Ford Global Technolgoies, LLC

Ford Motor Company Limited

Liying Qi

Linh Ngoc Doan

Nicholas Andrew Mazzocchi

Frank Qiukui Liu

Kenneth J Kwasnik

Li Lu

Yi Yang Tay

Jeffrey Kloberdanz

Jeffrey Peter Webb

Hui Wang

A method of forming a part includes locating an insert at an angle within a mold cavity, sending a quantity of molten resin through the mold cavity to form a first melt front, and sending another quantity of molten resin through the mold cavity to form a second melt front such that the first melt front meets the second melt front at a weld line and each front flows along opposite sides of the insert. The mold cavity can define opposed internal surfaces and the insert can be disposed at an angle between the internal surfaces at the weld line. Also, one end of the insert can be fixedly located to one of the opposed internal surfaces and another end of the insert can float within the mold cavity.

Insert to reduce weld line appearance defect in injection molding

A heat stake for a plastic part includes a body having a proximal end, a flared section and a distal end. The proximal end has a first cross-sectional area Aand the flared section has a second cross-sectional area Awhere A&#x3c;A. The distal end has a dual taper. That plastic part incorporating the heat stake is also disclosed.

Heat stake and method of eliminating heat stake sink marks in a plastic part

An air bag chute assembly for an automotive instrument panel is injection molded to form an integral deployment chute, door, and attachment flange, The flange attaches to the instrument panel around an aperture in the instrument panel. The tubular chute extends interiorly from the flange to a lower end configured to receive an inflating air bag from an air bag module and defines a deployment path along a longitudinal axis. A door flap is disposed in an upper end of the chute rotatable from the flange to emerge through the aperture. The flap has an interior side impacted by the inflating air bag carrying a plurality of raised strengthening ribs. The flap has at least one closed-section hollow channel protruding from the interior side to a channel height extending beyond the strengthening ribs formed by gas-assist injection molding.

Molded air bag chute with door reinforced by hollow channel

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Troy, MI, United States of America

Liying Qi