Molding method and metal-covered component formed thereby

• US 6,818,305 B2
• Filed: 09/12/2002
• Issued: 11/16/2004
• Est. Priority Date: 05/22/1998
• Status: Expired due to Fees

• Current Assignee: Global IP Holdings LLC
• Original Assignee: Patent Holding Company
• Inventors: Davis, David J., Murar, Jason T.
• Primary Examiner(s): Gorr, Rachel
• Application Number:
  US10/242,206
• Publication Number:
  US 20030008134A1
• Time in Patent Office: 796 Days
• Field of Search: 428/412, 428/423.1, 428/423.3, 428/423.7, 428/424.2, 428/424.6, 428/424.7, 428/424.8, 428/425.8, 428/425.9, 428/457, 428/458, 428/461-463, 428/480, 428/483, 428/500, 428/522, 428/688, 428/689, 428/704
• US Class Current: 428/412
• CPC Class Codes: B29C 2043/3411 mounted onto arms, e.g. grippers, fingers, clamping frame, suction means
• CPC Class Codes: B29C 2043/3422 rollers
• CPC Class Codes: B29C 2043/3602 with means for positioning, fastening or clamping the material to be formed or preforms inside the mould
• CPC Class Codes: B29C 2043/522 selectively heating a part of the mould to achieve partial heating, differential heating
• CPC Class Codes: B29C 2793/0081 before shaping
• CPC Class Codes: B29C 2793/009 after shaping
• CPC Class Codes: B29C 43/00 Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor by liberation of internal stresses B29C61/006
• CPC Class Codes: B29C 43/021 characterised by the shape of the surface
• CPC Class Codes: B29C 43/203 Making multilayered articles
• CPC Class Codes: B29C 43/36 Moulds for making articles of definite length, i.e. discrete articles
• CPC Class Codes: B29C 43/3697 comprising rollers or belts cooperating with non-rotating mould parts
• CPC Class Codes: B29C 43/40 with means for cutting the article
• CPC Class Codes: B29K 2105/256 Sheets, plates, blanks or films
• CPC Class Codes: B29K 2995/0026 Transparent
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B29L 2031/3041 Trim panels
• CPC Class Codes: B60R 21/21656 Steering wheel covers or similar cup-shaped covers
• CPC Class Codes: Y10T 428/26 Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
• CPC Class Codes: Y10T 428/31507 Of polycarbonate
• CPC Class Codes: Y10T 428/3154 Of fluorinated addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31551 : Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
• CPC Class Codes: Y10T 428/31554 : Next to second layer of polyamidoester
• CPC Class Codes: Y10T 428/31565 : Next to polyester [polyethylene terephthalate, etc.]
• CPC Class Codes: Y10T 428/31573 : Next to addition polymer of ethylenically unsaturated monomer
• CPC Class Codes: Y10T 428/3158 : Halide monomer type [polyvinyl chloride, etc.]
• CPC Class Codes: Y10T 428/31583 : Nitrile monomer type [polyacrylonitrile, etc.]
• CPC Class Codes: Y10T 428/31587 : Hydrocarbon polymer [polyethylene, polybutadiene, etc.]
• CPC Class Codes: Y10T 428/31605 : Next to free metal
• CPC Class Codes: Y10T 428/31609 : Particulate metal or metal compound-containing
• CPC Class Codes: Y10T 428/31678 : Of metal
• CPC Class Codes: Y10T 428/31681 : Next to polyester, polyamide or polyimide [e.g., alkyd, glue, or nylon, etc.]
• CPC Class Codes: Y10T 428/31692 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31696 : Including polyene monomers [e.g., butadiene, etc.]
• CPC Class Codes: Y10T 428/31699 : Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31797 : Next to addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31855 : Of addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31935 : Ester, halide or nitrile of addition polymer

Abstract

A molding method and a metal-covered plastic component such as partial or entire fascia, body side moldings, and the like, which have bright surface requirements and which includes a film sheet and a one-piece thermoplastic elastomeric structural carrier are provided. The film sheet includes a decorative layer of metal such as chrome. A plastic layer of the film sheet on which the layer of metal is formed is selected from a group consisting of polyester, polyurethane and polycarbonate. A bottom contact surface of the film sheet bonds with a front contact surface of the structural carrier by diffusion between the contact surfaces thereof within a mold cavity of an injection mold separate from the step of forming a preform which is securely positioned within the injection mold during injection molding to form the plastic part.

Claims

1. A metal-covered, molded plastic component comprising:

a preform including a film sheet having a decorative layer of metal, the film sheet being selected from the group consisting of polyester, polyurethane and polycarbonate that is placed into a mold cavity of an injection mold having a shape defining the desired plastic component; and

a structural carrier made from a thermoplastic elastomer that is injected into the mold cavity of the injection mold and bonded to a bottom surface of the preform to form the molded laminate plastic component wherein the decorative layer of metal is coated with polyvinylidine fluoride and a clear plastic layer.

2. The component of claim 1, wherein the polyvinylidine fluoride comprises more than 50% of the total thickness of the film sheet.

3. The component of claim 1, wherein the thermoplastic elastomer is a thermoplastic polyolefin.

4. The component of claim 1, wherein the structural carrier has a flexural modulus in the range of 15,000 to 400,000 psi.

5. The component of claim 1, wherein the structural carrier has a hardness durometer in the range of 15 Shore D to 100 Shore D.

6. The component of claim 1, wherein the film sheet has a total thickness of approximately 0.2 mils.

7. A metal-covered, molded laminate automotive component comprising:

a formed film sheet having a decorative layer of metal, the formed film sheet having top and bottom surfaces, the filmed film sheet being selected from the group consisting of polyester, polyurethane and polycarbonate that is placed into a mold cavity of an injection mold having a shape defining the desired plastic component; and

a structural carrier made from a thermoplastic elastomer that is injected into the mold cavity of the injection mold and bonded to the structural carrier to the bottom surface of the formed film sheet to form the molded laminate automotive component wherein the decorative layer of metal is coated with a layer of polyvinylidine fluoride and a clear plastic layer.

8. The component of claim 7, wherein the polyvinylidine fluoride comprises more than 50% of the total thickness of the film sheet.