Lear Corporation

David Turczynski

Gregory A Homann

James Hendry

John David Youngs

Michael P Schoemann

Thomas W Spanos

William J Noble

The present invention relates to a two-shot, non-shut-off method of manufacturing a 100% grained trim component for a vehicle. The method includes actuating a tool insert between a mold cavity and a secondary void to form a molded trim component having a groove. A first shot of material is injected to form a first trim element having a grained class-A side. During the first shot, flash enters the secondary void to provide a non-shut-off condition. The tool insert is retracted to define a ditch in the first trim element. A second shot of material is injected to form a second trim element having a grained class-A side, during which time a portion of the second shot enters the ditch to provide a non-shut-off condition. The trim elements are then bonded where a portion the second trim element bonded to the first trim element within the groove.

Method of manufacturing, 100% grained with non-shut-off condition two shot interior component

A method and system for producing hollow rib structures for trim components and panels using gas assisted injection molding. Movable insert members are provided in the mold cavity, particularly at the ends of the structural rib members. After the plastic material is injected into the mold cavity, the plastic is packed in the mold, and the insert members are locked in position. Selectively activatable locking mechanisms are used to lock up the insert members. Thereafter, gas or another fluid is introduced into the rib members in order to provide hollow channels therein. Movement of the insert members provides a recess or groove for placement of the displaced resin from the rib members. The displaced resin material completes the formation of the molded plastic article.

Plastic injection molding with moveable insert members

A method and system for producing thin walled plastic products with hollow rib members using gas-assisted plastic injection molding. The mold is allowed to open a predetermined distance as the gas is injected into the plastic material in the mold cavity. A plurality of post members, such as ejector pins, are located on a biased ejector frame and maintain their positions relative to the mold cavity in order to form solid portions or areas in the molded part.

Open mold molding

A method and system for producing hollow rib structures for trim components and panels using gas assisted injection molding. Spring biased movable insert members are provided in the mold cavity, particularly at the ends of the structural rib members. After the plastic material is injected into the mold cavity, gas is introduced into the rib members in order to provide hollow channels therein. The displaced resin material forces the insert members to the full cavity positions and completes the formation of the molded plastic article.

Plastic injection molded articles with hollow rib members

A method and system for producing hollow rib structures for trim components and panels using gas assisted injection molding. Rotatable insert members with recesses therein are provided in the mold cavity, particularly at the ends of the structural rib members. Once the plastic material has been injected into the mold cavity, the insert members are rotated, exposing said recesses to the mold cavity. Then, gas is introduced into the rib members displacing a portion of the molten plastic material into the recesses forming hollow channels or openings in the plastic material. The displaced resin material completes the formation of the molded plastic article.

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Highland, MI, United States of America

David Turczynski