Abstract: A vehicle bumper (20) integrates rigid and flexible components into a single co-injection molded structure. In a preferred embodiment, a flexible fascia (58) is provided with integrated rigid fastener brackets (62, 66, 70, 71), energy absorption structure and head lamp brackets and housings (62). 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.

Abstract: A vehicle bumper (20) integrates rigid and flexible components into a single co-injection molded structure. In a preferred embodiment, a flexible fascia (58) is provided with integrated rigid fastener brackets (62, 66, 70, 71), energy absorption structure and head lamp brackets and housings (62). 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.

Abstract: The present invention provides processes and an apparatus for injection-molding an article with a fluid channel formed therein. The process includes providing at least first and second resin streams within a mold cavity, causing the flow fronts (16) of the resin streams to meet at a longitudinal point in the mold cavity to form a first layer of solidified resin on a peripheral surface of the mold, the first layer having a knit line (20) at the longitudinal point where the resin streams meet; and introducing a fluid into the molten resin in the mold to form a fluid channel (50) and a second layer (32) of solidified resin, the second layer between the fluid channel and the first layer of solidified resin, wherein the second layer is devoid of a knit line at the longitudinal point in the mold cavity where the first and second flow fronts meet.

Abstract: A bumper beam extension for a bumper beam having left and right bumper beam extensions and a method for manufacturing the bumper beam extensions to provide impact crush resistance is disclosed. The bumper beam extensions include an insert end contoured and sized to fit in the end of the bumper beam and a main body portion having substantially a rearwardly facing saddle shape that includes an upper wing and a lower wing joined at a bight section. The main body portion is blow molded to configure the bight section to taper from a preselected distance from a forward wall of the main body portion until it is face to face with the forward wall. For increased stiffness, the bumper beam may be welded to a frame of a vehicle.

Abstract: The present invention provides a blow-molded vehicle part and a blow-molding process for generating a one-piece vehicle part with improved strength, aesthetic appearance and reduced weight and cost. The blow-molded vehicle part includes a front vehicle part portion and a back vehicle part portion, wherein the front vehicle part and the back vehicle part have at least an outer unreinforced layer of a thermoplastic that forms a smooth outer surface of the vehicle part and a reinforced inner layer.

Abstract: The present invention provides a co-injection molded, multiphase vehicle component having a microsphere enhanced region, as well as a method for constructing such a vehicle component. The vehicle component has an outer portion or phase that is formed by first injecting a preselected quantity of a desired thermoplastic material into a preselected mold (402) in a manner to achieve a first layer of the thermoplastic material in a cavity of the mold. Then, a microsphere enhanced inner portion or phase is formed by injection of a micrsophere enhanced core material (404) to fill a remaining portion of the cavity. The resulting vehicle component typically has a lower density, and thus a lower weight, is generally less costly, and maintains the desired strength by selection of suitable microspheres, typically substantially hollow, and a suitable proportion of microspheres per unit volume of core material.

Abstract: A vehicle bumper (20) integrates rigid and flexible components into a single co-injection molded structure. In a preferred embodiment, a flexible fascia (58) is provided with integrated rigid fastener brackets (62, 66, 70, 71), energy absorption structure and head lamp brackets and housings (62). 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.

Abstract: The present invention provides processes and an apparatus for injection-molding an article with a fluid channel formed therein. The process includes providing at least first and second resin streams within a mold cavity, causing the flow fronts (16) of the resin streams to meet at a longitudinal point in the mold cavity to form a first layer of solidified resin on a peripheral surface of the mold, the first layer having a knit line (20) at the longitudinal point where the resin streams meet; and introducing a fluid into the molten resin in the mold to form a fluid channel (50) and a second layer (32) of solidified resin, the second layer between the fluid channel and the first layer of solidified resin, wherein the second layer is devoid of a knit line at the longitudinal point in the mold cavity where the first and second flow fronts meet.

Abstract: A method and mold (10) for manufacturing a vehicle component such as a bumper beam (52) or body panel (62). The component is manufactured by: 1) injecting molten material into a parison cavity of a mold (10) to form a parison (40), wherein the mold has at least two sections (14, 18) that are moveable between a first position defining the parison cavity and an expanded second position defining predetermined blow cavities; 2) retracting the at least two sections (14, 18) to the expanded second position, and 3) injecting a gas into the parison (40) to expand the parison (40) to form blown part (44).

Abstract: A method, molding device and vehicle component (10) provide for minimized sink marks (30) caused by structural ribs (28) in the molding process. Molten material is injected into a first mold cavity to form a primary vehicle component part (20) having structural ribs (28) on a back side. Typically, sink marks (30) may develop at a front surface of the primary vehicle component part (20), located opposite to the structural ribs (28) on the back side. Molten material is injected into a second molding cavity that is arranged to overmold the front surface (26) of the primary vehicle component part (20) and to cover sink marks (30), if any, in the front surface (26). In this manner, a vehicle component (10) is manufactured with structural ribs (28) and without visible sink marks (30).

Abstract: A bumper beam extension for a bumper beam having left and right bumper beam extensions and a method for manufacturing the bumper beam extensions to provide impact crush resistance is disclosed. The bumper beam extensions include an insert end contoured and sized to fit in the end of the bumper beam and a main body portion having substantially a rearwardly facing saddle shape that includes an upper wing and a lower wing joined at a bight section. The main body portion is blow molded to configure the bight section to taper from a preselected distance from a forward wall of the main body portion until it is face to face with the forward wall. For increased stiffness, the bumper beam may be welded to a frame of a vehicle.

Abstract: A bumper beam extension for a bumper beam having left and right bumper beam extensions and a method for manufacturing the bumper beam extensions to provide impact crush resistance is disclosed. The bumper beam extensions include an insert end contoured and sized to fit in the end of the bumper beam and a main body portion having substantially a rearwardly facing saddle shape that includes an upper wing and a lower wing joined at a bight section. The main body portion is blow molded to configure the bight section to taper from a preselected distance from a forward wall of the main body portion until it is face to face with the forward wall. For increased stiffness, the bumper beam may be welded to a frame of a vehicle.