Three dimensional overmolding

Patent metadata

Field	Value
Publication number	US-12358351-B2
Application number	US-202017620413-A
Country	US
Kind code	B2
Filing date	Jun 19, 2020
Priority date	Jun 21, 2019
Publication date	Jul 15, 2025
Grant date	Jul 15, 2025

Abstract

A three-dimensional overmolding and process for manufacturing same. The three-dimensional overmolding has a three-dimensional structure with overmolding, which gives significant performance benefits. Assembly and joining of reinforcements is done before the overmolding or in the injection molding tool. The three-dimensional overmolding meets predetermined structural requirements without requiring secondary operations and at a lower mass and cost. The structural benefits are due to the three dimensional shape in combination with the benefit of the overmolding process.

First claim

What is claimed is:

1. A three-dimensional overmolding, comprising:
at least one three-dimensional (3D) reinforcement operably connected to at least one reinforcement forming a predetermined 3D geometry, said at least one 3D reinforcement including at least one rib; and
at least a partial overmold of said 3D geometry;
wherein said at least one reinforcement is operably coupled to a liftgate panel surface, and
wherein each overmolded 3D geometry is located at a respective upper corner of said liftgate panel surface.

2. The three-dimensional overmolding of claim 1 , wherein the 3D geometry is adapted for being in contact with a tool action operably supporting the 3D geometry structure for material overmold shots.

3. The three-dimensional overmolding of claim 1 , wherein the 3D geometry is adapted for being in contact with a lifter injector pin that strokes in for structural support of the 3D overmolding.

4. The three-dimensional overmolding of claim 1 , wherein the 3D geometry is adapted for being in contact with a temporary reinforcement for support of the 3D overmolding against collapse.

5. The three-dimensional overmolding of claim 1 , wherein said at least one rib comprises a metal rib with channel sized to overmold without an in-tool lifter or temporary reinforcement.

6. The three-dimensional overmolding of claim 1 , wherein the reinforcements at least one 3D reinforcement and at least one reinforcement are adapted to be pre-assembled before overmolding.

7. The three-dimensional overmolding of claim 1 , wherein the reinforcements are adapted to be assembled in an injection molding tool.

8. The three-dimensional overmolding of claim 1 , wherein the 3D reinforcement is a 3D stamped steel reinforcement.

9. The three-dimensional overmolding of claim 1 , wherein the reinforcements at least one 3D reinforcement and at least one reinforcement are not flat metal brackets.

10. The three-dimensional overmolding of claim 1 , comprising at least one additional reinforcement, wherein the plurality of reinforcements is at least one 3D reinforcement, at least one reinforcement and at least one additional reinforcement are at least partially overmolded.

11. The three-dimensional overmolding of claim 1 , wherein there are no spot welds.

12. The three-dimensional overmolding of claim 1 , wherein the three-dimensional overmolding meets predetermined structural requirements with the 3D geometry combined with overmolding.

13. The three-dimensional overmolding of claim 1 , wherein the three-dimensional overmolding is operably connected to the liftgate panel.

14. The three-dimensional overmolding of claim 1 , comprising a plurality of three-dimensional overmoldings, wherein each three-dimensional overmolding is operably connected at both upper corners of a plastic liftgate panel.

15. A three-dimensional overmolding operably adapted for a vehicle, comprising:
at least one first reinforcement that is metal and including 3D geometry;
at least one second reinforcement that is metal, said first and second reinforcement operably joined forming a predetermined 3D geometry interface; and
an overmold of at least the 3D geometry interface to meet predetermined structural requirements;
wherein said first or second reinforcement is operably coupled to a liftgate panel surface, and
wherein each overmolded 3D geometry interface is located at a respective upper corner of the liftgate panel surface.

16. A method of making a three-dimensional overmolding, comprising:
providing at least one 3D reinforcement operably connected to at least one reinforcement forming a predetermined 3D geometry, said at least one 3D reinforcement including at least one rib;
providing an injection molding tool; and
injecting a predetermined plastic material in a tool forming at least a partial overmold on at least one said of said 3D reinforcement;
wherein said at least one reinforcement is operably coupled to a liftgate panel surface, and
wherein each overmolded 3D geometry is located at a respective upper corner of the liftgate panel surface.

17. The method of claim 16 , further comprising preassembly the reinforcements before overmolding.

18. The method of claim 16 , wherein the reinforcements are assembled in the injection molding tool.

19. The method of claim 16 , further comprising spot welding the reinforcements at predetermined locations.

20. The method of claim 16 , wherein none of the reinforcements are spot welded.

21. The method of claim 16 , further comprising providing tool action supporting the 3D structure.

22. The method of claim 16 , further comprising providing a lifter injector pin that strokes in for structural support of 3D overmolding.

23. The method of claim 16 , further comprising providing a temporary reinforcement for support of 3D overmolding against collapse.

24. The method of claim 16 , further comprising providing a metal rib with channel sized to overmold without a lifter or temporary reinforcement.

Assignees

• Magna Exteriors Inc
• Tichy Stanislav

Inventors

• Tichy Stanislav
• Chaaya Riad
• Birka Mark P
• Kuntze Christopher J
• Salzmann Heiner

Classifications

• B29C45/14631

  Coating reinforcements (fibre reinforcements B29C45/0005) · CPC title

• B29L2031/3014

  Door linings · CPC title

• B29K2705/00

  Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts · CPC title

• E05Y2900/546

  Tailboards, tailgates or sideboards opening upwards · CPC title

• E05Y2600/626

  Plates or brackets · CPC title