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WO2024206420A1 - In-mold feature forming - Google Patents

In-mold feature forming
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Publication number
WO2024206420A1
WO2024206420A1PCT/US2024/021649US2024021649WWO2024206420A1WO 2024206420 A1WO2024206420 A1WO 2024206420A1US 2024021649 WUS2024021649 WUS 2024021649WWO 2024206420 A1WO2024206420 A1WO 2024206420A1
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WO
WIPO (PCT)
Prior art keywords
tool
sill plate
feature
outer layer
layer
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Pending
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PCT/US2024/021649
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French (fr)
Inventor
Antarpreet KALAIR
Vincent BUGNI
Shakeel THEODORE
Harold Mejia RUIZ
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Tesla Inc
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Tesla Inc
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Publication date
Application filed by Tesla IncfiledCriticalTesla Inc
Publication of WO2024206420A1publicationCriticalpatent/WO2024206420A1/en
Anticipated expirationlegal-statusCritical
Pendinglegal-statusCriticalCurrent

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Abstract

An aspect directed towards in-mold logo forming on an aluminum sheet using back-injected pressure. The tool may have a first tool feature such as a logo that is to be embossed or engraved. When plastic is back injected into the tool, the pressure of the plastic forces the aluminum sheet to deform into the negative area or around the positive area where the first tool feature is located, forming the first feature on the part and giving the feature durable support.

Description

TSLA.757WO/P2566-1NWO PATENT IN-MOLD FEATURE FORMING CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Application No. 63/456,351, filed March 31, 2023, the entire disclosure of which is hereby incorporated by reference in its entirety. TECHNICAL FIELD [0002] This application relates to back injecting, and more particularly relates to a method of producing intricate detail in a part using back injection pressure. BACKGROUND [0003] In the context of manufacturing metal components at mass scale, there is a need for processes capable of producing highly detailed and durable parts. Traditional metal stamping is capable of producing high detail, but not great durability. Thus, there is a need for an alternative method. SUMMARY [0004] An aspect is directed towards an in-mold logo forming on a metal sheet using back-injected plastic pressure. This manufacturing process forms a detailed embossed logo on a metal sheet faced component using the pressure of back-injected plastic. A metal sheet is cut to its starting shape and may be stamped to create an overall geometry. The metal plate may have removable tabs on its sides to assist in locating and holding the part during manufacturing. An adhesive may be applied to the backside of the metal sheet and may facilitate the aluminum bonding to the thermoplastic. The metal sheet may then be placed into a plastic injection molding tool. The cavity of the tool may have a first tool feature such as a logo that is to be embossed or engraved. The mold closes, and plastic is back injected onto the metal sheet. The pressure of the plastic forces the metal sheet to deform into the negative area or around the positive area where the first tool feature is located, forming the first feature on the part. After cooling, the part is removed from the tool and secondary operations are completed. [0005] The part now has uniform back-injected structural support under both the logo feature and the flat areas of the part, giving it superior durability over conventional stamped metal sheets attached to plastic substrates. The durability provided by the back injection allows very thin sheet metal to be used, between 0.2-1.0mm thickness. This thin sheet metal otherwise would not be able to retain its shape under load. Using thin metal further enables manufacturing of parts with intricate designs, because thin material can bend tighter radii. [0006] An aspect is directed to a sill plate for a vehicle. The sill plate comprises a metal sheet comprising a first feature, an adhesive, and a back injected layer. The adhesive layer strengthens the bond between the metal sheet and the back injected layer, and the back injected layer supports the first feature in the metal sheet. [0007] An aspect is directed to a method of forming a part. The method comprises forming a metal sheet into a first shape, placing the metal sheet into a tool, applying an adhesive to a side of the tool, and injecting a material into the tool with pressure so as to form a feature in the metal sheet. [0008] In some aspects, the techniques described herein relate to a process of manufacturing a sill plate for a vehicle, the process including: processing a sheet to form a processed sheet; placing the processed sheet into a tool, wherein the tool includes a first portion and a second portion; and injecting, through the second portion of the tool, an injection material to deform the processed sheet toward the first portion of the tool to form the sill plate and a visual feature on a surface of the sill plate. [0009] In some aspects, the techniques described herein relate to a process, further including: applying an adhesive to the processed sheet prior to injecting the injection material, wherein the adhesive bonds the injection material to the processed sheet to form the sill plate. [0010] In some aspects, the techniques described herein relate to a process, wherein processing the sheet to form the processed sheet includes cutting or stamping the sheet. [0011] In some aspects, the techniques described herein relate to a process, further including: removing the sill plate from the tool; and post-processing the sill plate, wherein post-processing the sill plate includes cooling, cleaning, sandblasting, anodizing, or removing excess material from the sill plate. [0012] In some aspects, the techniques described herein relate to a process, wherein the processed sheet includes aluminum, stainless steel, steel, alloy, or a metallic material. [0013] In some aspects, the techniques described herein relate to a process, wherein the injection material is selected from a group consisting of thermoplastic, plastic, polycarbonate (PC), acrylonitrile butadiene styrene (ABS), PC-ABS, glass-fiber, and combinations thereof. [0014] In some aspects, the techniques described herein relate to a process, wherein the visual feature includes a detailed embossed logo or a weld mark. [0015] In some aspects, the techniques described herein relate to a process, wherein the surface of the sill plate contacts the first portion of the tool without contacting the second portion of the tool. [0016] In some aspects, the techniques described herein relate to a sill plate for a vehicle, the sill plate including: an outer layer including a top surface and a bottom surface, wherein the top surface includes a visual feature; and a back injected layer bonded to the bottom surface of the outer layer, wherein the back injected layer structurally supports the outer layer. [0017] In some aspects, the techniques described herein relate to a sill plate, further including: an adhesive layer below the outer layer and above the back injected layer, wherein the adhesive layer bonds the back injected layer to the bottom surface of the outer layer. [0018] In some aspects, the techniques described herein relate to a sill plate, wherein the adhesive layer includes a thermoplastic polyurethane (TPU) or polyolefin. [0019] In some aspects, the techniques described herein relate to a sill plate, wherein the back injected layer includes a locating feature configured to locate the sill plate for mounting to the vehicle. [0020] In some aspects, the techniques described herein relate to a sill plate, wherein the back injected layer includes an engagement feature configured to secure the sill plate to the vehicle. [0021] In some aspects, the techniques described herein relate to a sill plate, wherein the outer layer includes aluminum, stainless steel, steel, alloy, or a metallic material. [0022] In some aspects, the techniques described herein relate to a sill plate, wherein the back injected layer includes thermoplastic, plastic, polycarbonate (PC), acrylonitrile butadiene styrene (ABS), PC-ABS, or glass-fiber. [0023] In some aspects, the techniques described herein relate to a sill plate, wherein the outer layer includes a locating hole configured to locate or guide placement of the outer layer in a tool for forming the sill plate. [0024] In some aspects, the techniques described herein relate to a tool for manufacturing a sill plate for a vehicle, wherein the sill plate includes an outer layer and a back injected layer, the tool including: a first portion including a tool feature, the tool feature configured to contact a top surface of the outer layer; and a second portion including a gate, the gate configured to inject an injection material to form a visual feature on the top surface of the outer layer and the back injected layer, wherein the visual feature is configured to be formed according to the tool feature. [0025] In some aspects, the techniques described herein relate to a tool, wherein the second portion further includes a cavity, and wherein the injection material is configured to be injected into the cavity to form the visual feature. [0026] In some aspects, the techniques described herein relate to a tool, wherein a bottom surface of the outer layer is between the top surface and the cavity. [0027] In some aspects, the techniques described herein relate to a tool, wherein the second portion further includes a holding pin configured to hold the outer layer when the injection material is injected to form the visual feature. BRIEF DESCRIPTION OF THE DRAWINGS [0028] The present disclosure is described with reference to the accompanying drawings, in which like reference characters reference like elements, and wherein: [0029] FIG.1 is a representation of a cross-section side view of an embodiment of a sill plate and a tool for forming a tool feature (e.g., embossed logo) in the sill plate. [0030] FIG.2A is a representation of an embodiment of a tool for making the sill plate. [0031] FIG.2B is a representation of an embodiment of an outer layer and a tool for making the sill plate. [0032] FIG.2C is a representation of an embodiment of a sill plate and a tool for making the sill plate. [0033] FIG.3 is a detailed representation of a portion of an embodiment of a sill plate and a tool for making the sill plate. [0034] FIG. 4 is a representation of a front view of an embodiment of a sill plate with the tool feature formed on a surface of the sill plate. [0035] FIG.5A is a picture of a sill plate with the tool feature formed on a surface of the sill plate. [0036] FIG.5B is a close-up view of a portion of the sill plate from FIG.5A. [0037] FIG.6 is a picture of the sill plate from FIG.5A after being anodized. [0038] FIG.7 is a representation of a method of making a sill plate. DETAILED DESCRIPTION [0039] Generally described, one or more aspects of the present disclosure relate to systems and methods for producing intricate detail in a part. For example, in certain embodiments, the method forms a detailed embossed logo on a sill plate for a vehicle. Of course the disclosure is not limited to sill plates and can be used to produce detailed, durable features on surfaces of other parts. [0040] Figure 1 is a representation of a sill plate 100 for a vehicle and a tool 200. The tool 200 is used to form the sill plate 100. In certain embodiments, the sill plate 100 may comprises an outer layer 102, an adhesive layer 104, and a back injected layer 106. The outer layer 102 may be referred to as a metal sheet or an aluminum sheet however it may be made of any metal (e.g., aluminum, stainless steel, steel, etc.) or an alternative material. In the present embodiment, the aluminum sheet has a high tensile strength, is highly formable, and anodizes well. For example, a 5000 series of aluminum exhibit these properties. More specifically, the AL 5052 series can be used in certain embodiments. In certain embodiments, the outer layer 102 may have a thickness between 0.2 mm-1.0 mm. Of course the thickness is not limited to the recited range and can have other thicknesses. [0041] The outer layer 102 comprises a first side 110 (e.g., a top surface) and a second side 112 (e.g., a bottom surface). The adhesive layer 104 may be applied to the second side 112 of the outer layer 102 and may bond the outer layer 102 to the back injected layer 106. The back injected layer 106 may be an injection material 108 such as plastic or an alternative material capable of being injected. The injection material 108 may be a thermoplastic. The thermoplastic may ideally have a low shrinkage and high dimensional stability. The injection material 108 may be a plastic such as PC, ABS, and PCABS. There may be additional materials mixed with the plastic such as Glass Fiber reinforcement which may further improve strength, stiffness, and dimensional stability. In certain embodiments, the injection material may be a PC+ABS thermoplastic with 30% glass-fiber fill. [0042] The tool 200 may comprise a first portion 210 and a second portion 230. The first portion 210 may comprise a cavity 212 and an insert 214. The second portion 230 may comprise a mold core 236 and a gate 238. The first portion 210 and the second portion 230 may form a part cavity 250. The gate 238 may be configured to facilitate the injection of the injection material 108 into the part cavity 250. In the present embodiment, the second portion 230 comprises the gate 238 but it in alternative embodiments the first portion 210 may comprise the gate 238. [0043] The insert 214 may comprise a first tool feature 216. The first tool feature 216 may comprise an embossed or engraved element in the insert 214. The first tool feature 216 is located on a tool feature face 218 of the insert 214 that contacts the outer layer 102. The first tool feature 216 may be a variety of shapes or designs such as a logo or text. The first tool feature 216 may be engraved in the tool feature face 218. [0044] Figure 2A is a representation of a tool 200. The tool 200 comprises cavity 212 and an insert 214. The insert 214 may comprise a first tool feature 216. The tool 200 further comprises holding pin 270 configured to against the outer layer 102 to hold the outer layer 102 in place when the material is injected to form the back injected layer 106. The tool 200 further comprises locating pins 260 configured to locate the outer layer 102 in a location. [0045] Figure 2B is a representation of an outer layer 102 and a tool 200. The outer layer 102 comprises the tabs 130. The outer layer is located in the tool 200. The tabs 130 interact with the locating pins 260 to locate the outer layer 102 in the tool. The locating pins 260 may interact with a locating hole 132 in the locating tab 130 to locate the outer layer 102 in the tool. The holding pins 270 may press against the outer layer 102 to hold the outer layer in place. The holding pins 270 may apply a force against the outer layer 102 during injection of the tool 200. [0046] Figure 2C is a representation of a sill plate 100 for a vehicle and a tool 200. The sill plate 100 comprises a back injected layer 106. The back injected layer 106 may comprise locating features 120, structural support 122, and engagement features 124. The locating features 120 may be used to locate the sill plate 100 when it is mounted in the vehicle. The structural support 122 may reinforce the sill plate 100 and provide structural support when in use, for example when the sill plate 100 is stepped on when someone is entering the vehicle. The engagement features 124 may serve to secure the sill plate 100 in its installed position. [0047] The sill plate 100 comprises an outer layer 102. The outer layer 102 may further comprise one or more tabs 130. The tabs 130 may be the same material and same part as the outer layer 102, or they may be different. The tabs 130 may further comprise a locating hole 132. The locating hole 132 may be used to locate or guide the placement of the outer layer 102 in the tool 200. [0048] The tool 200 may further comprise one or more locating pins 260. The locating pins 260 may interact with the one or more tabs 130, specifically the locating holes 132 of the one or more tabs 130. The tool 200 may further comprise holding pins 270. The holdings pin 270 may be located in a second portion of the tool 200 and may press against the backside of the sill plate 100 to hold it in place during the injection process. The holding pins 270 may apply a force on the sill plate 100, specifically on the outer layer 102, the adhesive layer 104, or the back injected layer 106, to hold the sill plate 100 in place. [0049] Figure 3 is a detailed cross-section representation of a sill plate 100 for a vehicle and a tool 200. The holding pin 270 presses against the outer layer 102 to hold the sill plate 100 in place when the material is injected to form the back injected layer 106. The holding pins 270 may slide out of the mold core 236 to hold the outer layer 102 during injection and then retract back into the mold core 236 mid-way through injection or once injection is complete. By retracting the pins 270 mid-way through injection, the tool 200 is able to hold the outer layer 102 in place during initial injection where it might move and the tool 200 is further able fill the holes that would be left in the back injected layer 106 by the pins 270 with injection material 108 during injection. [0050] Figure 4 is a representation of a sill plate 100 for a vehicle. Figure 4 shows the sill plate 100 from a frontal view. The outer layer 102 of the sill plate 100 comprise an aluminum sheet. The sill plate 100 further includes the tabs 130. The tabs 130 include locating holes 132. [0051] Figure 5A is a representation of a sill plate 100. The sill plate 100 includes a first feature 140 (e.g., a visual feature). The first feature 140 is located on the first side 110 of the sill plate 100. The first feature 140 corresponds to the first tool feature 216. In the present embodiment the first tool feature 216 is an engraved logo. During injection the outer layer 102 is deformed to form the first feature 140 in the form of an embossed logo. The pressure of the back injection process allows for the more precise and finite details in the first feature 140. The pressure of a typical injection molding process can be between 2,000-10,000 PSI, and the holding pressure can be about 80% of the injection pressure. In certain embodiments, both injection pressure and holding pressure are higher to ensure the outer layer 102 gets fully pressed into the cavity on the tool. In certain embodiments, the injection pressure for this process may be between 10,000-20,000 PSI. [0052] Figure 5B is a detailed representation of a portion of the sill plate 100 with the first feature 140 as seen in Figure 5A. In the present embodiment the first feature 140 comprises a logo, which includes a plurality of letters. The first feature 140 includes a plurality of finite feature details 142. In the illustrated embodiment, the finite feature details 142 comprise weld marks so as to replicate the appearance of a weld. [0053] Figure 6 is a representation of the sill plate 100 after being anodized. The anodization may occur after the sill plate 100 has been back injected. The sill plate 100 may be anodized with clear, black, or any color. [0054] Figure 7 is a representation of a method of making the sill plate 100. In step 302, the outer layer 102 (e.g., aluminum sheet) is cut to a desired shape. The shape may be the final shape or may include additional material that will be removed at a later time, such as tabs. In step 304 the outer layer 102 is stamped to form an overall geometry. The stamped shape may include curved faces and sides, bends, folds, or other geometric features. The stamping may further comprise stamping the logo and the back injection process may only be used to reinforce and provide support for the stamped logo. The step 304 may be optional depending on the overall geometry of the sill plate 100. [0055] In step 305 an adhesive is applied to a surface of the outer layer 102. The adhesive may be placed on the aluminum sheet, for example in the form of a tape. The adhesive may also be applied as a spray. The adhesive may be designed to bond polar plastic materials (PCABS, PC, ABS, etc.) to metals. The adhesive may be a multilayer film adhesive made with thermoplastic polyurethane (TPU) and modified polyolefin base. [0056] In step 306 the outer layer 102 is placed in the tool 200. The outer layer 102 may be placed in the first portion of the tool or the second. It should be understood that in certain embodiments step 305 may occur after step 306, or before step 302 or 304. The step 306 may further comprises holding the outer layer 102 in place via a plurality of tabs. The tool 200 is closed at step 308. [0057] In the step 310 the injection material 108 is injected into the part cavity 250. The plastic material is injected into the part cavity 250 through the gate 238. As the material is injected into the part cavity 250, the material fills the part cavity 250 and pushes against the second side 112 of the outer layer 102. The material may be in direct contact with the aluminum sheet or may be in contact with the adhesive layer 104. The injection material 108 applies a force on the second side of the outer layer 102, pushing the aluminum sheet into the first tool feature 216 located on a tool feature face 218 of the insert 214. The force deforms the outer layer 102 into the negative space of the first tool feature 216, forming a detailed feature in the outer layer 102 and giving the feature uniform structural support. [0058] In step 312 the sill plate 100 is removed from the tool 200. The step 312 may comprise separating the first portion of the tool 200 from the second portion of the tool 200. The step 312 can further comprise cooling the sill plate 100 before removing it from the tool 200. [0059] In step 314 secondary operations (e.g., post-processing) are completed on the sill plate 100. Secondary operations may comprise one or more of cleaning, sandblasting, anodization, removal of tabs, and other operations. The part may be sandblasted and cleaned. Then the part may be anodized with an in-organic pigment to provide durability and UV- resistance. The tabs may be used to hold the part during anodization and sandblasting. Then the tabs may be removed from the aluminum plate using a mill. The part may then be considered complete. [0060] The process and methods described in the application may further be used to create a composite structural sheet or part with aluminum on both sides. This method may also be used to create a back injected aluminum part with durable, detailed back injected features on both sides. Aluminum with pre-applied adhesive would be placed on both sides of the injection molding tool. The system may further include vacuum tubes in the tool to keep the aluminum sheets in place. The plastic may then be injected between the aluminum sheets from side gates or through holes in the aluminum sheets. [0061] It should be understood that the components described in this disclosure may be used outside of vehicles and on materials other than metal. The components described may be applicable in the aerospace, robotic, manufacturing equipment, industrial equipment, or other areas. [0062] The foregoing disclosure is not intended to limit the present disclosure to the precise forms or particular fields of use disclosed. As such, it is contemplated that various alternate embodiments and/or modifications to the present disclosure, whether explicitly described or implied herein, are possible in light of the disclosure. Having thus described embodiments of the present disclosure, a person of ordinary skill in the art will recognize that changes may be made in form and detail without departing from the scope of the present disclosure. Thus, the present disclosure is limited only by the claims. [0063] In the foregoing specification, the disclosure has been described with reference to specific embodiments. However, as one skilled in the art will appreciate, various embodiments disclosed herein can be modified or otherwise implemented in various other ways without departing from the spirit and scope of the disclosure. Accordingly, this description is to be considered as illustrative and is for the purpose of teaching those skilled in the art the manner of making and using various embodiments of the back-injected aluminum plate. It is to be understood that the forms of disclosure herein shown and described are to be taken as representative embodiments. Equivalent elements, materials, processes or steps may be substituted for those representatively illustrated and described herein. Moreover, certain features of the disclosure may be utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the disclosure. Expressions such as "including", "comprising", "incorporating", "consisting of", "have", "is" used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural. [0064] Further, various embodiments disclosed herein are to be taken in the illustrative and explanatory sense, and should in no way be construed as limiting of the present disclosure. All joinder references (e.g., attached, affixed, coupled, connected, and the like) are only used to aid the reader's understanding of the present disclosure, and may not create limitations, particularly as to the position, orientation, or use of the systems and/or methods disclosed herein. Therefore, joinder references, if any, are to be construed broadly. Moreover, such joinder references do not necessarily infer that two elements are directly connected to each other. Additionally, all numerical terms, such as, but not limited to, "first", "second", "third", "primary", "secondary", "main" or any other ordinary and/or numerical terms, should also be taken only as identifiers, to assist the reader's understanding of the various elements, embodiments, variations and/or modifications of the present disclosure, and may not create any limitations, particularly as to the order, or preference, of any element, embodiment, variation and/or modification relative to, or over, another element, embodiment, variation and/or modification. [0065] It will also be appreciated that one or more of the elements depicted in the drawings/figures can also be implemented in a more separated or integrated manner, or even removed or rendered as inoperable in certain cases, as is useful in accordance with a particular application.

Claims

WHAT IS CLAIMED IS: 1. A process of manufacturing a sill plate for a vehicle, the process comprising: processing a sheet to form a processed sheet; placing the processed sheet into a tool, wherein the tool comprises a first portion and a second portion; and injecting, through the second portion of the tool, an injection material to deform the processed sheet toward the first portion of the tool to form the sill plate and a visual feature on a surface of the sill plate.
2. The process of claim 1, further comprising: applying an adhesive to the processed sheet prior to injecting the injection material, wherein the adhesive bonds the injection material to the processed sheet to form the sill plate.
3. The process of claim 1, wherein processing the sheet to form the processed sheet comprises cutting or stamping the sheet.
4. The process of claim 1, further comprising: removing the sill plate from the tool; and post-processing the sill plate, wherein post-processing the sill plate comprises cooling, cleaning, sandblasting, anodizing, or removing excess material from the sill plate.
5. The process of claim 1, wherein the processed sheet comprises aluminum, stainless steel, steel, alloy, or a metallic material.
6. The process of claim 1, wherein the injection material is selected from a group consisting of thermoplastic, plastic, polycarbonate (PC), acrylonitrile butadiene styrene (ABS), PC-ABS, glass-fiber, and combinations thereof.
7. The process of claim 1, wherein the visual feature comprises a detailed embossed logo or a weld mark.
8. The process of claim 1, wherein the surface of the sill plate contacts the first portion of the tool without contacting the second portion of the tool.
9. A sill plate for a vehicle, the sill plate comprising: an outer layer comprising a top surface and a bottom surface, wherein the top surface comprises a visual feature; and a back injected layer bonded to the bottom surface of the outer layer, wherein the back injected layer structurally supports the outer layer.
10. The sill plate of claim 9, further comprising: an adhesive layer below the outer layer and above the back injected layer, wherein the adhesive layer bonds the back injected layer to the bottom surface of the outer layer.
11. The sill plate of claim 10, wherein the adhesive layer comprises a thermoplastic polyurethane (TPU) or polyolefin.
12. The sill plate of claim 9, wherein the back injected layer comprises a locating feature configured to locate the sill plate for mounting to the vehicle.
13. The sill plate of claim 9, wherein the back injected layer comprises an engagement feature configured to secure the sill plate to the vehicle.
14. The sill plate of claim 9, wherein the outer layer comprises aluminum, stainless steel, steel, alloy, or a metallic material.
15. The sill plate of claim 9, wherein the back injected layer comprises thermoplastic, plastic, polycarbonate (PC), acrylonitrile butadiene styrene (ABS), PC-ABS, or glass-fiber.
16. The sill plate of claim 9, wherein the outer layer comprises a locating hole configured to locate or guide placement of the outer layer in a tool for forming the sill plate.
17. A tool for manufacturing a sill plate for a vehicle, wherein the sill plate comprises an outer layer and a back injected layer, the tool comprising: a first portion comprising a tool feature, the tool feature configured to contact a top surface of the outer layer; and a second portion comprising a gate, the gate configured to inject an injection material to form a visual feature on the top surface of the outer layer and the back injected layer, wherein the visual feature is configured to be formed according to the tool feature.
18. The tool of claim 17, wherein the second portion further comprises a cavity, and wherein the injection material is configured to be injected into the cavity to form the visual feature.
19. The tool of claim 18, wherein a bottom surface of the outer layer is between the top surface and the cavity.
20. The tool of claim 17, wherein the second portion further comprises a holding pin configured to hold the outer layer when the injection material is injected to form the visual feature.
21. A sill plate for a vehicle, the sill plate comprising: an aluminum sheet comprising a first feature; an adhesive layer; and a back injected layer, wherein the aluminum sheet is bonded to the back injected layer, and wherein the back injected layer supports the first feature in the aluminum sheet.
22. A method of forming a part, the method comprising: forming a metal sheet into a first shape; placing the metal sheet into a tool; applying an adhesive to a side of the tool; and injecting a material into the tool with pressure so as to form a feature in the metal sheet.
PCT/US2024/0216492023-03-312024-03-27In-mold feature formingPendingWO2024206420A1 (en)

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US63/456,3512023-03-31

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