Trim panel

• US 20060226574A1
• Filed: 08/25/2004
• Published: 10/12/2006
• Est. Priority Date: 08/25/2003
• Status: Abandoned Application

• Current Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Original Assignee: Johnson Controls Technology Company (Johnson Controls International plc)
• Inventors: Von Holtz, Michael J, Kragt, Delwyn, White, Daniel F., Bozio, Ronald A., Fox, Bart W., Cussimanio, Jeffrey A.
• Application Number:
  US10/569,225
• Publication Number:
  US 20060226574A1
• Time in Patent Office: Days
• US Class Current: 264/248
• CPC Class Codes: B29C 45/1639 Removable partitions between adjacent mould cavity portions
• CPC Class Codes: B29C 45/1657 using means for adhering or bonding the layers or parts to each other mechanical anchoring B29C37/0082
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B29L 2031/3041 Trim panels
• CPC Class Codes: B60R 2013/0281 made of a plurality of visible parts

Abstract

A multi-material or multi-color molded article and a method of making the same is provided. The molded article comprises an integrated molded member having at least a first portion made of a first resin and a second portion made of a second resin. The integrated molded member may have additional portions as well. The method comprises providing a mold having a first mold section (24), a second mold section (22), and a retractor member (26), injecting a first resin (18) into a first cavity defined by the first mold section (24), the second mold section (22), and the retractor member (26), moving the retractor member (26) to define a second cavity (23) wherein the second cavity (23) is defined by the first mold section (24), the second mold section (22), the retractor member (26), and the first resin (18), and injecting a second resin (20) into the second cavity (23).

Claims

1-37. -37. (canceled)

38. A method of making a molded article for a vehicle interior, the method comprising:

providing a mold having a first mold section, a second mold section, and a shut-off member, the shut-off member movable between a first position and a second position and comprising a forward surface, a first side surface, a second side surface that shares an edge with the forward surface, and an angled surface that extends between the forward surface and the first side surface;

injecting a first resin into a first cavity which is defined by the first mold section, the second mold section, and the first side surface of the shut-off member when in the first position;

moving the shut-off member to define a second cavity defined by the first mold section, the second mold section, the first resin, the second side surface of the shut-off member, and the angled surface of the shut-off member when in the second position; and

injecting a second resin into the second cavity and forming an angled recess in the molded article having an upper surface provided by the angled surface of the shut-off member, wherein the upper surface is provided at a sufficiently flat angle relative to vertical by the angled surface of the shut-off member to obscure the interface between the first resin and the second resin from an occupant of the vehicle interior.

39. The method of claim 38 wherein the first resin is at least partially solidified when the second resin is injected.

40. The method of claim 38 further comprising a space between the shut-off member and the second mold section when the shut-off member is in the first position so that air can escape from the first cavity to the second cavity during the step of injecting the first resin into the first cavity.

41. The method of claim 38 wherein the first resin comprises a first color and the second resin comprises a second color different than the first color.

42. The trim panel of claim 38 wherein the first resin comprises at least one of a thermoplastic material, a thermoset material, or a elastomer material.

43. The trim panel of claim 42 wherein the second resin comprises at least one of a thermoplastic material, a thermoset material, or a elastomer material.

44. A method of making a molded article, the method comprising:

providing a mold having a first mold section, a second mold section, a first shut off member and a second shut-off member, the shut-off members are each separately movable between a first position and a second position;

injecting a first resin into a first cavity which is defined by the first mold section, the second mold section, the first shut-off member in the first position, and the second shut-off member in the first position;

moving the first shut-off member to the second position to define a second cavity without moving the first mold section relative to the second mold section wherein the second cavity is defined by the first mold section, the second mold section, the first material and the first shut-off member in the second position;

moving the second shut-off member to the second position to define a third cavity without moving the first mold section relative to the second mold section wherein the third cavity is defined by the first mold section, the second mold section, the first material, and the second shut-off member in the second position;

injecting a second resin into the second cavity; and

injecting a third resin into the third cavity.

45. The method of claim 44 wherein moving the first shut-off member between the first position and the second position comprises translating movement.

46. The method of claim 45 wherein the first position comprises an extended position and the second position comprises a retracted position wherein the shut-off member is disposed substantially within the first mold section.

47. The method of claim 44 further comprising a gap between the first shut-off member and the second mold section when the first shut-off member in the first position.

48. The method of claim 47 wherein the gap is configured to provide a vent to allow air to escape the first mold cavity when injecting the first resin into the first cavity.

49. The method of claim 44 further comprising the step of bonding the second resin to the first resin and bonding the third resin to the first resin.

50. The method of claim 49 wherein bonding the second resin to the first resin comprises fusion bonding and bonding the third resin to the first resin comprises fusion bonding.

51. The method of claim 44 wherein the third resin comprises at least one of a thermoplastic material, a thermoset material, or a elastomer material.

52. The method of claim 51 wherein the first resin comprises at least one of a thermoplastic material, a thermoset material, or a elastomer material.

53. The method of claim 52 wherein the second resin comprises at least one of a thermoplastic material, a thermoset material, or a elastomer material.

54. The method of claim 44 wherein the first shut-off member moves at about the same time as the second shut-off member.

55. The method of claim 44 wherein the first shut-off member moves before the second shut-off member.

56. The method of claim 44 wherein moving the first shut-off member comprises moving the first shut-off member in a first direction and moving the second shut-off member comprises moving the second shut-off member in a second direction that is parallel to the first direction.

57. The method of claim 44 wherein moving the first shut-off member comprises moving the first shut-off member in a first direction and moving the second shut-off member comprises moving the second shut-off member in a second direction that is not parallel to the first direction.

58. The method of claim 44 wherein the first resin comprises a first material property and the second resin comprises a second material property different than the first material property.

59. The method of claim 44 wherein the first resin comprises a first color and the second resin comprises a second color different than the first color.

60. The method of claim 44 wherein at least one of the first resin and the second resin comprises a material property different than the third resin.

61. A method of making a molded article for a vehicle interior, the method comprising:

providing a mold having a first mold section, a second mold section, a first shut off member and a second shut-off member, the shut-off members are each separately movable between a first position and a second position;

injecting a first resin into a first cavity defined by the first mold section, the second mold section, the first shut-off member in the first position, and the second shut-off member in the first position;

moving the first shut-off member to the second position and moving the second shut-off member to the second position to define a second cavity defined by the first mold section, the second mold section, the first material, the first shut-off member in the second position, and the second shut-off member in the second position;

injecting a second resin into the second cavity.

62. The method of claim 61 wherein the first resin provides the molded article with a first wall thickness located between the second shut-off member and the first mold section, and the second resin provides the molded article with a second wall thickness located between the second shut-off member and the first mold section and including the first wall thickness.