Ford Global Technolgoies, LLC

Ford Motor Company Limited

Haoliang Michael Sun

Junko Pauken

Manfred Koberstein

Sean Bayle West

Paul Bryan Hoke

Ellen Cheng-chi Lee

Lawrence C Karas

Vishwanath Daita

Erik Garland

Ellen Cheng-Chi Lee

A mold apparatus for forming a molded part includes a mold body, a mold cavity formed in said mold body, a plurality of valve gates associated with said mold body, and a controller in communication with said plurality of valve gates. The controller is programmed to time opening of each valve gate based on a selected flow rate required to eliminate weld lines in the product.

Method to chase weld lines by timing and positioning of gates

An apparatus and method for eliminating mold lines when molding a part having ferromagnetic pigments is provided. A mold assembly having a mold with a cavity and valve gates is formed. Pucks are fitted at the gates to collect residual cold plastic. The calculation of a specific sequence and timing of the opening of the valve gates is determined based on a calculation of the total number of valve gates needed to fill a part while maintaining acceptable injection molding pressure. Once calculated, the gates are positioned around the mold cavity to balance flow length ratio. A primary gate is chosen for initial injection. The time for the material to flow from the first to the second gate is established. The second gate is opened after the flow front reaches the second gate. This pattern continues until all valve gates are opened.

A method for determining a vehicle heating, ventilation, and air conditioning (HVAC) passenger cabin air filter filtration performance includes determining a vehicle-exterior atmospheric particulate contaminant concentration, a passenger cabin air filter efficiency, and an HVAC airflow rate. The passenger cabin particulate contaminant concentration is calculated from the determined atmospheric particulate contaminant concentration, passenger cabin air filter efficiency, and HVAC airflow rate.

Calculation-based vehicle cabin filtration performance

A one-piece trim bezel formed from multiple components. In the event of two co-molded components, the first co-molded part is composed of a polymerized material having an unpainted surface that may be a high gloss smooth surface or a textured low gloss surface and the second co-molded part, formed with the first part, is composed of a plateable plastic material. The plateable plastic material may be plateable with chrome. A multiple-shot injection molding process is used to form the one-piece trim bezel which joins the first co-molded part and the second co-molded part in one operation. The formed part is then subjected to a plating process during which time only the chrome deposits on the surface of the plateable plastic material of the second co-molded part while the surface of the first co-molded part remains unplated.

One-piece decorative trim bezel having plural unpainted finishes

An injection molding apparatus and method are provided. The method includes a molded cavity coupled to a resin injection apparatus which injects molten resin under pressure with a gas such that the resin foams within the mold cavity. An electrical heater is in contact with a first cavity surface, and a cooling medium cools the mold. The resin may include metallic flakes.

Foamed resin injection molding method

An energy absorbing panel assembly for the interior of a motor vehicle is disclosed. The energy absorbing panel assembly, typically the knee bolster panel adjacent the steering wheel, includes an energy absorbing structure integrally molded to the panel. The energy absorbing structure includes three outer side walls and a top wall. The outer side walls extend from the same side of the top wall to the panel. Extending from the top wall to the panel is at least one top wall supporting rib. The rib is positioned between the outer side walls. At least one of the outer walls is at an obtuse angle relative to the plane of the top wall. All three of the outer walls may be at an obtuse angle relative to the plane of the top wall. Lateral supports may be provided between the outer side walls and the panel.

Energy absorbing structure for vehicle knee bolster cover

An instrument panel assembly for a passenger vehicle is provided with a protective film. The protective film has only one unfolded layer. The film layer is sized to cover an opening in an instrument panel. The opening is sized for an airbag to deploy through. The film layer is provided with a slit for separating into portions. The portions extend through the instrument panel as the airbag deploys. The protective film prevents the airbag from being damaged. The film layer also prevents the airbag from damaging the instrument panel. The instrument panel may be provided with a door for selectively covering the opening. The instrument panel assembly may include a hinge for pivotally connecting the door to the instrument panel.

Growing community of inventors

Rochester Hills, MI, United States of America

Haoliang Michael Sun