Method for manufacturing interior door panels having concealed voids at the junction of integrally molded energy absorbers
First Claim
1. A method of manufacturing an automotive interior door panel having a decorative covering displayed to the interior compartment of a vehicle and a rigid substrate having a backing surface, the backing surface having a plurality of energy absorbers integrally molded onto said backing surface, said method comprising the following steps:
- providing a low pressure injection mold operable between open and closed positions, said mold having a covering receiving surface and an energy absorber producing surface, said energy absorber producing surface producing said energy absorbers;
positioning a covering juxtaposed said covering receiving surface while said mold is in the open position;
closing said mold and creating a space between said covering and said energy absorber producing surface, said space forming said substrate, said substrate having a nominal cross-sectional thickness between said energy absorbers, said energy absorber producing surface having a plurality of recesses having a width 75% or more of the nominal thickness;
injecting a molten plastic material between said covering and said energy absorber producing surface, said molten plastic material filing said space and said recesses; and
allowing said molten plastic material to cool and shrink, whereby said substrate produces sink marks at the intersection of said substrate and said energy absorbers that are concealed beneath said covering.
6 Assignments
0 Petitions
Accused Products
Abstract
An automotive interior door panel having a decorative covering displayed to the interior compartment of a vehicle and a rigid substrate having a backing surface. The backing surface includes a plurality of energy absorbers integrally molded thereon. The method utilizing the following steps. A low-pressure or high pressure injection mold operable between open and closed positions is moved to the open position. The mold has a covering receiving surface and an energy absorber producing surface. A flexible covering is positioned juxtaposed the covering receiving surface. The mold is moved to the closed position to create a space between the covering and the energy absorber producing surface. A molten plastic material is injected into the space to form the door substrate. The substrate has a nominal cross-sectional thickness between said energy absorbers. The energy absorber producing surface includes a plurality of recesses having a width 75% or more of the nominal substrate thickness producing thick-walled energy absorbers on the backing surface. The molten plastic material fuses to the covering to from an integral door panel. The plastic material is allowed to cool and shrink. The plastic shrinkage produces depressions in the substrate called sink marks overlying the intersection between the energy absorber and the substrate wall. The covering bridges the sink marks to conceal the depressions and produce an aesthetically pleasing surface.
57 Citations
8 Claims
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1. A method of manufacturing an automotive interior door panel having a decorative covering displayed to the interior compartment of a vehicle and a rigid substrate having a backing surface, the backing surface having a plurality of energy absorbers integrally molded onto said backing surface, said method comprising the following steps:
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providing a low pressure injection mold operable between open and closed positions, said mold having a covering receiving surface and an energy absorber producing surface, said energy absorber producing surface producing said energy absorbers; positioning a covering juxtaposed said covering receiving surface while said mold is in the open position; closing said mold and creating a space between said covering and said energy absorber producing surface, said space forming said substrate, said substrate having a nominal cross-sectional thickness between said energy absorbers, said energy absorber producing surface having a plurality of recesses having a width 75% or more of the nominal thickness; injecting a molten plastic material between said covering and said energy absorber producing surface, said molten plastic material filing said space and said recesses; and allowing said molten plastic material to cool and shrink, whereby said substrate produces sink marks at the intersection of said substrate and said energy absorbers that are concealed beneath said covering. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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Specification