US20110045727A1 - Method and Apparatus for Manufacturing Vehicle Parts - Google Patents
Method and Apparatus for Manufacturing Vehicle Parts Download PDFInfo
- Publication number
- US20110045727A1 US20110045727A1 US12/917,890 US91789010A US2011045727A1 US 20110045727 A1 US20110045727 A1 US 20110045727A1 US 91789010 A US91789010 A US 91789010A US 2011045727 A1 US2011045727 A1 US 2011045727A1
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- Prior art keywords
- mold cavity
- mold
- plastic
- movable wall
- wall part
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Classifications
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- 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
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- 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
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- 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
- B29C45/16—Making multilayered or multicoloured articles
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- 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
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
- B29C45/56—Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression moulding
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- 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
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
- B29C45/56—Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression moulding
- B29C45/561—Injection-compression moulding
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
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- 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
- B29C2045/0098—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor shearing of the moulding material, e.g. for obtaining molecular orientation or reducing the viscosity
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- 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
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
- B29C45/56—Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression moulding
- B29C45/561—Injection-compression moulding
- B29C2045/563—Enlarging the mould cavity during injection
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- 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
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
- B29C45/56—Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression moulding
- B29C45/561—Injection-compression moulding
- B29C2045/564—Compression drive means acting independently from the mould closing and clamping means
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- 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
- B29C45/14311—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 using means for bonding the coating to the articles
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- 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
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1635—Making multilayered or multicoloured articles using displaceable mould parts, e.g. retractable partition between adjacent mould cavities
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- 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
- B29K2713/00—Use of textile products or fabrics for preformed parts, e.g. for inserts
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- 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
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- 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
- B29L2031/3041—Trim panels
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/249921—Web or sheet containing structurally defined element or component
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3049—Including strand precoated with other than free metal or alloy
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/30—Woven fabric [i.e., woven strand or strip material]
- Y10T442/3854—Woven fabric with a preformed polymeric film or sheet
Definitions
- the invention relates to a method for manufacturing vehicle parts from plastic in a mold.
- Plastic vehicle parts are typically manufactured by injection molding. Because these parts are typically relatively large in proportion to their wall thickness, this requires large, heavy-duty injection molding machines, being costly in purchase and use. Enlarging the wall thicknesses, which renders flowing easier, entails a prolonged injection molding cycle, increased material use, increased weight and can lead to unwanted stresses. This is therefore an undesirable solution.
- the object of the invention is to provide a method for manufacturing vehicle elements, whereby at least a number of the drawbacks known from the prior art are prevented. To that end, a method according to the invention is characterized by the features according to claim 1 .
- the plastic can be introduced into the mold cavity at relatively low temperature, after which the plastic, through movement of at least one wall part of the mold cavity, is brought into its eventually desired shape. That requires relatively little force and hence relatively little pressure.
- the mold cavity is reduced so fast as to result in adiabatic heat development in the plastic, so that the flow behavior of the plastic is further improved.
- the plastic In reducing the volume of the mold cavity, the plastic is forced in the direction of the ends of the mold cavity, whereby at all times the optimum ratio between the melt flow index and the incidental flow path can be obtained.
- the mold can be kept closed with a particularly low closing force compared with closing forces required in conventional injection molding technique for manufacturing a comparable product.
- An additional advantage of a method according to the invention is that it allows wall thicknesses to be reduced locally, even to a thickness below that which can be achieved with conventional injection molding technique in a product of comparable dimensions, without unwanted stress concentrations occurring.
- inserts can be laid in the mold cavity, for fastening in or to the plastic. Since low pressures and flow rates are achieved, these inserts will not be damaged, at least less easily than in conventional technique.
- labels in particular in-mold labels, can be placed for obtaining a desired finish.
- decorative labels can be used for coloring or patterns, such as, for instance, wood finish.
- natural materials can be used, for instance wood.
- inserts can be used that are based on textile, such as woven or nonwoven textile. With such inserts, covering panels can be manufactured in one piece, in one production pass, while moreover a switch in material for the covering can be made particularly fast and simply.
- an inner covering panel for a door, seat, wall finish, roof lining or the like can be manufactured, with one side covered with a fabric covering matching the interior of the vehicle.
- Fabric or textile is here understood to mean at least comprising natural or synthetic woven or nonwoven materials. It is then preferred that the textile, at least the fabric, is provided with a plastic backing and/or plastic threads or threads which are covered with plastic, for instance as warp and/or weft, so that a proper connection can be obtained with the plastic from which the part is manufactured.
- plate parts can be manufactured for, for instance, the outside of a vehicle, such as bodywork parts for a car or boat or covering panels for airplanes and ships.
- a desired profiling or other surface finish can be directly obtained, for instance drop or rib structures for influencing air resistance, flow, dirt repulsion and the like.
- a part is built up by injection molding different layers against each other, as described in claim 8 .
- the volume of the mold cavity is enlarged each time after an injection molding pass, after which a new layer of plastic is introduced into the thus created space.
- a gleaming inner layer for a reflector can be injection molded, after which a support is formed from a suitable plastic against the “outer side” thereof, or vice versa.
- sandwich constructions can be manufactured.
- manufacturing costs can be considerably reduced and accuracy enhanced, while mechanical properties can be considerably improved.
- the volume of the mold cavity is enlarged and subsequently reduced to the shape of the desired product.
- the movable wall part can also be pushed away by the injected plastic, so that a constant back pressure is maintained and a suitable flow path melt flow index ratio is maintained at all times.
- Such a method is particularly suitable for, for instance, PET.
- a method and mold according to the invention can be used particularly suitably for a variety of covering elements such as TRIM parts and the like, plating, bodywork parts and the like.
- the speed of moving the or each movable wall part is preferably chosen to be higher than the speed at which the mold is opened and/or closed.
- the closing pressure can be kept relatively low, for instance lower than the injection pressure for the plastic, at least lower than such an injection pressure for conventional injection molding of a comparable product.
- the invention furthermore relates to a vehicle part according to claim 15 and to a textile for use according to claim 19 , as well as to a mold according to claim 20 .
- FIG. 1 shows schematically in sectional side view a mold for manufacturing a vehicle part according to the invention, in a first phase of manufacture
- FIG. 2 shows the mold according to FIG. 1 during a second phase of manufacture
- FIGS. 3A-C show an alternative embodiment of a mold according to the invention
- FIG. 4 shows schematically in sectional side view a vehicle part manufactured with a mold according to FIG. 3 ;
- FIG. 5 shows in sectional side view a covering panel according to the invention
- FIG. 6 shows, enlarged, a portion of a panel according to FIG. 5 ;
- FIG. 7 shows in sectional side view a portion of an alternative embodiment of a covering panel according to the invention.
- a mold 50 comprising a first part 51 and a second part 52 , while in the second part 52 a movable wall part 53 is provided, operable from outside of the mold 50 by arms 54 , schematically represented in FIGS. 1 and 2 .
- a mold cavity 55 is recessed, a portion of which is defined by the movable wall part 53 .
- a vehicle part 1 such as a covering element, can be formed.
- the movable wall part 53 is moved in the direction of the first part 51 to a second position, so that the volume of the mold cavity decreases to the desired end volume, while or whereupon holding pressure is applied in the usual manner to fill the mold cavity completely and obtain a substantially stress-free product.
- a vehicle part 1 has been formed being wholly dimensionally stable.
- the mold 50 is kept closed, represented schematically by closing elements 56 .
- FIG. 3 schematically shows in sectional side view an alternative embodiment of a mold 50 according to the invention, again with two mold parts 51 , 52 and a mold cavity 55 .
- the mold cavity 55 in this embodiment is bounded on one side by a movable wall part 53 , controllably movable with the aid of drive means 60 , such as piston rods 61 movable by pistons 62 .
- drive means 60 such as piston rods 61 movable by pistons 62 .
- there may be different operating means for instance screw means, electrically operable means, pneumatic means and the like.
- the movable wall part 53 can be moved to a first position, shown in FIG. 3A ; to a second position, in which the volume of the mold cavity 55 is reduced, as shown in FIG. 3B ; or to a third position, as shown in FIG. 3C , in which the volume is increased still further.
- a product as shown in FIG. 4 can be manufactured.
- a label 63 has been laid, for instance, on the wall part 53 or on the opposite part 51 .
- a first layer of plastic 64 has been injected against the label.
- the movable wall part 53 has been retracted into the third position as shown in FIG. 3C , after which a second layer of plastic 65 has been injection molded against it.
- the label 63 and/or the first layer 64 can be, for instance, reflecting and resistant to, for instance, heating by lamps, while the second layer of plastic 65 can serve as carrier.
- FIG. 5 shows schematically in sectional side view a covering panel for, for instance, a door, seat, wall or like vehicle parts.
- This vehicle part comprises a plate-shaped carrier 2 , which can be mounted in a vehicle, for instance in a door, with mounting lugs 3 which have been integrally injection molded or have been provided as inserts.
- a covering 4 is provided, substantially manufactured from textile in the embodiment shown.
- This can be a woven or nonwoven textile, preferably matching a vehicle interior.
- the textile may be manufactured from synthetic and from natural materials.
- This covering 4 has been arranged by placing it in a mold cavity 55 , similarly to in-mold labeling technique, after which the panel 2 has been formed against it with a method as described earlier.
- a covering panel can be obtained in one piece in this way.
- FIG. 6 shows, enlarged, a portion of a panel 1 according to FIG. 5 , comprising the panel 2 and the covering 4 .
- the covering 4 is provided with a carrier 5 manufactured from a plastic compatible with the plastic of the panel 2 , such that these are connected through fusion and/or chemical bonding.
- a proper connection has been obtained.
- the textile of the covering 4 is protected by the layer 5 .
- a woven textile can be used, with at least a portion of warp and/or weft being provided with a plastic covering or being designed in plastic, comparably compatible with the plastic of the panel 2 . In that way too, a proper connection can be obtained.
- FIG. 7 shows schematically an alternative embodiment of a panel 1 according to the invention, again comprising a carrier 2 with a covering 4 , which covering, in this embodiment, is arranged as a label, for instance for decorative purposes.
- the label 4 can have a profiling, for instance ribs, drops or the like, so that flow can be influenced, resistance can be changed, the appearance can be modified, and so forth.
- vehicle parts can be manufactured for, for instance, cars, airplanes, and ships, in particular trim elements, such as inner coverings, dashboards, roof lining and door covering elements, or external covering elements, such as plating parts, bumpers, engine covering and guarding parts, parts of seats, seat benches, bodywork parts and the like. Also, in this way, for instance complete doors, hoods, boot lids and the like can be manufactured, as well as sliding roofs and the like.
- trim elements such as inner coverings, dashboards, roof lining and door covering elements
- external covering elements such as plating parts, bumpers, engine covering and guarding parts, parts of seats, seat benches, bodywork parts and the like.
- complete doors, hoods, boot lids and the like can be manufactured, as well as sliding roofs and the like.
- the movable wall part 53 is held in a forwardly moved second position during injection of plastic, so as to be pushed away by the plastic to the first position.
- This is specifically advantageous for, for instance, low melt plastics or plastics such as PET, specifically if these are to be translucent.
- movable wall parts can be combined in a mold cavity, which can be moved simultaneously or sequentially.
- the movable wall parts can move both rectilinearly and along curves, for instance for the controlled displacement of plastic.
- the plastic can be introduced in molten condition but may also be introduced as granulate or the like directly into the mold cavity.
- Parts manufactured with a method according to the invention can be provided on one or more sides with a finish or covering such as textile or label, for instance from plastic.
Abstract
The invention relates to a method for manufacturing at least partly plastic vehicle parts in a mold with at least one mold cavity, comprising the steps of at least partly closing the mold, wherein the at least one mold cavity is brought in a first position by means of at least one movable wall part of the at least one mold cavity; introducing plastic into the at least one mold cavity; upon complete closure of the mold and/or movement of the at least one movable wall part, bringing the at least one mold cavity in a second position, the at least one mold cavity in the second position having a different volume than in the first position; all this in such a manner that by bringing the at least one mold cavity from the first into the second position, the plastic fills the respective mold cavity completely.
Description
- The invention relates to a method for manufacturing vehicle parts from plastic in a mold.
- Plastic vehicle parts are typically manufactured by injection molding. Because these parts are typically relatively large in proportion to their wall thickness, this requires large, heavy-duty injection molding machines, being costly in purchase and use. Enlarging the wall thicknesses, which renders flowing easier, entails a prolonged injection molding cycle, increased material use, increased weight and can lead to unwanted stresses. This is therefore an undesirable solution.
- It has previously been proposed to make use of cascade injection molding techniques, whereby a flow front moving through the mold is obtained. However, this requires special injection molding machines and peripheral equipment therefor and makes placement of inserts such as labels and the like, fastening elements and strengthening elements difficult to apply.
- The object of the invention is to provide a method for manufacturing vehicle elements, whereby at least a number of the drawbacks known from the prior art are prevented. To that end, a method according to the invention is characterized by the features according to
claim 1. - In a method according to the invention, it has surprisingly been found that, as a consequence, the plastic can be introduced into the mold cavity at relatively low temperature, after which the plastic, through movement of at least one wall part of the mold cavity, is brought into its eventually desired shape. That requires relatively little force and hence relatively little pressure. Without wishing to be bound to any theory, this seems to be at least the result of the fact that as the mold cavity can be temporarily enlarged, the plastic can flow into the mold cavity with less back pressure, while moreover the plastic needed for the part only needs to spread over a smaller surface. Preferably, further, the mold cavity is reduced so fast as to result in adiabatic heat development in the plastic, so that the flow behavior of the plastic is further improved. In reducing the volume of the mold cavity, the plastic is forced in the direction of the ends of the mold cavity, whereby at all times the optimum ratio between the melt flow index and the incidental flow path can be obtained. As a result, the mold can be kept closed with a particularly low closing force compared with closing forces required in conventional injection molding technique for manufacturing a comparable product.
- An additional advantage of a method according to the invention is that it allows wall thicknesses to be reduced locally, even to a thickness below that which can be achieved with conventional injection molding technique in a product of comparable dimensions, without unwanted stress concentrations occurring.
- With a method according to the invention, furthermore, inserts can be laid in the mold cavity, for fastening in or to the plastic. Since low pressures and flow rates are achieved, these inserts will not be damaged, at least less easily than in conventional technique. Thus, for instance, labels, in particular in-mold labels, can be placed for obtaining a desired finish. For instance, decorative labels can be used for coloring or patterns, such as, for instance, wood finish. Also, natural materials can be used, for instance wood. Further, inserts can be used that are based on textile, such as woven or nonwoven textile. With such inserts, covering panels can be manufactured in one piece, in one production pass, while moreover a switch in material for the covering can be made particularly fast and simply.
- Thus, for instance, an inner covering panel for a door, seat, wall finish, roof lining or the like can be manufactured, with one side covered with a fabric covering matching the interior of the vehicle. Fabric or textile is here understood to mean at least comprising natural or synthetic woven or nonwoven materials. It is then preferred that the textile, at least the fabric, is provided with a plastic backing and/or plastic threads or threads which are covered with plastic, for instance as warp and/or weft, so that a proper connection can be obtained with the plastic from which the part is manufactured.
- Also plate parts can be manufactured for, for instance, the outside of a vehicle, such as bodywork parts for a car or boat or covering panels for airplanes and ships. With the aid of labels or the like, a desired profiling or other surface finish can be directly obtained, for instance drop or rib structures for influencing air resistance, flow, dirt repulsion and the like.
- In an alternative embodiment, in a mold, a part is built up by injection molding different layers against each other, as described in claim 8.
- In such a method, the volume of the mold cavity is enlarged each time after an injection molding pass, after which a new layer of plastic is introduced into the thus created space. Thus, for instance, in a light unit, first a gleaming inner layer for a reflector can be injection molded, after which a support is formed from a suitable plastic against the “outer side” thereof, or vice versa. Also, in this way, sandwich constructions can be manufactured. Thus, manufacturing costs can be considerably reduced and accuracy enhanced, while mechanical properties can be considerably improved.
- Preferably, when injecting plastic via an injection point such as a hot runner, the volume of the mold cavity is enlarged and subsequently reduced to the shape of the desired product. Alternatively, the movable wall part can also be pushed away by the injected plastic, so that a constant back pressure is maintained and a suitable flow path melt flow index ratio is maintained at all times. Such a method is particularly suitable for, for instance, PET.
- A method and mold according to the invention can be used particularly suitably for a variety of covering elements such as TRIM parts and the like, plating, bodywork parts and the like.
- The speed of moving the or each movable wall part is preferably chosen to be higher than the speed at which the mold is opened and/or closed. The closing pressure can be kept relatively low, for instance lower than the injection pressure for the plastic, at least lower than such an injection pressure for conventional injection molding of a comparable product.
- The invention furthermore relates to a vehicle part according to claim 15 and to a textile for use according to claim 19, as well as to a mold according to claim 20.
- In the further claims, advantageous embodiments of the invention are shown and described.
- To clarify the invention, exemplary embodiments of a method and apparatus according to the invention, as well as of products thereby obtained are presently described with reference to the drawing, wherein:
-
FIG. 1 shows schematically in sectional side view a mold for manufacturing a vehicle part according to the invention, in a first phase of manufacture; -
FIG. 2 shows the mold according toFIG. 1 during a second phase of manufacture; -
FIGS. 3A-C show an alternative embodiment of a mold according to the invention; -
FIG. 4 shows schematically in sectional side view a vehicle part manufactured with a mold according toFIG. 3 ; -
FIG. 5 shows in sectional side view a covering panel according to the invention; -
FIG. 6 shows, enlarged, a portion of a panel according toFIG. 5 ; and -
FIG. 7 shows in sectional side view a portion of an alternative embodiment of a covering panel according to the invention. - In this description, the same or corresponding parts have the same or corresponding reference numerals.
- The exemplary embodiments shown in the drawing are shown only by way of illustration and should not be construed as limiting in any way.
- In
FIG. 1 , amold 50 is shown, comprising afirst part 51 and asecond part 52, while in the second part 52 amovable wall part 53 is provided, operable from outside of themold 50 byarms 54, schematically represented inFIGS. 1 and 2 . Within themold 50, amold cavity 55 is recessed, a portion of which is defined by themovable wall part 53. In themold cavity 55, avehicle part 1, such as a covering element, can be formed. When injection molding is started, plastic is introduced into themold cavity 55 withmovable wall part 53 retracted in a first position, that is, the space of themold cavity 55 is relatively large. Next, when themold cavity 55 is substantially completely filled with plastic, for instance upwards of 80%, themovable wall part 53 is moved in the direction of thefirst part 51 to a second position, so that the volume of the mold cavity decreases to the desired end volume, while or whereupon holding pressure is applied in the usual manner to fill the mold cavity completely and obtain a substantially stress-free product. In the position shown inFIG. 2 , avehicle part 1 has been formed being wholly dimensionally stable. It is clear that during injection molding, themold 50 is kept closed, represented schematically byclosing elements 56. With such a method, in a particularly simple manner, apart 1 can be manufactured which is relatively dimensionally stable, using relatively light tools, and moreover a high degree of freedom in the choice of plastic is obtained. This is because by virtue of the movable wall part, during the major part of the filling of the mold, large flow paths are obtained, so that plastics having a high as well as plastics having a very low melt can be used. -
FIG. 3 schematically shows in sectional side view an alternative embodiment of amold 50 according to the invention, again with twomold parts mold cavity 55. Themold cavity 55 in this embodiment is bounded on one side by amovable wall part 53, controllably movable with the aid of drive means 60, such aspiston rods 61 movable bypistons 62. Of course, there may be different operating means, for instance screw means, electrically operable means, pneumatic means and the like. With these, themovable wall part 53 can be moved to a first position, shown inFIG. 3A ; to a second position, in which the volume of themold cavity 55 is reduced, as shown inFIG. 3B ; or to a third position, as shown inFIG. 3C , in which the volume is increased still further. - With such a
mold 50, for instance a product as shown inFIG. 4 can be manufactured. In this case, alabel 63 has been laid, for instance, on thewall part 53 or on theopposite part 51. Next, a first layer ofplastic 64 has been injected against the label. Next, themovable wall part 53 has been retracted into the third position as shown inFIG. 3C , after which a second layer ofplastic 65 has been injection molded against it. Thus, a sandwich construction has been obtained. Thelabel 63 and/or thefirst layer 64 can be, for instance, reflecting and resistant to, for instance, heating by lamps, while the second layer ofplastic 65 can serve as carrier. - It will be clear that with a comparable mold, also multiple layers can be provided and that also differently shaped products can be manufactured, for instance sandwich panels and the like.
-
FIG. 5 shows schematically in sectional side view a covering panel for, for instance, a door, seat, wall or like vehicle parts. This vehicle part comprises a plate-shapedcarrier 2, which can be mounted in a vehicle, for instance in a door, with mountinglugs 3 which have been integrally injection molded or have been provided as inserts. On the opposite side, acovering 4 is provided, substantially manufactured from textile in the embodiment shown. This can be a woven or nonwoven textile, preferably matching a vehicle interior. The textile may be manufactured from synthetic and from natural materials. Thiscovering 4 has been arranged by placing it in amold cavity 55, similarly to in-mold labeling technique, after which thepanel 2 has been formed against it with a method as described earlier. As a result of the relatively low pressures that occur in the mold cavity and relatively low temperatures, at least on the side of the textile, a covering panel can be obtained in one piece in this way. -
FIG. 6 shows, enlarged, a portion of apanel 1 according toFIG. 5 , comprising thepanel 2 and thecovering 4. It shows that thecovering 4 is provided with acarrier 5 manufactured from a plastic compatible with the plastic of thepanel 2, such that these are connected through fusion and/or chemical bonding. As a result, a proper connection has been obtained. Moreover, the textile of thecovering 4 is protected by thelayer 5. Alternatively, a woven textile can be used, with at least a portion of warp and/or weft being provided with a plastic covering or being designed in plastic, comparably compatible with the plastic of thepanel 2. In that way too, a proper connection can be obtained. -
FIG. 7 shows schematically an alternative embodiment of apanel 1 according to the invention, again comprising acarrier 2 with acovering 4, which covering, in this embodiment, is arranged as a label, for instance for decorative purposes. Thelabel 4 can have a profiling, for instance ribs, drops or the like, so that flow can be influenced, resistance can be changed, the appearance can be modified, and so forth. - With a method according to the present invention, vehicle parts can be manufactured for, for instance, cars, airplanes, and ships, in particular trim elements, such as inner coverings, dashboards, roof lining and door covering elements, or external covering elements, such as plating parts, bumpers, engine covering and guarding parts, parts of seats, seat benches, bodywork parts and the like. Also, in this way, for instance complete doors, hoods, boot lids and the like can be manufactured, as well as sliding roofs and the like.
- In an alternative embodiment, the
movable wall part 53 is held in a forwardly moved second position during injection of plastic, so as to be pushed away by the plastic to the first position. This is specifically advantageous for, for instance, low melt plastics or plastics such as PET, specifically if these are to be translucent. - The invention is not limited in any way to the embodiments as shown and described. Many variations thereon are possible within the framework of the invention outlined by the claims.
- Thus, also other parts can be manufactured with a method according to the invention, in particular according to claim 8. Also, multiple movable wall parts can be combined in a mold cavity, which can be moved simultaneously or sequentially. The movable wall parts can move both rectilinearly and along curves, for instance for the controlled displacement of plastic. The plastic can be introduced in molten condition but may also be introduced as granulate or the like directly into the mold cavity.
- Parts manufactured with a method according to the invention can be provided on one or more sides with a finish or covering such as textile or label, for instance from plastic.
Claims (13)
1. A vehicle part manufactured in a mold with at least one mold cavity, the vehicle part comprising a form that is shaped by:
at least partly closing the mold, wherein the at least one mold cavity is brought in a first position by moving at least one wall part of the at least one mold cavity;
introducing plastic into the at least one mold cavity;
upon complete closure of the mold and/or movement of the at least one movable wall part, bringing the at least one mold cavity in a second position, the at least one mold cavity in the second position having a different volume than in the first position;
wherein by bringing the at least one mold cavity from the first in the second position, the plastic fills the respective mold cavity completely.
2. A vehicle part according to claim 1 , wherein the part is provided on at least a portion of an outer surface thereof with a covering, which is fixedly connected to the part.
3. A vehicle part according to claim 2 , wherein the covering comprises textile manufactured from natural and/or synthetic materials.
4. A vehicle part according to claim 1 , which part is substantially thin-walled and of a substantially two-dimensional configuration.
5. A textile for use for the manufacture of a part according to claim 1 , wherein either a partly plastic backing is provided or wholly or partly plastic threads or threads provided with a finishing layer are provided as warp and/or weft.
6. A mold for the manufacture of a part according to claim 1 .
7. A mold according to claim 6 , provided with at least one mold cavity with a movable wall part which is controllably movable for compressing plastic in the mold cavity when the mold is closed, thereby generating adiabatic heat development in the plastic.
8. A plastic part manufactured in a mold with at least one mold cavity, the plastic part comprising a form that is shaped by:
at least partly closing the mold, wherein the at least one mold cavity is brought in a first position by means of at least one movable wall part of the at least one mold cavity;
introducing plastic into the at least one mold cavity;
upon complete closure of the mold and/or movement of said at least one movable wall part, bringing the at least one mold cavity in a second position, the at least one mold cavity in the second position having a different volume than in the first position;
wherein by bringing the at least one mold cavity from the first in the second position, the plastic fills the respective mold cavity completely.
9. A plastic part according to claim 8 , wherein the part is provided on at least a portion of an outer surface thereof with a covering which is fixedly connected to the part.
10. A plastic part according to claim 9 , wherein the covering comprises textile manufactured from natural and/or synthetic materials.
11. A plastic part according to claim 8 , which part is substantially thin-walled and of a substantially two-dimensional configuration.
12. A method for manufacturing at least partly plastic parts in a mold with at least one mold cavity, comprising:
at least partly closing the mold, wherein the at least one mold cavity is brought in a first position by means of at least one movable wall part of the at least one mold cavity;
introducing plastic into the at least one mold cavity;
upon complete closure of the mold and/or movement of said at least one movable wall part, bringing the at least one mold cavity in a second position, the at least one mold cavity in the second position having a different volume than in the first position;
wherein by bringing the at least one mold cavity from the first in the second position, the plastic fills the respective mold cavity completely.
13. A method for manufacturing at least partly plastic parts in a mold with at least one mold cavity, comprising:
at least partly closing the mold, wherein the at least one mold cavity is brought in a first position by means of at least one movable wall part of the at least one mold cavity;
introducing plastic into the at least one mold cavity, pushing the at least one movable wall part away from the first position;
upon complete closure of the mold and/or movement of said at least one movable wall part, bringing the at least one mold cavity in a second position, the at least one mold cavity in the second position having a different volume than in the first position;
wherein by bringing the at least one mold cavity from the first in the second position, the plastic fills the respective mold cavity completely.
Priority Applications (1)
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US12/917,890 US20110045727A1 (en) | 2003-05-08 | 2010-11-02 | Method and Apparatus for Manufacturing Vehicle Parts |
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US10/555,685 US7833462B2 (en) | 2003-05-08 | 2004-05-10 | Method and apparatus for manufacturing vehicle parts |
US12/917,890 US20110045727A1 (en) | 2003-05-08 | 2010-11-02 | Method and Apparatus for Manufacturing Vehicle Parts |
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US11/555,685 Continuation US7783958B1 (en) | 2005-11-03 | 2006-11-01 | Broadband satellite system for the simultaneous reception of multiple channels using shared iterative decoder |
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EP (3) | EP2309044A3 (en) |
JP (1) | JP2006525151A (en) |
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2004
- 2004-05-10 BR BRPI0410073 patent/BRPI0410073A/en not_active IP Right Cessation
- 2004-05-10 JP JP2006507882A patent/JP2006525151A/en active Pending
- 2004-05-10 EP EP20100185375 patent/EP2309044A3/en not_active Withdrawn
- 2004-05-10 AU AU2004236562A patent/AU2004236562A1/en not_active Abandoned
- 2004-05-10 CN CN2004800193827A patent/CN1820102B/en not_active Expired - Fee Related
- 2004-05-10 EP EP04732060A patent/EP1636408A2/en not_active Withdrawn
- 2004-05-10 WO PCT/NL2004/000310 patent/WO2004099480A2/en active Application Filing
- 2004-05-10 CA CA 2524919 patent/CA2524919A1/en not_active Abandoned
- 2004-05-10 US US10/555,685 patent/US7833462B2/en not_active Expired - Fee Related
- 2004-05-10 MX MXPA05012028A patent/MXPA05012028A/en not_active Application Discontinuation
- 2004-05-10 KR KR1020057021144A patent/KR20060020619A/en not_active Application Discontinuation
- 2004-05-10 EP EP20100180956 patent/EP2278053A3/en not_active Withdrawn
- 2004-05-10 RU RU2005138313A patent/RU2351699C2/en not_active IP Right Cessation
-
2005
- 2005-12-08 NO NO20055828A patent/NO20055828L/en unknown
-
2010
- 2010-11-02 US US12/917,890 patent/US20110045727A1/en not_active Abandoned
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Also Published As
Publication number | Publication date |
---|---|
CA2524919A1 (en) | 2004-11-18 |
NL1023365C2 (en) | 2004-11-09 |
WO2004099480A3 (en) | 2005-01-20 |
AU2004236562A1 (en) | 2004-11-18 |
EP2309044A3 (en) | 2011-05-25 |
EP2309044A2 (en) | 2011-04-13 |
EP2278053A2 (en) | 2011-01-26 |
RU2005138313A (en) | 2006-08-27 |
EP2278053A3 (en) | 2011-05-25 |
CN1820102A (en) | 2006-08-16 |
NO20055828D0 (en) | 2005-12-08 |
NO20055828L (en) | 2006-02-07 |
KR20060020619A (en) | 2006-03-06 |
US7833462B2 (en) | 2010-11-16 |
JP2006525151A (en) | 2006-11-09 |
BRPI0410073A (en) | 2006-05-23 |
MXPA05012028A (en) | 2006-02-03 |
CN1820102B (en) | 2010-06-16 |
WO2004099480A2 (en) | 2004-11-18 |
EP1636408A2 (en) | 2006-03-22 |
US20070104955A1 (en) | 2007-05-10 |
RU2351699C2 (en) | 2009-04-10 |
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