Conix Corporation

Todd C Parker

Keith G Korte

Michael B Smith

Russell R York

Marshall Ray Porter

Norman E Guschewski

A vehicle bumper () integrates rigid and flexible components into a single co-injection molded structure. In a preferred embodiment, a flexible fascia () is provided with integrated rigid fastener brackets (), energy absorption structure and head lamp brackets and housings (). A method for manufacturing such a bumper provides for the injection of two different plastic materials during the same molding process. The flexible plastic material first injected into the mold. Then, the rigid plastic material is injected at gates located where the rigid material is desired. In one embodiment, the rigid material is completely contained within the flexible material. The rigid material may be either a higher stiffness plastic or a fiber reinforced plastic.

Integrated co-injection molded vehicle components and methods of making the same

The present invention (FIGS.) provides an injection molding method and apparatus. A hot manifold is provided having a plurality of independently controlled valve gates. A controller is operably connected to each of the valve gates enabling independent opening and closing thereof. A mold has at least two cavities, a larger cavity and a relatively smaller cavity. The larger cavity has at least two inlets each communicating with the valve gates of the hot manifold. The smaller cavity has at least one inlet communicating with respective valve gate of the hot manifold. The larger cavity is filled with a first plasticized material by sequentially opening and closing the valve gates communicating with the large cavity. The larger cavity is packed out. Simultaneously with the packing out step, the smaller cavity is filled and packed out with a second plasticized material by opening and closing the at least one respective valve gate. A large and a small part may be molded in the same time as required for molding solely the large part.

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Nashville, IL, United States of America

Todd C Parker