Method of manufacturing resin member
First Claim
1. A method of manufacturing an article, part of which comprises a resilient surface element, using a first mold and a second mold, which mate with each other and form a cavity therebetween for molding said article, said cavity including a first cavity section corresponding to said resilient surface element and a second cavity section formed adjacent to said first cavity section, said method comprising the steps of:
- (a) forming a resilient surface element in a predetermined shape corresponding to the part being manufactured;
(b) setting the resilient surface element in said first mold so as to be disposed at a predetermined position in said first cavity section while said first mold is separate from said second mold;
(c) feeding a volume of a first thermoplastic resin into said first cavity section between said second mold and said resilient surface element set in said first mold, and closing and pressing said first mold and said second mold against each other, the volume of said first thermoplastic resin being such that it spreads out over only said resilient surface element; and
(d) injecting a second thermoplastic resin into said second cavity section before said first thermoplastic resin is completely hardened in said first cavity section.
1 Assignment
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Accused Products
Abstract
A resilient surface sheet element 14 is vacuum molded from a resilient laminate sheet member 13 including a skin sheet 10 and a foam sheet 12. The resilient surface sheet element 14 is placed in a predetermined recess 16 of a female mold 15 for molding an instrument panel. After a first thermoplastic resin 18 is fed into a space between a male mold 17 and the resilient surface sheet element 14 placed in the female mold 15, the female mold 15 and the male mold 17 are closed tightly. The first thermoplastic resin 18 then flows through a first cavity section formed on a rear face of the resilient surface sheet element 14 to be integrated with the resilient surface sheet element 14. Before the first plastic resin 18 completely hardens in the first cavity section, a second thermoplastic resin 21 is injected from an injection gate 20 into a second cavity section adjacent to the first cavity section to securely fuse and join with the first thermoplastic resin 18.
45 Citations
15 Claims
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1. A method of manufacturing an article, part of which comprises a resilient surface element, using a first mold and a second mold, which mate with each other and form a cavity therebetween for molding said article, said cavity including a first cavity section corresponding to said resilient surface element and a second cavity section formed adjacent to said first cavity section, said method comprising the steps of:
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(a) forming a resilient surface element in a predetermined shape corresponding to the part being manufactured; (b) setting the resilient surface element in said first mold so as to be disposed at a predetermined position in said first cavity section while said first mold is separate from said second mold; (c) feeding a volume of a first thermoplastic resin into said first cavity section between said second mold and said resilient surface element set in said first mold, and closing and pressing said first mold and said second mold against each other, the volume of said first thermoplastic resin being such that it spreads out over only said resilient surface element; and (d) injecting a second thermoplastic resin into said second cavity section before said first thermoplastic resin is completely hardened in said first cavity section. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method for manufacturing a resin member, comprising the steps of:
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forming a resilient surface sheet element; placing said resilient surface sheet element on a first mold member; feeding a heated first thermoplastic resin to a second mold member; pressing the first and second mold members together so that said first thermoplastic resin integrated with said resilient surface sheet element on a rear cavity thereof; and injecting a heated second thermoplastic resin, between said first and second mold members into a second cavity so as to contact said first thermoplastic resin away from said rear cavity; wherein said second thermoplastic resin is heated to a temperature higher than said first thermoplastic resin so as to fuse the first and second resins together. - View Dependent Claims (14, 15)
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Specification