Abstract: A method for molding panels in a sheet molding system comprised of a thermoplastic sheet delivery station and two mold halves, the method comprising the steps of delivering two sheeting layers of thermoplastic material between the two mold halves; inserting a rigidizing insert between the two sheeting layers of thermoplastic material; closing the mold halves to bring the two sheeting layers of thermoplastic material in contact with the insert; and compressing the thermoplastic sandwich between the mold halves to form a panel. A thermoplastic-insert sandwich and a laminate panel comprised of thermoplastic layers abutting a pre-manufactured insert are also claimed.

Abstract: A method of manufacturing a rear shelf trim and speaker grill panel (12) for an automotive vehicle (10) includes steps of punching a substrate layer (16) of a polypropylene and flax material with a punch set (46) and placing a decorative carpet layer (18) over the substrate layer (16) and molding the two layers into a combined speaker grill and rear shelf trim panel (12).

Abstract: A method for molding parts in a thermoplastic molding system comprised of a thermoplastic material delivery station, and two or more clam shell molds mounted on a rotating frame, each clam shell mold comprised of a mounted die half and a hinged die half connected by a hinge directly or indirectly to the mounted die half, said die halves in a closed position forming a mold cavity, the method comprising the steps of (a) rotating the rotating frame to move the die halves in an open position past a thermoplastic material deliver station; (b) delivering thermoplastic material to at least one die half of a clam shell mold at the thermoplastic material delivery station; (c) closing the die halves as the claim shell mold rotates past the thermoplastic material delivery station by rotating the hinged die half on its hinge onto to the mounted die half to form a mold cavity; (d) cooling the clam shell mold as it continues to rotate on the rotating frame; and (e) opening the clam shell mold by rotating the hinged die hal

Abstract: A method for molding panels in a sheet molding system comprised of a thermoplastic sheet delivery station and two mold halves, the method comprising the steps of delivering two sheeting layers of thermoplastic material between the two mold halves; inserting a rigidizing insert between the two sheeting layers of thermoplastic material; closing the mold halves to bring the two sheeting layers of thermoplastic material in contact with the insert; and compressing the thermoplastic sandwich between the mold halves to form a panel. A thermoplastic-insert sandwich and a laminate panel comprised of thermoplastic layers abutting a pre-manufactured insert are also claimed.

Abstract: A method of manufacturing a multi-layered plastic manifold (10) including molding an outer layer (22) of the manifold (10) about a blow molded core insert (20). The outer layer (22) is molded by either a thermoplastic injection molding process or a urethane casting process. While the outer layer (22) is being molded, the pressure and temperature within the core insert (20) are controlled to preserve the structural integrity of the core insert (20).

Abstract: A pull strap handle meeting all the standards of the automotive industry is formed economically with molding operations. The handle is formed with a strip 15 of strong resilient material with high tensile strength that serves as a support element. Support element 15 is enclosed within a molded cover having a firm outer side 17 and a soft inner side 18. Soft side 18 is molded of foamed resin material directly onto support element 15 to form a secure bond. Firm side 17 can be molded in a single operation with soft side 18 or can be molded separately, attached to support element 15, and located in a cavity mold that forms soft side 18. The cover can also be molded to support element 15 within a cavity mold that forms both cover sides 17 and 18 or the cover can be extruded onto support element 15 in a continuous operation.

Abstract: A method of decorating the front surface of a molded resin panel 10 to provide a decorative material 15 in one region 12 and a contrasting decorative coating 18 in another region 14. A resin undercoat 17 and a clear resin top coat 19 are provided for decorative coating 18. The method includes securing decorative material 15 to region 12 of panel 10, masking the decorative material throughout region 12, applying the decorative coating to the unmasked front surface regions of the panel, and unmasking the decorative surface material. A top coat 19 is formed to extend over both decorative coating 18 and decorative material 15 to protect and secure the decorative material with the same top coating that is required for the decorative coating.

Abstract: A dispensing system uses a molded resin cartridge 10 and a plunger 11 arranged with an interlock that prevents the plunger from backing out of the rear end of the cartridge. The cartridge wall 12 has an interlock surface 20 just forward of its open rear end 13, and a locking ring 40 has a sleeve 25 extending around the outside of the cartridge wall with a hook 27 that engages interlock surface 20. A radial wall 41 of the locking ring holds the plunger 11 against moving out of the rear end of the cartridge and improves the seal between the plunger and cartridge. The radial wall 41 can be joined to the plunger skirt 15 along a line of weakness 31 that allows sleeve 25 to tear away as the plunger advances to dispense the cartridge contents.

Abstract: The apparatus and method for making a resin caulker 10 begins with continuous extrusion of a resin cylinder 15. A multimandrel indexing machine 20 has a receiving station 22 positioned to align an empty mandrel 21 with extruded cylinder 15 so a leading end 18 of extruded cylinder 15 advances onto empty mandrel 21. A cut off device 19 cuts cylinder 15 at a predetermined length to form a resin caulker barrel 11 supported on mandrel 21. Indexing machine 20 then moves cut off barrel 11 to an assembly station 23 and brings another empty mandrel 21 to receiving station 22. An end closure 12 is joined to cut off barrel 11 at assembly station 23; and successive stations 24-29 of the indexing machine finish, print, and dry the assembled caulkers while supported on mandrels 21.

Abstract: An automotive trim strip laminate formed of a strip of polyester material bearing a layer of metallic material covered by a thin polyvinyl chloride layer bonded to a supporting substrate of a flexible plasticized polyvinyl chloride material is made so that the laminate can be thermally bonded to a support material along a curved path without any irregularity, which is recognized as caused by compression wrinkling from thermal stress along radially inner regions of the curved path. This is prevented by selecting the polyester strip and the thin polyvinyl chloride layer with physical characteristics and dimensions to provide the metallized polyester strip with sufficient dimensional stability relative to the polyvinyl chloride substrate to prevent any such compression wrinkling, and one preferred way is to make the thin polyvinyl chloride layer substantially unplasticized and formed of a smooth, medium impact material.

Abstract: An automotive trim strip laminate formed of a thin strip of polyester material bearing a layer of metallic material and bonded to a substrate of a polyvinyl chloride material is made so that the laminate can be thermally bonded to a support material along a curved path without any wrinkling or other irregularity. This is done by longitudinally tensioning the laminate after it has cooled below its annealing temperature following extrusion of the substrate to strain the laminate sufficiently so that it tends to shorten upon reheating to its annealing temperature. The strain is insufficient to cause strain-relief shortening of the laminate at ambient temperatures encountered during storage and transport but is sufficient so that when the strained laminate is held accurately to the curved path and thermally bonded to the support material, its thermal expansion cooperates with strain relief to bring the laminate into smooth and uniform conformity with the curved path.

Abstract: A cylinder, such as the barrel of a caulking cartridge, interlocks with an internal member, such as the closure plunger for the caulker, by means of two to four cuts through the cylinder wall evenly spaced from the end of the cylinder to form catches from the segments of the wall between each of the cuts in the end of the cylinder. The catches are longer circumferentially of the wall than their width from the cut to the end of the cylinder, and they are deformed inward from the locus of the cylindrical wall toward a chord orientation. The member has a body fitting the inside of the cylinder and slidable past the catches, and the body is seated inside the cylinder so the catches are disposed between the body and the end of the cylinder to interlock with the body to prevent its movement out of the end of the cylinder.

Abstract: A cartridge such as a caulking cartridge is formed of extruded and injection molded resin parts assembled and welded together. A resin tube is extruded and cut off in lengths to form cartridge barrels, and single-piece resin end caps and nozzles are injection molded. The barrel cylinders are fed to an assembly station where the end caps and nozzles are fitted over one of the severed ends of the barrel cylinders in concentric registry with the barrel cylinders and are successively welded to the barrel cylinders to form cartridges.

Abstract: A cartridge plunger has a flexible forward wall with a forwardly extending central projection shaped to fit part way into the nozzle. The flexible forward wall is moved to a rearward position when the plunger engages the contents of the cartridge as it is inserted in the rear end of the cartridge. Although the forward-extending projection displaces some of the contents, the volume made available around the projection from the forward wall being in the rearward position is greater than the volume displaced by the projection. This allows a slight increase in the total volume of contents loadable into the cartridge, and when the plunger is forced against the front of the cartridge, the contents are not only forced out of the cartridge itself, but also from a portion of the nozzle occupied by the forward projection of the plunger.

Abstract: A dispenser of the type using a threaded rod with a turning knob is applied to a disposable cartridge and plunger. The cartridge plunger has a threaded central sleeve that is sealed closed, and the threaded rod, knob, and an anchorage adapter are separate from the cartridge until dispensing is to begin. Then the rod is threaded through the sleeve to puncture the seal and advance through the material to bring the anchorage adapter adjacent the rear end of the cartridge. The anchorage adapter is then releasably secured to the rear end of the cartridge, and the rod turned in the opposite direction to advance the plunger for dispensing material. The plunger can be backed up to stop drool if dispensing is interrupted, and the rod, knob, and adapter can be removed and reused after dispensing is completed.

Abstract: A cartridge such as a caulking cartridge is formed of extruded and injection molded resin parts assembled and welded together. A resin tube is extruded and cut off in lengths to form cartridge barrels, and single-piece resin end caps and nozzles are injection molded. The barrel cylinders are fed to an assembly station where the end caps and nozzles are fitted over one of the severed ends of the barrel cylinders in concentric registry with the barrel cylinders and are successively welded to the barrel cylinders to form cartridges.