Abstract: Improved lifter (32) for injection molding apparatus and method of use thereof are disclosed. To inhibit the unsightly blemishes that may be formed in plastic parts wherein the lifter (32) comprises a leading edge (44) that is perpendicularly oriented relative to the longitudinal axis of the molded part, a lifter plate is provided wherein the leading edge (44) thereof is obliquely angled relative to the longitudinal axis of the molded part.

Abstract: Methods for making fused film-plastic parts and parts made thereby are disclosed. The paint film covered parts include a show surface section with a paint film laminate overlying the plastic substrate of this section of the part to provide the desired aesthetic appeal. An attachment flange section of the part is provided and is usually hidden from sight when the part is assembled to the auto or truck body structure. The flange serves as a location at which clamps, bolts, rivets or the like can support or attach to the auto to truck structure. A raised portion, such as a boss section, is provided intermediate the show surface section and the attachment flange. This boss is adapted for contiguous or closed spaced positioning adjacent the auto or truck structural part. The boss is completely covered by the paint film with the paint film terminating along the attachment flange.

Abstract: A window weatherstrip that can be clipped onto a mounting structure of a motor vehicle door frame adjacent an opening containing a window glass such that the weatherstrip can be completely hidden from view thereby avoiding the need for any decorative type finish. More specifically, the window weatherstrip is clipped onto a mounting structure having a horizontally extending mounting flange integrally connected with a downwardly projecting vertical mounting flange such that the weatherstrip can be completely hidden from view underneath a door liner.

Abstract: A window weatherstrip that can be clipped onto a mounting structure of a motor vehicle door frame adjacent an opening containing a window glass such that the weatherstrip can be completely hidden from view thereby avoiding the need for any decorative type finish. More specifically, the window weatherstrip is clipped onto a mounting structure having a horizontally extending mounting flange integrally connected with a downwardly projecting vertical mounting flange such that the weatherstrip can be completely hidden from view underneath a door liner.

Abstract: Methods for making fused film-plastic parts and parts made thereby are disclosed. The paint film covered parts include a show surface section with a paint film laminate overlying the plastic substrate of this section of the part to provide the desired aesthetic appeal. An attachment flange section of the part is provided and is usually hidden from sight when the part is assembled to the auto or truck body structure. The flange serves as a location at which clamps, bolts, rivets or the like can support or attach to the auto to truck structure. A raised portion, such as a boss section, is provided intermediate the show surface section and the attachment flange. This boss is adapted for contiguous or closed spaced positioning adjacent the auto or truck structural part. The boss is completely covered by the paint film with the paint film terminating along the attachment flange.

Abstract: A method and apparatus for laser trimming a shaped plastic workpiece use a laser beam positioned and directed by a robotic arm traveling along a pre-programmed path to trim the edges of a workpiece held against a positioning block. Preferably, the positioning block includes a laser beam capturing channel comprising suction holes for removing smoke generated by the ablation and burning of the plastic so as to minimize the risk of smoke damage to the workpiece and to remove soot and vapors from the work area. At the same time, laser beams are inhibited form reflecting back off the block onto the workpiece by positioning the channel under the workpiece and along the predetermined cutting path.

Abstract: A method for injection molding a plastic part having a coating which suppresses the appearance of colored interference fringes in fluorescent light including the steps of injection molding a plastic substrate; injection molding a light transmissive intermediate layer having an optical thickness of about 800-1,200 &mgr;m onto a show surface of the plastic substrate; and forming a light transmissive outer coating having an optical thickness of about 5.5-11.5 &mgr;m over the intermediate layer. The outer coating should be harder than the substrate such that the resulting part has a scratch resistance superior to that of the substrate alone.

Abstract: A paint film laminate is co-molded over a desired plastic substrate to produce an automobile bumper member, chin spoiler or rocker panel part. Along a desired surface of the part, such as, for example, a border between a part surface having one segment covered by paint film and a second segment comprising the exposed substrate, the edge of the paint film is embedded in the plastic substrate along a surface discontinuity such as a recess or ridge so that an aesthetically pleasing sight edge having a desired contour exists along this surface portion. The sight edge is formed during the co-molding process via the provision of an incline or ramp along a desired mold cavity surface. When the co-molded part is installed in its intended application, the paint film edge is substantially hidden from view by the surface discontinuity.

Abstract: A pressure-activated valve for conducting pressurized gas into a mold cavity of an injection molding apparatus is preferably constructed as an easily replaceable unit. The preferred valve includes a pin having a flared head section. The head section has a planar face transverse to an axis of the pin so as to approximately conform to a neighboring contour of the mold cavity. The valve also includes a body in which a passageway intersects a second end of the body to define a port and a flaring seat communicates through a first end of the body between the passageway and the mold cavity. A restrainer which abuts against the second end of the body includes a guideway aligned with the passageway through the body as well as at least one cross-channel which admits pressurized gas to that passageway through the port. The pin extends through both the passageway and the guideway so that its head portion is positioned near the seat.

Abstract: Methods for pre-shaping paint film laminates and co-molding processes using such laminates are disclosed. The methods comprise the steps of providing (e.g., forming or procuring) a plastic paint film laminate, softening the paint film laminate with heat such that one or more localized portions of the member absorb more heat than the remainder, and deforming the plastic film member to form a pre-shaped article. The formation of different heat absorption areas on the paint film laminate is referred to as the provision of heat sink areas. These heat sink areas can be provided for example by surface coating of heat retention means such as black paint or ink pigments on localized areas of the surface of the laminate followed by uniform heating of the laminate in an oven or the like or the sheet can be heated in localized areas to a greater extent (i.e. time and/or temperature) than in remainder portions by the means of heat guns or the like.

Abstract: A flexible star plug comprising a cylindrical portion having fins projecting radially outwardly therefrom for insertion into an axial extending cavity or hollow of a rubber weather strip is provided. A method of stabilizing or reinforcing the hollow weather strip comprises inserting the plug co-axially along the hollow, and twisting the plug to create a torque force on the fins as they engage the cavity walls.

Abstract: A method for molding a plastic part comprises preforming a film laminate and insert molding a plastic substrate against the film laminate. According to one embodiment, the film laminate is preformed with re-entrant edge portions. The insert molding step involves positioning the film laminate in a mold cavity, closing the mold and injecting molten resin into the mold cavity against the film laminate. The force of the closing of the mold and the injection of the resin causes the re-entrant edge portions to curl up under the solidifying resin to ensure complete coverage of the longitudinal edges of the plastic substrate by the film laminate. According to another embodiment, a stencil of an image is made in the film laminate prior to the insert molding. The resin injected into the mold flows into the stencil so that the image is visible against the surrounding surface of the film laminate.

Abstract: Improved methods of superposing a film laminate over a plastic substrate and fused film-plastic parts made thereby. Improvement in traditional techniques is provided by preforming the film laminate proportionately relative to the size and shape of the underlying plastic substrate whereby improved gloss consistency of the fused film-plastic part is observed. The film laminate is preformed by shaping it over a pattern block wherein the film laminate is provided with an inner height and inner face width. The inner height of the film laminate is less than the height of the plastic substrate while the inner face width of the film laminate is greater than the face width of the plastic substrate. The film laminate is next positioned in a mold cavity wherein a molten resin is injected thereby forming the plastic substrate and fusing the film laminate thereover.

Abstract: Improved methods of insert molding a laminated film or the like over a plastic substrate and fused film--plastic parts made thereby are disclosed. Improvement in traditional insert molding techniques is provided by use of a specific mold cavity structure which facilitates overlaying of the paint film over the desired edge portion of the plastic part. In the mold cavity portion corresponding to the part edge for which overlapping is desired, a special extension or pocket portion of the mold cavity is constructed. The pocket portion is bounded by a wall surface that extends or slopes from the female mold side (cavity side) of the mold to the male mold side. The painted side of the paint film laminate is inserted against this wall with the paint side of the paint film laminate facing the wall. During the injection molding process, the pressurized resin injected into the mold impinges upon the backing sheet side of the film forcing the film to extend along the wall.

Abstract: A method for molding a plastic part comprises preforming a film laminate and insert molding a plastic substrate against the film laminate. According to one embodiment, the film laminate is preformed with re-entrant edge portions. The insert molding step involves positioning the film laminate in a mold cavity, closing the mold and injecting molten resin into the mold cavity against the film laminate. The force of the closing of the mold and the injection of the resin causes the re-entrant edge portions to curl up under the solidifying resin to ensure complete coverage of the longitudinal edges of the plastic substrate by the film laminate. According to another embodiment, a stencil of an image is made in the film laminate prior to the insert molding. The resin injected into the mold flows into the stencil so that the image is visible against the surrounding surface of the film laminate.