Global IP Holdings, LLC

Steven A Mitchell

Christopher A Heikkila

Darius John Preisler

Jeffrey P Schmelzer

An automated manufacturing method and system and in-mold coated plastic article produced thereby are provided. The system includes a compression mold and a plurality of program-controlled manipulators. An automatic sprayer supported on a first manipulator sprays at least a portion of a mold surface with an in-mold coating composition. An end effector supported on a second manipulator picks up a heated blank of moldable plastic sheet material from an oven and places the heated blank between upper and lower mold halves of the mold. An inner portion of the heated blank is forced into an article-defining cavity of the mold and into contact with at least a portion of the in-mold coating composition. The in-mold coating composition and the inner portion of the heated blank cure and bond to one another so as to form the coated plastic article.

Automated manufacturing method and system and in-mold coated plastic article produced thereby

An automated manufacturing method and system and in-mold coated plastic article produced thereby are provided. The system includes a combination compression and injection mold and a plurality of program-controlled manipulators. An automatic sprayer supported on a first manipulator sprays at least a portion of a mold surface with an in-mold coating composition. An end effector supported on a second manipulator picks up a heated blank of moldable plastic sheet material from an oven and places the heated blank in the mold. An inner portion of the heated blank is forced into an article-defining cavity of the mold and into contact with at least a portion of the composition. The composition and the inner portion cure and bond to one another and a plastic compatible with the plastic of the sheet is injected into the mold so as to form the coated plastic article.

A method of making a trimmed, laminated trim component is provided. A heated plastic composite sheet is pressed against a heated laminated sheet to bond a plastic cushioning layer of the laminated sheet to the plastic composite sheet. The step of pressing compresses a portion of the laminated sheet spaced inwardly from an outer periphery of the laminated sheet to locally compact and thin the cushioning layer at the portion to form a compressed portion of the cushioning layer. Unwanted portions of the laminated sheet are trimmed.

Method of making a trimmed, laminated trim component

A method of making a laminated trim component is provided. A heated plastic composite sheet is pressed against a heated laminated sheet to bond a plastic cushioning layer of the laminated sheet to the plastic composite sheet. The step of pressing compresses a portion of the laminated sheet spaced inwardly from an outer periphery of the laminated sheet to locally compact and thin the cushioning layer at the portion to form a compressed portion of the cushioning layer. Interior portions of the sheets stretch during the step of pressing while remaining intact.

Method of making a laminated trim component

A method of making a laminated trim component at a molding station is provided. A heated plastic composite sheet is pressed against a heated laminated sheet to bond a plastic cushioning layer of the laminated sheet to the plastic composite sheet at the molding station. The step of pressing compresses a portion of the laminated sheet spaced inwardly from an outer periphery of the laminated sheet to locally compact and thin the cushioning layer at the portion to form a compressed portion of the cushioning layer. A plastic compatible with the plastic of the composite sheet is molded around the composite sheet to form at least one component at the inner surface of the composite sheet at the molding station.

Method of making a laminated trim component at a molding station

A method of making a laminated trim component at a pair of spaced first and second molding stations is provided. A heated plastic composite sheet is pressed against a heated laminated sheet to bond a plastic cushioning layer of the laminated sheet to the composite sheet at the first molding station. The step of pressing compresses a portion of the laminated sheet spaced inwardly from an outer periphery of the laminated sheet to locally compact and thin the cushioning layer at the portion to form a compressed portion of the cushioning layer. The bonded sheets are transferred to the second molding station where a plastic compatible with the plastic of the composite sheet is molded around the composite sheet to form at least one component at the inner surface of the composite sheet.

Method of making a laminated trim component at a pair of spaced first and second molding stations

A cargo management system including a vehicle load floor having a cellulose-based core to compartmentalize a cargo area of the vehicle into an upper compartment and a covered lower compartment is provided. The floor has a wood grain finish. The load floor includes a compression-molded composite panel that includes first and second outer layers of fiber-reinforced thermoplastic material, first and second sheets of thermoplastic adhesive and a core of cellulose-based material and positioned between the outer layers. The core has a cellular structure. The outer layers are bonded to the core by the first and second sheets and by press molding. The first outer layer having a top surface on which a multi-layer sheet is bonded by the press molding. The multi-layer sheet has a substantially planar upper support surface to support cargo in the upper compartment and to provide the load floor with the wood grain finish.

Cargo management system including a vehicle load floor having a cellulose-based core with a cellular structure and made by a composite, compression molding process and having a wood grain finish

A cargo management system including a vehicle load floor having a cellulose-based core to compartmentalize a cargo area of the vehicle into an upper compartment and a covered lower compartment is provided. The floor has a wood grain finish. The load floor includes a compression-molded composite panel that includes first and second outer layers of fiber-reinforced thermoplastic material, first and second sheets of thermoplastic adhesive and a core of cellulose-based material and positioned between the outer layers. The core has a large number of cavities. The outer layers are bonded to the core by the first and second sheets and by press molding. The first outer layer having a top surface on which a multi-layer sheet is bonded by the press molding. The multi-layer sheet has a substantially planar upper support surface to support cargo in the upper compartment and to provide the load floor with the wood grain finish.

Cargo management system including a vehicle load floor having a cellulose-based core and made by a composite, compression molding process and having a wood grain finish

A cargo management system including an automotive vehicle seat having a backrest which separates the vehicle interior into a passenger area at the front of the vehicle and a cargo area at the rear of the vehicle is provided. The system includes a vehicle load floor which includes first and second outer layers and a core of cellulose-based material positioned between the outer layers and having a large number of cavities. The outer layers of the load floor are bonded to the core by press molding. The load floor has a wood grain finish. A compression-molded, composite cargo trim panel is secured to the backrest and includes a base layer and a coverstock sheet bonded to the base layer by press molding. The coverstock sheet provides the trim panel with a wood grain finish in an upper compartment of the cargo area.

Cargo management system including an automotive vehicle seat having a cargo trim panel made by a composite, compression molding process and having a wood grain finish

A cargo management system including a vehicle load floor and a pair of opposing cargo trim panels supported above the load floor at opposite sides of the load floor within the interior of the vehicle is provided. The load floor has a wood grain finish. The load floor includes a first outer layer, a second outer layer and a core of cellulose-based material positioned between the outer layers and having a large number of cavities. The outer layers are bonded to the core by press molding. The trim panels are compression-molded, composite cargo trim panels supported above the vehicle load floor at opposite sides of the load floor. Each panel includes a base layer and a coverstock sheet bonded to the base layer by press molding. Each coverstock sheet provides its respective trim panel with a wood grain finish.

Cargo management system for a vehicle and including a pair of opposing cargo trim panels, each of which is made by a composite, compression molding process and has a wood grain finish

A cargo management system including a vehicle load floor to compartmentalize a cargo area of the vehicle into an upper compartment and a covered lower compartment is provided. The floor has a wood grain finish. The load floor includes a compression-molded composite panel that includes first and second outer layers and a core positioned between the outer layers. The core has a large number of cavities. The outer layers are bonded to the core by press molding. The first outer layer having a top surface on which a multi-layer sheet is bonded by the press molding. The sheet has a substantially planar upper support surface to support cargo in the upper compartment and to provide the load floor with the wood grain finish.

Cargo management system including a vehicle load floor made by a composite, compression molding process and having a wood grain finish

A cargo management system including an automotive vehicle seat having a backrest which separates the vehicle interior into a passenger area at the front of the vehicle and a cargo area at the rear of the vehicle is provided. The system includes a vehicle load floor to compartmentalize the cargo area into an upper compartment and a covered lower compartment. The load floor has a wood grain finish. A compression-molded, composite cargo trim panel is secured to the backrest and faces the upper compartment of the cargo area above the load floor in an upright sitting position of the backrest. The panel includes a base layer and a coverstock sheet bonded to the base layer by press molding. The coverstock sheet provides the trim panel with a wood grain finish in the upper compartment of the cargo area.

A cargo management system including a vehicle load floor and a pair of opposing cargo trim panels supported above the load floor at opposite sides of the load floor within the interior of the vehicle is provided. The vehicle load floor compartmentalizes a cargo area into an upper compartment and a covered lower compartment. The load floor has a wood grain finish. The trim panels are compression-molded, composite cargo trim panels supported above the vehicle load floor at opposite sides of the load floor within the interior of the vehicle to at least partially define the upper compartment of the cargo area. Each panel includes a base layer and a coverstock sheet bonded to the base layer by press molding. Each coverstock sheet provides its respective trim panel with a wood grain finish in the upper compartment of the cargo area.

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Linden, MI, United States of America

Steven A Mitchell