Method of molding a composite sheet

Patent metadata

Field	Value
Publication number	US-2017246782-A2
Application number	US-201514645453-A
Country	US
Kind code	A2
Filing date	Mar 12, 2015
Priority date	Mar 12, 2015
Publication date	Aug 31, 2017
Grant date	—

Abstract

A method is provided for molding a composite sheet in an injection molding press including a female mold tool and a cooperating male mold tool. The method includes the steps of loading the composite sheet into an open mold, positioning a heating element between the composite sheet and the female mold tool to preheat the composite sheet and a cavity of the female mold tool and removing the heating element and closing the mold.

First claim

What is claimed:

1 . A method of molding a composite sheet in an injection molding press including a female mold tool and a cooperating male mold tool, comprising:
loading the composite sheet into an open mold; positioning a heating element between said composite sheet and the female mold tool to preheat the composite sheet and a cavity of the female mold tool; removing said heating element; and closing said mold.

2 . The method of claim 1 , including holding said composite sheet on locating pins in the mold.

3 . The method of claim 2 , including maintaining the composite sheet a predetermined distance from said female mold tool upon loading into the open mold in order to maintain said desired clearance for the heating element.

4 . The method of claim 3 , including using springs on said locating pins in order to maintain said desired clearance.

5 . The method of claim 4 , including injecting plastic onto one side of the composite sheet while said mold is closed.

6 . The method of claim 4 , including injecting plastic through an injection pathway in the male mold tool onto one side of the composite sheet while said mold is closed.

7 . The method of claim 6 , including compressing the springs into recesses in the female mold tool when the mold is closed.

8 . The method of claim 7 , including opening the mold.

9 . The method of claim 8 , including removing an injected molded part from the open mold.

10 . The method of claim 9 , including trimming excess composite material from the injected molded part removed from the mold.

11 . The method of claim 9 , including trimming excess composite material from the injected molded part removed from the mold by die cutting.

12 . The method of claim 9 , including trimming excess composite material from the injected molded part removed from the mold by laser cutting.

13 . The method of claim 9 , including trimming excess composite material from the injected molded part removed from the mold by water jet cutting.

14 . The method of claim 1 , including completing the loading of the composite sheet into the open mold while the composite sheet is at room temperature.

15 . The method of claim 14 , including positioning punched holes in the composite sheet over locating pins in the mold when loading the composite sheet into the open mold.

16 . An injection molding press, comprising:
a female mold tool; a cooperating male mold tool; a plurality of locator pins projecting from said female mold tool; and a plurality of clearance springs, one spring of said plurality of clearance springs being received concentrically around each of said plurality of locator pins for holding a composite sheet a desired distance from a face of said female mold tool.

17 . The molding press of claim 16 , wherein said female mold tool includes a plurality of recesses for receiving and holding said plurality of clearance springs around said plurality of locator pins.

18 . The molding press of claim 17 , further including a heating element that is inserted between said composite sheet held on said plurality of locator pins and said face of said female mold tool.

19 . The molding press of claim 18 , wherein said face includes a mold cavity.

20 . The molding press of claim 19 , further including a plurality of bores in said male mold tool aligned with and receiving said plurality of locator pins when said female mold tool and said male mold tool are closed together.

Assignees

• Ford Global Tech Llc

Inventors

• Conley Jeffery N
• Rocco Charles Alan

Classifications

• B29C45/40 Primary

  Removing or ejecting moulded articles · CPC title

• B29L2009/00

  Layered products · CPC title

• B29C45/7207

  of the moulded articles · CPC title

• B29C45/14786 Primary

  Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced material · CPC title

• B29C45/1418

  the inserts being deformed or preformed, e.g. by the injection pressure · CPC title