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WO2002016107A1 - Procede de fabrication d'elements bicolores pour habitacles d'automobiles - Google Patents

Procede de fabrication d'elements bicolores pour habitacles d'automobiles Download PDF

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Publication number
WO2002016107A1
WO2002016107A1 PCT/US2001/026343 US0126343W WO0216107A1 WO 2002016107 A1 WO2002016107 A1 WO 2002016107A1 US 0126343 W US0126343 W US 0126343W WO 0216107 A1 WO0216107 A1 WO 0216107A1
Authority
WO
WIPO (PCT)
Prior art keywords
polymer material
liquid
polymer
mold
mask
Prior art date
Legal status (The legal status 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 status listed.)
Ceased
Application number
PCT/US2001/026343
Other languages
English (en)
Inventor
John D. Gray
Bruce Batchelder
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Textron Automotive Co Inc
Original Assignee
Textron Automotive Co Inc
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 Textron Automotive Co Inc filed Critical Textron Automotive Co Inc
Priority to AU2001286667A priority Critical patent/AU2001286667A1/en
Publication of WO2002016107A1 publication Critical patent/WO2002016107A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

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
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/003—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor characterised by the choice of material
    • 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
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/18—Slush casting, i.e. pouring moulding material into a hollow mould with excess material being poured off
    • 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
    • B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
    • B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C41/22—Making multilayered or multicoloured 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
    • 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
    • B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
    • B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/0058—Liquid or visquous
    • B29K2105/0061—Gel or sol
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/25—Solid
    • B29K2105/251—Particles, powder or granules
    • 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

Definitions

  • the present invention pertains to a method of forming two-tone parts particularly suitable for automotive interior applications. More specifically, the present invention relates to the preparation of a two-tone part, utilizing a first liquid spray material in combination with a second dry-cast material.
  • panels on the interior of an automobile comprise an outer skin, a supportive substrate, and a polyurethane foam layer sandwiched between the skin and the substrate. Because the outer skin is the portion that is the most visible to the consumer, it must be aesthetically pleasing, durable, and functional.
  • One method for improving the aesthetic appeal of trim features is the use of outer skins having different colors, textures or materials contained within a single panel, a so called two- tone effect.
  • the first method consists of initially manufacturing the entire skin having a single first color using conventional techniques, such as dry casting. After the skin has been formed and removed from the mold, a paint mask is applied along a break line or styling feature masking off the portion of the skin that is desired to be the first color. Once the skin has been appropriately masked the exposed portion of the skin is painted. While this manufacturing method allows the skin to be molded using standard molding equipment, any painting defects, such as bleed through along the mask line or misalignment of the mask, will result in a defective part that must be discarded. Also, the skin beneath the paint is of a different color than the paint, therefore, any full thickness damage to the paint will reveal the underlying skin of a different color. This is generally considered to be unacceptable to automobile manufacturers.
  • the second method of producing a two-tone skin is a reactive urethane spray method.
  • a shell tool is masked off such that the region of the tool corresponding to desired region of the first color remains exposed.
  • a urethane precursor liquid comprising an isocyanate and a polyol, of the first desired color is sprayed and reactively cured.
  • the mask is then removed exposing the remainder of the tool, and the entire tool, including the previously sprayed urethane layer, is then sprayed with a urethane precursor liquid of the second desired color. While the process used does not require a great deal of specialized and/or expensive equipment, any waste or scrap urethane pieces are not recyclable, and the liquid urethanes contain hazardous components, resulting in environmental and health concerns.
  • the third method of making two-tone skins for trim features is via dry casting using a single powder box.
  • a conventional dry casting tool is used in conjunction with a single powder box containing two colors of powder separated by a divider.
  • the top edge of the divider is provided with a gasket that seals against the tool surface during casting, therein allowing a skin to be simultaneously cast with regions of different colors.
  • the exposed line resulting from the gasket is then filled by spraying the region with a powder of one of the colors.
  • the line resulting from the gasket is seldom as crisp as demanded by the manufacturers, often resulting in a blurred and uneven transition between colors. This defect usually requires that one of the color regions be covered and painted to produce the desired crispness of the transition.
  • the final method commonly used to produce skins having a two-tone appearance is a dry casting method using two powder boxes.
  • a standard dry casting tool is used, wherein the a first region of the tool is cast in a first color using a first powder box.
  • the first powder box is equipped with a gasket corresponding to the mold surface along the perimeter of the region to be formed in the first color.
  • a second powder box containing a resin having a second color is used to cast the entire mold, therein also over casting the region having the first color.
  • a method for making a molded plastic article comprising the steps of providing a mold having an inner surface and covering said mold surface with a mask wherein said mask leaves a portion of said inner surface exposed. This is followed by application of a liquid comprising a first polymer material within said exposed portion and at least partial solidifying said liquid comprising said first polymer material on said exposed portion. The mask is then removed, followed by the application of a particulate comprising a second polymer material to said second region of said mold surface and a portion of said partially solidified first polymer and bonding together said first and second polymer material.
  • the first and second polymer material may be either a thermoplastic or thermoset material.
  • FIG. 1 is a perspective view of a portion of an exemplary mold after application of the masking
  • FIG. 2 is a perspective view of the exemplary mold portion after forming the first layer and removing the masking
  • FIG. 3 is a perspective view of the exemplary mold portion after forming of the second layer.
  • FIG. 4 is a cross-sectional perspective view of the exemplary mold portion illustrating the use of a gasketed divider to prevent casting of the second layer over the entire first layer.
  • the method of forming a two-tone plastic article i.e. a plastic article having multiple colors, textures, or materials integrated into a single article, according to the present invention may be carried out on a standard slush molding shell tool, indicated generally at 10.
  • a standard slush molding shell tool indicated generally at 10.
  • it is not limited to two-tone plastic articles, and more generally allows for the casting and formation of two different polymer resins on the inner surface of a mold, such that the polymer resins are bonded together and joined along an edge thereof.
  • the polymer resins are bonded together, it should be appreciated that such bonding relates to either a chemical or physical bond between the resins.
  • one of the resin is a thermoset resin, which will solidify upon crosslinking, it will be understood that the bonding between the indicated resins may actually result in a chemical bond between the two polymer resin surfaces.
  • thermoplastic type resins when such resins are molded and solidified, although no chemical reaction occurs as in the case of thermoset resins, the resins may nonetheless bond together, simply as a consequence of the physical molding process.
  • the typical shell tool comprises an electro-formed tool surface 12 being heated from the backside by forced hot air or other conventional methods.
  • the shell tool 10 Prior to start of the casting process, the shell tool 10 is preheated.
  • the mold preheat time and temperature are dependent upon the polymer materials to be used in the casting and the desired thickness of the final part. The parameters required to form an article having the desired characteristics will be readily evident to one having ordinary skill in the art.
  • a mask 14, as illustrated in FIG. 1 is applied to the surface of the mold.
  • the mask 14 applied to the surface of the mold leaves a first portion of the surface of the mold exposed and defines a first layer region 16 on the surface of the tool that is to be formed of the first material.
  • the first layer region 16 corresponds to regions of the final skin that are to be formed having a first character, such as a first color that may be different than the portion of the skin corresponding to the region of the mold surface 12 that is covered by the mask.
  • the difference in character of the first layer region 16 may include differences in color, material, texture, etc.
  • An example of this difference in character is a region of a trim feature that is to include a color that is different that the remainder of the trim feature. Additionally, logos, raised regions, and various other stylistic featured may be formed by or included in the first region.
  • a liquid comprising a first polymer material is applied to the exposed first layer region 16.
  • the liquid material is preferably applied to the first layer region 16 by a spraying technique.
  • the liquid material may be applied to the first layer region 16 by other conventional techniques such as liquid casting, wherein the first liquid polymer formulation is supplied to the surface of the mold by a conventional liquid casting apparatus.
  • the liquid material includes thermoplastic or thermoset polymer formulations in which the polymer itself may be in liquid form, such as a thermosetting polyurethane comprising liquid reactant components, or a polymer formulation in which a polymer resin is in solution or in a liquid continuous matrix dispersion, including a solvent or an aqueous dispersion.
  • exemplary liquid plastic material include plastisols in which a finely divided plastic resin is dispersed in a liquid plasticizer continuous phase.
  • hydrosols may be employed in which a finely divided plastic resin is dispersed in an aqueous continuous phase.
  • organosols i.e.
  • the polymer material may additionally include any additives or processing aid that may be deemed desirable, such as plasticizer, colorants, stabilizers, etc.
  • the thickness of the first layer 18 is preferably about 0.010 - 0.060", and can vary within said range by 0.001" increments. However, it has been found that preferably, the first layer is of thickness 0.015".
  • the polymer layer resulting therefrom must be sufficiently solidified such that the first polymer material will maintain its shape on the tool surface 12.
  • the mask 14 is removed from the tool surface 12, therein also removing any of the first plastic material that was applied outside of the first layer region 16. As illustrated in FIG. 2, the removal of the mask 14 from the tool surface 12 exposes the remainder of the tool surface having deposited thereon a first layer 18.
  • the mask may be removed after the liquid material is applied.
  • elevated level of viscosity as a partial-cure, or partial-set, indicating that solidification, while in progress, is not yet complete.
  • thermoset materials may be due to such factors as an increase in crosslinking, as applied to thermoset materials. Accordingly, in a thermoset material, as crosslinking proceeds, viscosity increases, the material approaches solidification, and crosslinking can therefore be relied upon to maintain the shape of the first layer on the tool surface.
  • thermoplastic materials partial solidification may be achieved when the polymer material is just below its melting point or Tm. Continual cooling therein results in an increase in solid characteristics, until such time as the Tg of the material may be reached, at which point those skilled in the art will recognize that the material has in general reached it highest level of rigidity. Accordingly, within the broad scope of the invention, and as applied to thermoplastic material, the first layer of polymer material is preferably cooled to a temperature between Tg and Tm, and well as those temperatures at or below Tg, prior to application of the second polymer material to the mold surface, as herein described. Furthermore, those skilled in the art will recognize that values of Tg and Tm of plastic materials can be conveniently determined by reference to the available literature concerning polymeric resins.
  • a second polymer material may be applied to the tool surface 12.
  • the second polymer material is preferably applied to the tool surface using a conventional dry casting charge box.
  • a charge box containing the second polymer material is affixed to the mold, wherein the mold and the charge box are rotated to evenly distribute the second polymer material on the tool surface 12.
  • the first layer 18 is over cast by the second polymer material resulting a second layer 20 and an overcast layer 22, as illustrated in FIG. 3. Accordingly, it can be appreciated that by practice of the method herein, the use of a sealing mechanics (gasketing) within the tooling to form a two-tone color line has been eliminated.
  • the charge box herein may be configured to include a gasketed divider such that when the second layer 20 is cast only a portion of the first layer 18 is over cast.
  • FIG. 4 which in cross-section, illustrates the first layer 18 and gasket dividers 24 and 26 along with sealing surfaces 30 and 32. Accordingly, it can be appreciated that when the second layer is to be cast in the tooling illustrated in FIG. 4, only a portion of the first layer 18 will be overcast.
  • the second polymer material may comprise any form of particulate, including what is commonly termed as powders, beads, pellets, etc.
  • the second polymer material comprises a thermoplastic or thermoset resin, and more preferably comprises a powdered PVC based formulation.
  • the second plastic material may comprise a material including, but not limited to, other vinyls or vinyl copolymers, urethanes (e.g. PU or TPU), olefins (e.g. polyethylene, polypropylene, thermoplastic olefin materials), polyester materials, styrene based materials (e.g., ABS, ASA), as well as thermoplastic and thermoset elastomers.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Moulding By Coating Moulds (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention concerne un procédé de fabrication d'un article en plastique moulé. Ce procédé consiste à produire un moule (10) doté d'une surface interne (12) et à recouvrir la surface de ce moule (12) à l'aide d'un masque (14), lequel laisse apparaître une partie de la surface intérieure du moule (12). On applique ensuite un liquide contenant une première matière polymérique sur la partie à nu de la surface intérieure du moule (12), ce liquide se solidifiant au moins partiellement sur la partie à nu. On retire alors le masque (14) avant d'appliquer une seconde matière particulaire renfermant une seconde matière polymérique sur la seconde zone de la surface du moule (12) et sur une partie de la première matière polymérique partiellement solidifiée, lesdites première et seconde matières polymériques se liant ensemble.
PCT/US2001/026343 2000-08-23 2001-08-23 Procede de fabrication d'elements bicolores pour habitacles d'automobiles Ceased WO2002016107A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2001286667A AU2001286667A1 (en) 2000-08-23 2001-08-23 Method for forming two-tone parts for automotive interior applications

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US64491700A 2000-08-23 2000-08-23
US09/644,917 2000-08-23

Publications (1)

Publication Number Publication Date
WO2002016107A1 true WO2002016107A1 (fr) 2002-02-28

Family

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Family Applications (1)

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PCT/US2001/026343 Ceased WO2002016107A1 (fr) 2000-08-23 2001-08-23 Procede de fabrication d'elements bicolores pour habitacles d'automobiles

Country Status (2)

Country Link
AU (1) AU2001286667A1 (fr)
WO (1) WO2002016107A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10311654A1 (de) * 2003-03-14 2004-09-23 Peguform Gmbh & Co. Kg Mehrfarbiges Kunststoffformteil
US8802767B2 (en) 2011-07-27 2014-08-12 Dow Global Technologies Llc Redispersible polymer powder from polyolefin dispersions and the use thereof in construction applications

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0355219A (ja) * 1989-07-06 1991-03-11 Inoatsuku Corp:Kk 多色表皮材の製造方法

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0355219A (ja) * 1989-07-06 1991-03-11 Inoatsuku Corp:Kk 多色表皮材の製造方法

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE10311654A1 (de) * 2003-03-14 2004-09-23 Peguform Gmbh & Co. Kg Mehrfarbiges Kunststoffformteil
WO2004080685A3 (fr) * 2003-03-14 2004-11-25 Peguform Gmbh & Co Kg Piece moulee en matiere plastique multicolore
US8802767B2 (en) 2011-07-27 2014-08-12 Dow Global Technologies Llc Redispersible polymer powder from polyolefin dispersions and the use thereof in construction applications

Also Published As

Publication number Publication date
AU2001286667A1 (en) 2002-03-04

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