Injection molding of hollow articles

Patent metadata

Field	Value
Publication number	US-2017190141-A1
Application number	US-201715464578-A
Country	US
Kind code	A1
Filing date	Mar 21, 2017
Priority date	Feb 4, 2015
Publication date	Jul 6, 2017
Grant date	—

Abstract

A hollow article such as an active bolster for an automobile is formed of an injection molded panel having a ridge and furrow adjacent a panel perimeter and an injection molded sheet having a bonding section at a sheet outer periphery, wherein the bonding section is within the furrow. An injection molded bond is formed between the bonding section and furrow, wherein a compression area where the sheet overlies a region of the panel adjacent the furrow is configured to constrain the bond to the furrow. An associated process and system facilitates mold alignment, part alignment, material strength, design adaptability, efficient processing, reduced labor, increased production rates, reduced energy consumption per part, aesthetically pleasing surfaces, and reduces or eliminates the need for a separate welding operation.

First claim

What is claimed is:

1 . A hollow article, comprising:
an injection molded panel having a ridge and furrow adjacent a panel perimeter; an injection molded sheet having a bonding section at a sheet outer periphery, wherein the bonding section is within the furrow; an injection molded bond between the bonding section and furrow; and a compression area where the sheet overlies a region of the panel adjacent the furrow, configured to constrain the bond to the furrow.

2 . The hollow article of claim 1 wherein the article is an active bolster assembly configured for mounting in an interior of a motor vehicle.

3 . The hollow article of claim 2 wherein the panel is a vehicle trim panel and the sheet is a pleated bladder.

4 . The hollow article of claim 3 further comprising a plurality of detachably affixed tabs extending from the panel through the bladder, wherein an injection molded anchor attaches the tabs to the sheet.

5 . The hollow article of claim 1 wherein the sheet further comprises a flange extending outwardly at the bonding section periphery and wherein the flange forms an attachment surface for the injection molded bond.

6 . The hollow article of claim 1 wherein the panel and sheet are formed substantially simultaneously in a single injection molding machine.

7 . The hollow article of claim 1 wherein the panel and sheet are co-molded in a three-part formation mold, and wherein the panel remains in a first mold of the formation mold and the sheet remains in a second mold of the formation mold during the injection molding of the bond.

8 . The hollow article of claim 7 wherein a compression area between the panel and the sheet constrains the bond to the furrow.

Assignees

• Ford Global Tech Llc

Inventors

• Roychoudhury Raj S

Classifications

• B29C45/1657 Primary

  using means for adhering or bonding the layers or parts to each other (mechanical anchoring B29C37/0082) · CPC title

• B29L2031/3041

  Trim panels · CPC title

• B29C45/164

  The moulding materials being injected simultaneously · CPC title

• B29C45/1675

  using exchangeable mould halves · CPC title

• B29C2045/1668

  Penetration bonds · CPC title