Davidson Textron Inc.

Alfred F Brault

John D Gray

Josh Kelman

David R Pinson

Roberto Rosa-Miranda

Randy Reed

William W Knight

Stephen N Roberts

An automotive interior trim part (10) is made by molding a substrate retainer layer (16), forming a skin layer (12) and forming an intermediate layer (14). The intermediate layer (14) is formed from a plurality of clusters of entangled high melt and low melt kinked fibers of polyethylene terephthalate (PET). The PET layer is blown into a partially closed mold that has the skin and retainer positioned in each mold die. The mold undergoes induced vibrations to promote tightening of the packed clusters. The mold is then fully closed to compress the PET fibers into full density. Heated air is then blown into the mold to soften the low melt fibers to adhere them to the retainer layer and skin. Cool air is then blown into the mold to resolidfy the clusters and form the intermediate layer into its molded shape.

Cushioned automotive interior trim part and process or making same

A process for forming a multi-colored integral vinyl skin shell including a heated mold and dual powder box arrangement wherein the mold is formed to include alternately positioned tear surfaces and recessed surfaces. After the first powder box supplies a layer of powder to cover all the surfaces to form a shell, the strips of shell on the tear surfaces are removed, after which the first powder box is replaced by a second powder box. The second powder box has a plurality of spaced dams or dividers formed therein such that the dams cooperate with the respective recessed surfaces of the mold to provide clearances therewith that permit different colored powders in the compartments between the dams to cover the previously cleared tear surfaces and to flow past the selectively formed free ends of the dams to become integrally secured to the adjacent edge portions of the shell segments remaining in the areas of the recessed surfaces of the mold, forming the multi-colored, integral plastic shell. The dams or dividers have tapered sides formed on their distal ends for approximately the outer two thirds of the width of each dam, and an opening is formed therebetween into a central hollow section for recovering 'contaminated' or mixed powders from two adjacent compartments.

Process for molding multi-colored plastic shells

An apparatus for depositing a layer of thermoplastic material onto a surface bearing a recessed logo or other decorative design of a logo plaque mold, wherein the apparatus includes a cylindrical housing enclosing a rotatable shaft and spray gun extension. The rotatable shaft may be operatively connected to the housing for rotation along the centerline thereof, and the spray gun extension in secured to a side of the shaft such that the axis of the extension is parallel to the axis of the shaft so as to be rotated concentrically with the shaft when the latter is rotated. Thus, a suitable thermoplastic material is deposited on the recessed logo or design of an associated mold surface, providing for the retention of segments in the recesses for being bonded onto a subsequent base layer of thermoplastic material.

Logo spray apparatus

An apparatus for forming a multi-colored integral vinyl skin shell including a heated mold and dual powder box arrangement wherein the mold is formed to include alternately positioned tear surfaces and recessed surfaces. The powder box has a plurality of spaced dams or dividers formed therein such that the dams cooperate with the respective recessed surfaces of the mold to provide clearance therewith that permit different colored powders in the compartments between the dams to cover the previously cleared tear surfaces and to flow past the selectively formed free ends of the dams to become integrally secured to the adjacent edge portions of the shell segments remaining in the areas of the recessed surfaces of the mold, forming the multi-colored, integral plastic shell. The dams or dividers have tapered sides formed on their distal ends for approximately the outer two thirds of the width of each dam, and an opening is formed therebetween into a central hollow section for recovering 'contaminated' or mixed powders from two adjacent compartments.

Apparatus for molding multi-colored plastic shells

A method for manufacturing decorative features in situ in a base layer cast plastic material includes the steps of providing a mold tool having a surface thereon which is recessed in the form of a desired decorative feature and includes a sharp break line between the recess and the surrounding mold surface; depositing a covering of thermoplastic material in the recess surface and heating the tool to melt the thermoplastic material on the recess surface to form segments of plastic corresponding to the desired decorative feature; thereafter cooling the covering and stripping it from the mold by separating it at the sharp break line interface between the deposited material on the recessed surface and a thin film membrane formed on the remainder of the mold surface so as to retain segments of material deposited in the recesses of the mold tool; reheating the mold tool recess to partially remelt the retained segments and thereafter depositing a base layer of thermoplastic material across the surface of the mold and reheating the mold to bond the retained segments to the base layer and cooling and stripping the mold to form a finished plastic shell having a decorative feature formed in situ therein.

Growing community of inventors

South Berwick, ME, United States of America

Alfred F Brault