公开(公告)号：US4880588A

公开(公告)日：1989-11-14

申请号：US232624

申请日：1988-08-15

申请人： Alfred F. Brault ,  John D. Gray

发明人： Alfred F. Brault ,  John D. Gray

IPC分类号： B29C37/00 ,  B29C41/08 ,  B29C41/18 ,  B29C41/22

CPC分类号： B29C41/22 ,  B29C41/18 ,  B29C37/0057 ,  B29C41/08

摘要： A method for manufacturing decorative features in situ in a base layer cast plastic material includes the steps of providing a mold tool having a surface thereon which is recessed in the form of a desired decorative feature and includes a sharp break line between the recess and the surrounding mold surface; depositing a covering of thermoplastic material in the recess surface and heating the tool to melt the thermoplastic material on the recess surface to form segments of plastic corresponding to the desired decorative feature; thereafter cooling the covering and stripping it from the mold by separating it at the sharp break line interface between the deposited material on the recessed surface and a thin film membrane formed on the remainder of the mold surface so as to retain segments of material deposited in the recesses of the mold tool; reheating the mold tool recess to partially remelt the retained segments and thereafter depositing a base layer of thermoplastic material across the surface of the mold and reheating the mold to bond the retained segments to the base layer and cooling and stripping the mold to form a finished plastic shell having a decorative feature formed in situ therein.

摘要翻译： 一种用于在基层铸造塑料材料中原位制造装饰特征的方法包括以下步骤：提供具有在其上的表面的模具，该模具以期望的装饰特征的形式凹陷，并且包括在凹部和周围 模具表面; 在所述凹陷表面中沉积热塑性材料的覆盖物并加热所述工具以将所述热塑性材料熔化在所述凹部表面上，以形成与期望的装饰特征相对应的塑料段; 然后冷却覆盖物并将其从模具中剥离，通过在凹陷表面上沉积的材料与形成在模具表面的其余部分上的薄膜膜之间的尖锐断裂线界面处将其分离，以便保留沉积在模具表面中的材料段 模具的凹槽; 重新加热模具工具凹口以部分地重新保留保留的区段，然后在模具的表面上沉积热塑性材料的基层，并重新加热模具以将保留的区段结合到基层，并冷却和剥离模具以形成成品塑料 壳体具有在其中原位形成的装饰特征。

公开(公告)号：US4938906A

公开(公告)日：1990-07-03

申请号：US440319

申请日：1989-11-22

申请人： Alfred F. Brault

发明人： Alfred F. Brault

IPC分类号： B29C37/00 ,  B29C41/18 ,  B29C41/22

CPC分类号： B29C41/18 ,  B29C41/22 ,  B29C37/0057 ,  B29K2995/0021 ,  B29L2031/3014

摘要： A process for forming a multi-colored integral vinyl skin shell including a heated mold and dual powder box arrangement wherein the mold is formed to include alternately positioned tear surfaces and recessed surfaces. After the first powder box supplies a layer of powder to cover all the surfaces to form a shell, the strips of shell on the tear surfaces are removed, after which the first powder box is replaced by a second powder box. The second powder box has a plurality of spaced dams or dividers formed therein such that the dams cooperate with the respective recessed surfaces of the mold to provide clearances therewith that permit different colored powders in the compartments between the dams to cover the previously cleared tear surfaces and to flow past the selectively formed free ends of the dams to become integrally secured to the adjacent edge portions of the shell segments remaining in the areas of the recessed surfaces of the mold, forming the multi-colored, integral plastic shell. The dams or dividers have tapered sides formed on their distal ends for approximately the outer two thirds of the width of each dam, and an opening is formed therebetween into a central hollow section for recovering "contaminated" or mixed powders from two adjacent compartments.

摘要翻译： 一种形成多色整体乙烯基皮肤外壳的方法，包括加热模具和双重粉末盒装置，其中模具形成为包括交替设置的撕裂表面和凹陷表面。 在第一粉盒供应一层粉末以覆盖所有表面以形成壳体之后，将撕开表面上的外壳条移除，然后用第二粉盒替换第一粉盒。 第二粉盒在其中形成有多个间隔开的大坝或分隔件，使得坝与模具的相应凹入表面配合以提供间隙，从而允许坝之间的隔室中的不同着色粉末覆盖先前清除的撕裂面和 流过选择性地形成的坝的自由端，以一体地固定到保持在模具的凹入表面的区域中的壳段的相邻边缘部分，形成多色整体的塑料外壳。 大坝或分隔件在其远端形成有大致约每个坝的宽度的二分之三的锥形侧面，并且在其间形成有中间中空部分的开口，用于从两个相邻的隔室回收“被污染的”或混合的粉末。

公开(公告)号：US4894004A

公开(公告)日：1990-01-16

申请号：US267356

申请日：1988-11-04

申请人： Alfred F. Brault

发明人： Alfred F. Brault

IPC分类号： B29C37/00 ,  B29C41/18 ,  B29C41/22 ,  B29C41/36 ,  B29C41/40 ,  B29K27/06 ,  B29L9/00 ,  B29L31/58

CPC分类号： B29C41/18 ,  B29C41/22 ,  B29C37/0057 ,  B29K2995/0021 ,  B29L2031/3014 ,  Y10S264/60

摘要： An apparatus for forming a multi-colored integral vinyl skin shell including a heated mold and dual powder box arrangement wherein the mold is formed to include alternately positioned tear surfaces and recessed surfaces. The powder box has a plurality of spaced dams or dividers formed therein such that the dams cooperate with the respective recessed surfaces of the mold to provide clearance therewith that permit different colored powders in the compartments between the dams to cover the previously cleared tear surfaces and to flow past the selectively formed free ends of the dams to become integrally secured to the adjacent edge portions of the shell segments remaining in the areas of the recessed surfaces of the mold, forming the multi-colored, integral plastic shell. The dams or dividers have tapered sides formed on their distal ends for approximately the outer two thirds of the width of each dam, and an opening is formed therebetween into a central hollow section for recovering "contaminated" or mixed powders from two adjacent compartments.

公开(公告)号：US5679296A

公开(公告)日：1997-10-21

申请号：US536063

申请日：1995-09-29

申请人： Josh Kelman ,  Stephen N. Roberts ,  William W. Knight ,  Randy Reed ,  David R. Pinson ,  Alfred F. Brault

发明人： Josh Kelman ,  Stephen N. Roberts ,  William W. Knight ,  Randy Reed ,  David R. Pinson ,  Alfred F. Brault

IPC分类号： B29C35/04 ,  B29C35/16 ,  B29C43/00 ,  B29C43/18 ,  B29C70/84 ,  B29C51/10

CPC分类号： B29C43/183 ,  B29C43/006 ,  B29C70/84 ,  B29C2035/1658 ,  B29C35/045 ,  B29K2067/00 ,  B29K2105/25 ,  B29L2031/3005 ,  Y10S264/913

摘要： An automotive interior trim part (10) is made by molding a substrate retainer layer (16), forming a skin layer (12) and forming an intermediate layer (14). The intermediate layer (14) is formed from a plurality of clusters of entangled high melt and low melt kinked fibers of polyethylene terephthalate (PET). The PET layer is blown into a partially closed mold that has the skin and retainer positioned in each mold die. The mold undergoes induced vibrations to promote tightening of the packed clusters. The mold is then fully closed to compress the PET fibers into full density. Heated air is then blown into the mold to soften the low melt fibers to adhere them to the retainer layer and skin. Cool air is then blown into the mold to resolidfy the clusters and form the intermediate layer into its molded shape.

摘要翻译： 通过模制衬底保持层（16），形成表皮层（12）并形成中间层（14）制成汽车内饰件（10）。 中间层（14）由聚对苯二甲酸乙二醇酯（PET）的多个缠结的高熔体和低熔点扭结纤维簇形成。 将PET层吹入部分封闭的模具中，其中皮肤和保持器位于每个模具中。 模具经受诱导振动，以促进包装簇的紧固。 然后将模具完全关闭，以将PET纤维压缩至全密度。 然后将加热的空气吹入模具中以软化低熔点纤维，使其粘附到保持层和皮肤上。 然后将冷却的空气吹入模具中以解冻簇并将中间层形成其模制形状。