Method of forming a partially covered panel

• US 6,413,460 B1
• Filed: 09/10/1998
• Issued: 07/02/2002
• Est. Priority Date: 09/10/1998
• Status: Expired due to Term

• Current Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Original Assignee: Visteon Global Technologies Incorporated (Visteon Corporation)
• Inventors: Homburg, Frederick J., Wagner, Hazel, Berry, Charles Luke, Wisniewski, Aaron Stanley, Nichols, Calvin Columbus, Suryanarayan, Talavane
• Primary Examiner(s): Silbaugh, Jan H.
• Assistant Examiner(s): Lee, Edmund H.
• Application Number:
  US09/151,004
• Time in Patent Office: 1,391 Days
• Field of Search: 264/254, 264/255, 264/278, 264/267, 264/112, 264/120, 264/127, 264/129.1, 264/328.8, 264/251, 264/328.7, 264/247
• US Class Current: 264/254
• CPC Class Codes: B29C 2045/14901 Coating a sheet-like insert smaller than the dimensions of the adjacent mould wall
• CPC Class Codes: B29C 45/1671 with an insert

Abstract

A method of producing a partially covered panel comprising a series of manufacturing steps. A covering is formed to have a perimeter portion. The covering is generally formed using a thermoforming operation. The perimeter portion is formed into a flange-shape. A mold movable between open and closed position is moved to an open position. The mold includes a first and second surface. The covering is placed juxtaposed the first surface. A retainer is extended to retain the covering in position prior to and during the molding operation. The retainer engages the perimeter flange portion of the covering. The mold is moved to the closed position. The retainer, covering and first surface define a first cavity section. A first quantity of molten plastic is injected under pressure into this first cavity section. The molten plastic pushes the flange portion against the retainer and the retainer prevents the seepage of plastic between the first surface and the covering.

After the first cavity is filled, the retainer is retracted and a second quantity of molten plastic is injected into the mold. The second quantity of plastic surrounds the first cavity and forms the partially covered panel. The panel displaces at least two distinct surfaces. One surface comprises the covering and another surface displays the solidified second quantity of plastic.

Claims

1. A method of producing a partially covered panel comprising the following steps:

forming a covering having a perimeter portion;

forming said perimeter portion into a flange;

providing a movable mold having a core and a cavity;

placing said covering with said perimeter flange portion within said mold and juxtaposed said cavity;

closing said mold after placing said covering with said perimeter flange portion therein;

extending a retainer within the closed mold to support said perimeter flange portion and to form a first cavity section, wherein said first cavity section is bounded by said retainer, said covering with said perimeter flange portion, and said core;

injecting a first quantity of molten plastic into said first cavity section to form a covered surface after said mold is closed, wherein the injected first quantity of molten plastic fills said first cavity section;

retracting said retainer to form a second cavity section that is bounded by said covered surface, said core, and said cavity; and

filling said second cavity section with a second quantity of molten plastic to form an uncovered surface that is adhered to said covered surface, said perimeter flange portion contained within said first quantity of molten plastic and second quantity of molten plastic, said partially covered panel displaying said covered and uncovered surfaces.

2. The method of claim 1, wherein said second quantity of molten plastic is injected.

3. The method of claim 2, wherein said second cavity section surrounds said first cavity section.

4. The method of claim 1, wherein said retainer extends and retracts from said cavity.

5. The method of claim 1, wherein the retracted retainer extends a distance above said cavity.

6. The method of claim 5, wherein said second quantity of plastic flows over the retracted retainer and forms a groove adjacent said perimeter flange portion.