent/AU7481596A/en
Publication of WO1997016294A1 publication Critical patent/WO1997016294A1/fr

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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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/78—Moulding material on one side only of the preformed part
    • 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
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14811—Multilayered articles
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • B29C48/08—Flat, e.g. panels flexible, e.g. films
    • 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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/681—Component parts, details or accessories; Auxiliary operations
    • B29C70/683—Pretreatment of the preformed part, e.g. insert
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • 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
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/001—Shaping in several steps
    • 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
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/006—Using vacuum
    • 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
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0081—Shaping techniques involving a cutting or machining operation before shaping
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0011—Combinations of extrusion moulding with other shaping operations combined with compression moulding
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0017—Combinations of extrusion moulding with other shaping operations combined with blow-moulding or thermoforming
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0023—Combinations of extrusion moulding with other shaping operations combined with printing or marking
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/07—Flat, e.g. panels
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/15—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor incorporating preformed parts or layers, e.g. extrusion moulding around inserts
    • B29C48/154—Coating solid articles, i.e. non-hollow articles
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • 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
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/10—Forming by pressure difference, e.g. vacuum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2711/00—Use of natural products or their composites, not provided for in groups B29K2601/00 - B29K2709/00, for preformed parts, e.g. for inserts
    • B29K2711/14—Wood, e.g. woodboard or fibreboard
    • 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
    • B29L2009/00—Layered products
    • 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
    • B29L2009/00—Layered products
    • B29L2009/005—Layered products coated
    • B29L2009/006—Layered products coated painted
    • 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
    • B29L2031/3005—Body finishings
    • 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
    • B29L2031/3005—Body finishings
    • B29L2031/3038—Air bag covers
    • 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
    • B29L2031/722—Decorative or ornamental articles

Definitions

  • This invention relates to methods of manufac- turing painted parts, and in particular to methods of manufacturing painted plastic parts adapted for use on motor vehicles such as air bag covers and doors.
  • plastic automotive parts are painted after they are molded.
  • plastic parts are composite plastic parts wherein an outer layer of the part is in-molded with a structural substrate of the part.
  • Supplemental occupant restraint systems for motor vehicles typically require plastic covers which allow an air bag to exit the air bag cover when deployed.
  • One type of air bag cover includes a front panel which has a predetermined tear seam design formed therein to allow the air bag to exit the air bag cover when deployed.
  • Another type of air bag cover i.e., on the passenger side
  • the air bag cover performs the utilitarian function of breaking apart along its prede ⁇ termined tear seam design, but it should also match the vehicle interior decor and trim materials such as the instrument panel, seats, door panels, steering wheel and posts .
  • the air bag cover not only must the air bag cover allow the air bag to exit the air bag cover when deployed, but also the air bag cover must stay together to the extent that it does not break apart so as to present projec ⁇ tile (s) which may injure an occupant of the motor vehi ⁇ cle.
  • the air bag cover be relatively stiff so as to be properly secured to the rest of the air bag system and also possibly during horn actuation, it is also desirable that the surface of the air bag which faces the occupants of a vehicle be soft and smooth to the touch.
  • U.S. Patent No. 5,354,397 discloses a molding product, such as an interior automotive product, which is covered with a "soft touch feeling” sheet and is produced by placing the sheet in a mold and covering the sheet with a resin.
  • U.S. Patent No. 5,178,708 discloses a multi ⁇ layer molded article, such as an automotive part, including a fiber-reinforced resin sheet in a vertical press and which has a "soft feeling".
  • U.S. Patent No. 5,401,449 discloses an automo ⁇ tive door panel having a "soft luxurious feel" made by laying a facing layer of soft trim on a mold, placing a reinforced fiber mat, a foam layer, and an adhesive layer over the facing layer and injecting plastic into the mold.
  • U.S. Patent No. 5,362,342 discloses a method of producing a molded panel for a vehicle using a low pressure stream of two-component foamable liquid.
  • U.S. Patent Nos. 5,304,273 and 5,106,679 disclose molded panels for vehicles having laminated fibrous layers.
  • U.S. Patent No. 5,261,984 discloses a stamp press for printing decorative textures in thermoplastic composites.
  • An object of the present invention is to provide a method for manufacturing a painted vehicle part while addressing paint quality issues such as: drips, runs, spits, dry spray, light coverage, gloss, color match, contamination and paint adhesion.
  • Another object of the present invention is to provide a method for manufacturing a painted vehicle part and reducing molding scrap due to splay, flow marks and minor surface imperfections which can be completely covered.
  • Yet still another object of the present invention is to provide a method for manufacturing a painted vehicle part, such as a composite air bag cover, wherein the air bag cover has increased durability.
  • a method for manufacturing a painted plastic part adapted for use on a motor vehicle.
  • the method includes the steps of providing a bondable film carrier having top and bottom surfaces, coating the top surface of the film carrier with a layer of paint to obtain a painted film carrier and placing the painted film carrier in a mold cavity of an injection mold having a shape defining the plastic part.
  • the method further includes the step of injecting a thermoplastic elastomer into the mold cavity of the injection mold to generate a structural substrate for the plastic part. The generation of the structural substrate creates sufficient pressure and heat to bond the structural substrate to the bottom surface of the film carrier to form the painted plastic part.
  • a method for manufacturing a painted air bag cover for an inflatable air bag system.
  • the method includes the steps of providing a bondable film carrier having top and bottom surfaces, coating the top surface of the film carrier with a layer of paint to obtain a painted film carrier and placing the painted film carrier in a mold cavity of an injection mold having a shape defining the air bag cover.
  • the method also includes the step of injecting a thermoplastic elastomer into the mold cavity of the injection mold to generate a structural substrate for the air bag cover. The generation of the structural substrate creates sufficient pressure and heat to bond the structural substrate to the bottom surface of the film carrier to form the air bag cover.
  • FIGURE 1 is an environmental view showing two types of air bag covers constructed in accordance with the method of the present invention
  • FIGURE 2 is a front elevational view of one type of air bag cover adapted to be mounted at an end of a steering wheel post;
  • FIGURE 3 is a sectional view of the air bag cover of Figure 2 taken along lines 3-3 in Figure 2;
  • FIGURE 4 is a sectional view of the air bag cover of Figure 2 taken along lines 4-4 in Figure 2;
  • FIGURE 5 is a front elevational view of the second type of air bag cover adapted to be secured within an opening formed in a dashboard or instrument panel on the passenger side;
  • FIGURE 6 is a sectional view of the air bag cover of Figure 5 taken along lines 6-6 of Figure 5;
  • FIGURE 7 is a sectional view of the air bag cover of Figure 5 taken along lines 7-7 of Figure 5;
  • FIGURE 8 is a schematic view of a conventional injection molding system and a conventional vacuum molding system which may be utilized to make the air bag covers of the present invention.
  • FIGURE 9 is a block diagram flow chart illus- trating the various method steps taken to practice the method of the present invention in order to make the air bag covers.
  • FIG 1 an environmental view showing first and second embodiments of an air bag cover, generally indicated at 10 and 110, respectively, con ⁇ structed in accordance with the method of the present invention.
  • the air bag cover 10 preferably is installed over an inflatable air bag system, a portion of which is shown at 12 in Figure 4, mounted at the end of a steer ⁇ ing wheel post (not shown) having a steering wheel 14.
  • the occupant restraint air bag system is typically mounted at the interior end of the steering wheel post within the steering wheel 14 so that the air bag may deploy between the vehicle driver and the steering wheel post to prevent injury during an accident or other period of sudden deceleration.
  • the air bag cover 110 is typically mounted in a surface 112 of a dashboard or instrument panel, generally indicated at 114, located in underlying rela ⁇ tionship to a sloped front windshield 116.
  • the air bag cover 10 includes a one-piece thermoplastic elastomeric body, generally indicated at 16, which is preferably injection molded in an injection mold ( Figure 8) and has a predetermined tear seam design as indicated at 18.
  • the thermoplastic elastomeric body 16 includes a front panel 20 having front contact and back surfaces 22 and 24, respectively, and side panels 26 and 28 which extend from the back surface 24 of the front panel 20 and which are adapted to secure the air bag cover 10 over an inflatable air bag system by incorporating holes therein to enable fastening members such as screws to secure the air bag cover 10 to a canister or mounting plate 12 of the air bag system.
  • the air bag cover 10 also includes a painted one-piece outer layer, generally indicated at 30, vacuum molded in a vacuum mold ( Figure 8) from a thermoplastic material compatible with the thermoplastic elastomer of the body 20 so that a bottom contact surface 32 of the film carrier 30 bonds with the front contact surface 22 of the front panel 20 by diffusion between the surfaces 22 and 32 thereof in the injection mold to prevent the body 20 from separating from the film carrier 30 during use of the air bag cover 10.
  • the plastic material of the film carrier 30 is painted or covered by wiping with a "soft touch" flexi- ble paint which gives the perception of a soft feel to the outer surface of the cover or door.
  • the soft feel may be achieved by wiping a clear, low- gloss coating 33 over a layer of two component paint 31.
  • the film carrier can be PVC, urethane or other similar bondable film such as is currently avail ⁇ able from Kay Automotive Graphics located in Auburn Hills, Michigan.
  • the thermoplastic elastomer of the body 16 is TPO, polyester or similar thermoplastic. The durometer and elastic or flex modulus of the materials can vary depending on the desired stiffness of the cover.
  • the duro ⁇ meter of the body 20 will be in the range of about 37 Shore D to 52 Shore D, while the flexural modulus will be in the range of about 30,000 to 70,000 psi. Also, typically, the durometer of the film carrier 30 will be in the range of about 85 Shore A to 90 Shore A if urethane and 30 Shore D to 40 Shore D if PVC.
  • the film carrier 30 does not have a predetermined tear seam design formed therein coincident with the predetermined tear seam designed 18 formed in the front panel 20. Rather, the thickness of the film carrier 30 is so small (i.e., typically 6.5 to 9.5 mm with paint if urethane and 5 to 8 mm with paint if PVC) that the film carrier 30 tears to allow the air bag to exit the air bag cover 10 when deployed.
  • the front panel 20 has curved side contact surfaces 36 and 38 extending from the front surface 22 and wherein the contact surface 32 of the film carrier 30 is bonded with the contact surfaces 36 and 38 of the front panel 20 by diffusion between the surfaces.
  • the unitary composite air bag cover 110 also includes a one-piece thermoplastic elastomeric body, generally indicated at 118, which is injection molded in an injection mold ( Figure 8) with a predetermined tear seam design 120 formed therein, as illustrated in Figure 7.
  • the body 118 also includes a panel 122 having front contact and back surfaces 124 and 126, respectively.
  • the body 118 also includes side panels 128 which extend from the back surface 126 of the panel 122 and which are adapted to secure the air bag cover 110 over an inflat ⁇ able air bag system (not shown) by being apertured at holes 130.
  • the holes 130 are adapted to receive screws or other fasteners to secure the air bag cover 110 to a canister or mounting plate of its covered air bag system.
  • the air bag cover 110 also includes a painted one-piece film carrier, generally indicated at 132, which is vacuum molded in a vacuum mold ( Figure 8) from a thermoplastic material compatible with the thermoplas ⁇ tic elastomer of the body 118 so that a bottom contact surface 134 of the film carrier 132 bonds with the contact surface 124 of the front panel 122 by diffusion between the contact surfaces 124 and 134 thereof in the injection mold ( Figure 8) to prevent the body 118 from separating from the outer layer 132 during use of the air bag cover 110.
  • a painted one-piece film carrier generally indicated at 132, which is vacuum molded in a vacuum mold ( Figure 8) from a thermoplastic material compatible with the thermoplas ⁇ tic elastomer of the body 118 so that a bottom contact surface 134 of the film carrier 132 bonds with the contact surface 124 of the front panel 122 by diffusion between the contact surfaces 124 and 134 thereof in the injection mold ( Figure 8) to prevent the body 118 from separating from the outer layer 132 during use of
  • the film carrier 132 is painted in the same fashion as the film carrier 30 so that the painted film carrier 132 has a "soft touch" .
  • the thermoplastic elastomer of the body 118 is TPO, polyester or similar thermoplastic and the corresponding thermoplastic material of the film carrier 132 is PVC, urethane, or similar thermoplastic, as in the case of the air bag cover 10.
  • one of the side panels 128 of the body 118 has the predetermined tear seam 120 formed therein to allow the air bag to exit the air bag cover 110 when deployed.
  • the 122 has curved side contact surface 136 extending from the front contact surface 124 and the contact surface 134 of the film carrier 132 is bonded with the contact surfaces 136 of the front panel 122 by diffusion between the contact surfaces 136 and 134 by the temperature and pressure within the mold cavity of the injection mold.
  • FIG 8 there is illustrat ⁇ ed a conventional injection molding system, generally indicated at 210, and a conventional vacuum molding system, generally indicated at 310, for collectively making a unitary composite air bag cover (either 10 or 110) of the present invention.
  • the injection molding system 210 includes an injection molding machine, generally indi- cated at 212, having a nozzle, generally indicated at 214, for injecting predetermined amounts or shots of molten resin.
  • the injection molding machine 212 in ⁇ cludes a hydraulic screw ram 216 which is disposed in a bore 218 formed in a barrel 220 of the injection molding machine 212.
  • the ram 216 plasticizes and advances resin towards the nozzle 214.
  • the screw ram 216 Upon complete plasticization of -li ⁇ the resin, the screw ram 216 is hydraulically advanced towards threaded portions 222 of the barrel 220 to inject molten plastic through the nozzle 214, as is well known in the art.
  • the system 210 also includes a mold or mold body generally indicated at 228.
  • the mold 220 comprises a two-plate mold body.
  • One of the plates includes a locating ring 230 for locating the injection end of the nozzle 214.
  • the locating ring 230 is mounted on a clamp plate 232 which, in turn, is fixably connected to a cavity retainer plate or cavity plate 234.
  • a sprue bushing 236 is disposed within the locating ring 230 and is supported by the clamp plate 232.
  • Leader pins 238 on the cavity plate 234 provide the male half of the male-female connection of the first plate with the second plate of the two- plate mold 228.
  • the second plate in ⁇ cludes leader pin bushings (not shown) which slidably receive and retain the leader pins therein in the closed position of the mold 228.
  • the leader pin bushings are retained within a core retainer plate 242.
  • the core retainer plate 242 is fixably connected to a support plate 244 which in turn is connected to an injector retainer plate 246.
  • the injector retainer plate 246 is connected to an injector plate 248 which, in turn, is supported by support pillars 250.
  • Support plate 244 is also fixably connected to the ends of a U-shaped ejector housing 252 to which the support pillars 250 are also connected.
  • the plate 246 supports a plurality of return pins 254 and ejector pins 256 which extend toward the plate 234 and through the plates 242 and 244.
  • the ejector pins 256 are provided for ejecting particular injection molded part(s) from the mold 228.
  • Opposing surfaces of male and female mold parts 258 and 260 respectively define a mold cavity 262.
  • the mold part 258 is supported on the plate 242 and the mold part 260 is supported on the cavity retainer plate 234.
  • thermoplastic film carrier 300 As illustrated in Figure 8, there is illus ⁇ trated how a one-piece thermoplastic film carrier 300 is first vacuum molded in the vacuum molding system 310 and then placed in the mold cavity 262. Thereafter, the body or structural substrate is molded in the plastic injection molding system 210 to form a completed unitary composite air bag cover wherein the one-piece painted film carrier 302 is bonded to the body.
  • thermoplastic substrate which includes a predetermined tear seam design to allow the air bag to exit the cover when deployed is molded with a painted preform formed in a vacuum molding system. After this procedure, the substrate and the painted film carrier are bonded through the thermoplastic injection process to produce an air bag cover.
  • the body 16 or 18 of the air bag cover 10 or 110 may also be formed from polypropyl- ene, TPO (thermoplastic olefin) , TPU (thermoplastic ure ⁇ thane) or other similar thermoplastic.
  • TPO thermoplastic olefin
  • TPU thermoplastic ure ⁇ thane
  • the correspond ⁇ ing film carrier 30 or 132 must be compatible with the plastic of the body 16 or 118 so that diffusion (i.e., bonding) between contact surfaces occurs.
  • the unique features of the driver's side air bag and the passenger's side air bag cover are: i) a soft outer shell or layer to increase customer's satisfaction; ii) a stiff inner material to support the air bag cover during deployment (and during horn actuation with respect to the driver's side air bag cover) ; iii) reduction and/or elimination of paint problems such as drips, runs, spits, dry spray, light coverage and gloss and improved color match and paint adhesion; iv) reduced molding scrap due to splay, flow marks and minor surface imperfections, which can be completely covered; and v) increased durability of the air bag cover.
  • the film carrier can be positioned in the injection mold either by way of preform, as described above, or by way of a film roll supply. In this way, one can mold in the color at the press or mold thereby avoiding a secondary painting operation.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Manufacturing & Machinery (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

Procédé de fabrication d'une pièce peinte en matière plastique, telle qu'un masque (10) de sac gonflable de sécurité, comportant un corps (16) d'une seule pièce en élastomère thermoplastique ou un substrat structurel et un support (30) laminaire peint en une seule pièce réalisée dans un matériau thermoplastique compatible avec l'élastomère thermoplastique du corps (16). Une surface de contact de fond (32) du support laminaire (30) forme une liaison avec une surface de contact superficielle (22) du panneau superficiel (20) du corps (16) par diffusion entre leur surfaces de contact respectives. La température du masque (10) de sac de sécurité gonflable ainsi obtenue est ramenée à un niveau inférieur au point de ramolissement des deux matières plastiques de sorte qu'un gradient de concentration moléculaire se forme à l'interface entre la première et la deuxième matière plastique par diffusion à l'intérieur de la cavité de moulage (262) d'un moule à injection (210) distincte de la cavité de moulage d'un moule à vide (310) utilisé pour mouler sous vide le support laminaire (30) une fois que ledit support est peint.
PCT/US1996/017313 1995-11-01 1996-10-30 Procede de fabrication d'une piece de vehicule peinte WO1997016294A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU74815/96A AU7481596A (en) 1995-11-01 1996-10-30 Method of manufacturing a painted vehicle part

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US55151795A 1995-11-01 1995-11-01
US551,517 1995-11-01

Publications (1)

Publication Number Publication Date
WO1997016294A1 true WO1997016294A1 (fr) 1997-05-09

Family

ID=24201591

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1996/017313 WO1997016294A1 (fr) 1995-11-01 1996-10-30 Procede de fabrication d'une piece de vehicule peinte

Country Status (2)

Country Link
AU (1) AU7481596A (fr)
WO (1) WO1997016294A1 (fr)

Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3122598A (en) * 1960-11-03 1964-02-25 Foster Grant Co Inc Plastic decorating method
US4810749A (en) * 1987-05-04 1989-03-07 Corvita Corporation Polyurethanes
US4902557A (en) * 1988-01-25 1990-02-20 E. I. Du Pont De Nemours And Company Thermoplastic polyolefin composite structure
US4927675A (en) * 1985-12-31 1990-05-22 General Electric Company Filled core materials having unfilled outer attached layers
US4933237A (en) * 1989-02-17 1990-06-12 Eastman Kodak Company Paint coated sheet material with adhesion promoting composition
US5183615A (en) * 1990-11-13 1993-02-02 Takata Corporation Molding method of air bag cover
US5217563A (en) * 1988-12-01 1993-06-08 Bayer Aktiengesellschaft Apparatus for producing a deep-drawn formed plastic piece
US5286528A (en) * 1987-11-03 1994-02-15 Eastman Kodak Company Protective and decorative sheet material having a transparent topcoat
US5316822A (en) * 1991-07-23 1994-05-31 Nihon Plast Co., Ltd. Cover for vehicular air bag
US5344183A (en) * 1993-05-17 1994-09-06 Davidson Textron Inc. Multi-layer air bag cover with filled reinforced vinyl
US5466412A (en) * 1992-09-28 1995-11-14 Davidson Textron Inc. Method for forming an outer skin for a cover assembly
US5520412A (en) * 1995-06-02 1996-05-28 Larry Winget Thermoplastic air bag cover having a membrane switch

Patent Citations (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3122598A (en) * 1960-11-03 1964-02-25 Foster Grant Co Inc Plastic decorating method
US4927675A (en) * 1985-12-31 1990-05-22 General Electric Company Filled core materials having unfilled outer attached layers
US4810749A (en) * 1987-05-04 1989-03-07 Corvita Corporation Polyurethanes
US5286528A (en) * 1987-11-03 1994-02-15 Eastman Kodak Company Protective and decorative sheet material having a transparent topcoat
US4902557A (en) * 1988-01-25 1990-02-20 E. I. Du Pont De Nemours And Company Thermoplastic polyolefin composite structure
US5217563A (en) * 1988-12-01 1993-06-08 Bayer Aktiengesellschaft Apparatus for producing a deep-drawn formed plastic piece
US4933237A (en) * 1989-02-17 1990-06-12 Eastman Kodak Company Paint coated sheet material with adhesion promoting composition
US5183615A (en) * 1990-11-13 1993-02-02 Takata Corporation Molding method of air bag cover
US5316822A (en) * 1991-07-23 1994-05-31 Nihon Plast Co., Ltd. Cover for vehicular air bag
US5466412A (en) * 1992-09-28 1995-11-14 Davidson Textron Inc. Method for forming an outer skin for a cover assembly
US5344183A (en) * 1993-05-17 1994-09-06 Davidson Textron Inc. Multi-layer air bag cover with filled reinforced vinyl
US5520412A (en) * 1995-06-02 1996-05-28 Larry Winget Thermoplastic air bag cover having a membrane switch

Also Published As

Publication number Publication date
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