WO1991007289A1 - Method of manufacturing plastic coated components - Google Patents
Method of manufacturing plastic coated components Download PDFInfo
- Publication number
- WO1991007289A1 WO1991007289A1 PCT/US1990/006624 US9006624W WO9107289A1 WO 1991007289 A1 WO1991007289 A1 WO 1991007289A1 US 9006624 W US9006624 W US 9006624W WO 9107289 A1 WO9107289 A1 WO 9107289A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- fascia
- base
- wheel
- rim
- molded
- Prior art date
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C63/00—Lining or sheathing, i.e. applying preformed layers or sheathings of plastics; Apparatus therefor
- B29C63/26—Lining or sheathing of internal surfaces
- B29C63/34—Lining or sheathing of internal surfaces using tubular layers or sheathings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
- B60B5/00—Wheels, spokes, disc bodies, rims, hubs, wholly or predominantly made of non-metallic material
- B60B5/02—Wheels, spokes, disc bodies, rims, hubs, wholly or predominantly made of non-metallic material made of synthetic material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1671—Making multilayered or multicoloured articles with an insert
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60B—VEHICLE WHEELS; CASTORS; AXLES FOR WHEELS OR CASTORS; INCREASING WHEEL ADHESION
- B60B7/00—Wheel cover discs, rings, or the like, for ornamenting, protecting, venting, or obscuring, wholly or in part, the wheel body, rim, hub, or tyre sidewall, e.g. wheel cover discs, wheel cover discs with cooling fins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/32—Wheels, pinions, pulleys, castors or rollers, Rims
Definitions
- This invention relates a method of manufacturing plastic components wherein the plastic overlay coat is mechanically locked over a thermoplastic polymer resin base material and, in particular, to a method of applying a plastic fascia through a low-pressure injection molding process to a polystyrene base which has been molded to the desired configuration of the component.
- plastics With the increased emphasis on the reduction of vehicle weight for improved performance and fuel savings more vehicle components are being manufactured of lightweight plastics. Additionally, the properties of plastics lends itself in molding ornamental and performance components of motor vehicles. Examples of components which have in the past been molded from plastics include wheel covers, vehicle dams and spoilers, dashboards, etc. However, the pliable nature of thin plastic components requires that a support intrastructure be provided usually by adding metal support structure. Although the ornamental properties of the plastic component are retained, the weight and cost reduction advantages are negated.
- the present invention overcomes the disadvantages of the prior art by providing components which include a polystyrene base molded in the desired configuration and a thermoplastic fascia coat molded over the base and mechanically locked thereto to prevent separation.
- the process of the present invention can be utilized to manufacture various vehicle components including ornamental wheels, air dams, spoilers, dashboards and instrument panels as well as various components for the marine industry.
- the components generally comprise a polystyrene base which is molded into the general configuration of the component. In the case of the vehicle wheel, the polystyrene base is molded against the metal rim. Applied to the molded base is a plastic coating which assumes the configuration of the base. The coating is applied in such a manner as to "mechanically" lock the thermoplastic fascia to the base. As a result, no adhesive is required although the overlay is secured to the base which provides rigidness to the component.
- the general configuration of the component is first formed by molding a thermoplastic polymer resin in accordance with the final specifications of the product.
- a thermoplastic polymer resin is a polyphenylene oxide polystyrene developed by G.E. Plastics and marketed under the trademark GECET ®.
- GECET resin is a high performance expandable foam bead material capable of withstanding high temperatures. During the molding process, the resin will expand to fill the mold.
- thermoplastic fascia is applied through a low-pressure injection molding process in order to prevent damage to the base material.
- the thermoplastic fascia is allowed to flow around the base to form a mechanical lock eliminating the need for adhesives.
- the thermoplastic material flows around the edges of the vent openings engaging the underlying wheel rim to secure the overlay to the rim.
- FIGURE 1 is a perspective view of a vehicle wheel manufactured using the method of manufacturing of the present invention
- FIGURE 2 is a perspective view partially in cross-section of the vehicle wheel manufactured using the process of the present invention
- FIGURE 3 is a flow diagram of the manufacturing process of the present invention.
- FIGURE 4a is a partial cross-sectional view of the base formation of the manufacturing process of the present invention.
- FIGURE 4b is a partial cross-sectional view of the fascia molding of the manufacturing process of the present invention.
- FIG. 1 there is shown a vehicle wheel 10 constructed using the method of manufacture described and defined herein.
- the method of the present invention will be described in conjunction with a vehicle wheel 10 although it is to be understood that the method may be used to manufacture various components including air dams, spoilers, dashboards, etc.
- Description of the vehicle wheel 10 will provide a clear understanding of the composition of related vehicle components.
- the wheel 10 preferably includes a drop center steel rim 12 with a central steel disc 14 provided by a manufacturer and adapted to receive a tire.
- the central disc 14 is provided with a plurality of bolt holes 16 and a wheel spindle-aperture 18 to facilitate removable attachment of the wheel 10 to a wheel hub and its associated brake assembly.
- the central disc 14 also includes a plurality of circumferentially spaced vent openings 20.
- the steel wheel comprising the rim 12 and disc 14 is constructed from a functional standpoint to provide the necessary strength and ventilation.
- an ornamental cover 22 formed by the process described herein is attached to the rim 12 and disc 14.
- the ornamental cover 22 generally comprises a base material 24 molded into the desired configuration and a decorative fascia 26 molded over the base material 24 as will be subsequently described.
- the base 24 is formed from a thermoplastic polymer resin which has a high heat resistance to withstand the heat associated with such wheels 10 and their brakes.
- a resin is a polyphenylene oxide polystyrene marketed under the product name GECET ® Resin by G.E. Plasti.cs of Pi.ttsfi.eld,
- the resin is provided in solid beads 0.01 to
- the resin is a high performance expandable foam bead material with high heat resistance capable of use with temperatures up to
- thermoplastic fascia 26 is molded over the foam core 24 such that a mechanical lock is formed thereby eliminating the need for adhesives.
- the fascia 26 and base 24 are molded such that openings
- the mechanical lock of the fascia 26 around the base 24 and to the rim 12 is formed through the vent openings 20 by molding the thermoplastic around the edges of the openings 20 as will be subsequently described.
- a flanged lip 32 is formed to secure the fascia 26 to the steel wheel.
- the lip 32 may also be formed around the bolt holes 16.
- no adhesive is required.
- the peripheral edge 34 of the fascia 26 extends to the edge of the wheel. This same securement principal can be used in other components which have spaced openings such as dashboards or instrument panels. In components which do not include openings, the fascia material may be extended completely around the base material 24 to completely enclose the material.
- a steel wheel 12 is loaded 100 into a tool as half of the mold to which the ornamental cover 22 will be applied.
- An injection mold 40 is mated with the wheel 12 between which is molded 102 the expandable polystyrene structural base 24.
- the steel wheel 12 with the integral foam base 24 is transferred to a second station whereat the thermoplastic fascia 26 is applied through a low-pressure injection molding process 104.
- Low-pressure injection molding 104 is needed to prevent destruction of the base 24 during molding while allowing the thermoplastic material to fill the mold voids including forming the mechanical lock 32 through the vent openings 20.
- a backing mold 42 is inserted through the back side of the wheel 12 while an injection mold 44 is mated to the front of the wheel 12.
- the cooperation of the two mold portions 42 and 44 with the wheel 12 forms the ornamental fascia 26 over the base 24 as well as the mechanical locks 32 to the steel wheel itself.
- the present invention provides an ornamental vehicle wheel which has the ornamental cover attached in such a manner so as to eliminate the retention failure found in conventional wheel covers.
- the process by which the components are manufactured offers flexibility in styling while maintaining manufacturing costs.
- the configuration of the plastic cover can be conveniently altered by changing the configuration of the structural core.
- vehicle components such as spoilers and ground effect components and marine components because of the inherent buoyancy of the materials which make up such parts.
- alternative structural foam products such as closed cell fiberboards can be utilized to form the base as well as alternate molding methods to form the overlay.
Abstract
Description
Claims
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP3500566A JPH0628878B2 (en) | 1989-11-13 | 1990-11-13 | Manufacturing method of plastic coated parts |
KR1019910700724A KR920700890A (en) | 1989-11-13 | 1990-11-13 | How to make plastic coated parts |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US43415589A | 1989-11-13 | 1989-11-13 | |
US434,155 | 1989-11-13 |
Publications (1)
Publication Number | Publication Date |
---|---|
WO1991007289A1 true WO1991007289A1 (en) | 1991-05-30 |
Family
ID=23723043
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1990/006624 WO1991007289A1 (en) | 1989-11-13 | 1990-11-13 | Method of manufacturing plastic coated components |
Country Status (5)
Country | Link |
---|---|
EP (1) | EP0453553A4 (en) |
JP (1) | JPH0628878B2 (en) |
KR (1) | KR920700890A (en) |
CA (1) | CA2044624A1 (en) |
WO (1) | WO1991007289A1 (en) |
Cited By (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2678366A1 (en) * | 1991-06-27 | 1992-12-31 | France Etat Armement | Multi-spectral camouflage for a roller of the undercarriage of a vehicle |
EP0648661A1 (en) * | 1993-10-15 | 1995-04-19 | GERSTEEN exerçant ses activités sous la dénomination ISODELTA | Steering wheel for motor vehicles, mounting piece and steering column adopted to cooperate with this steering wheel, and process for its fabrication |
WO1995025019A1 (en) * | 1994-03-17 | 1995-09-21 | Hayes Wheels International, Inc. | Vehicle wheel |
US5597213A (en) * | 1995-06-06 | 1997-01-28 | Lacks Industries, Inc. | Wheel and overlay assembly |
US5779951A (en) * | 1996-05-16 | 1998-07-14 | Hayes Lemmerz International, Inc. | Method of forming a vehicle wheel having injection molded annular filler ring in wheel cavity |
FR2836865A1 (en) * | 2002-03-11 | 2003-09-12 | Michelin Soc Tech | WHEEL WITH COMPOSITE RIM MADE BY RTM PROCESS |
Citations (30)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2266432A (en) * | 1939-02-28 | 1941-12-16 | Whitchall Patents Corp | Method of die casting heads on pins |
US2977151A (en) * | 1956-06-06 | 1961-03-28 | Jr Frank W Ford | Wheel flange protectors |
US3062254A (en) * | 1959-10-20 | 1962-11-06 | Keefe Arthur | Molded wheel having internal reinforcing |
US3356421A (en) * | 1966-07-28 | 1967-12-05 | Kelsey Hayes Co | Wheel and wheel cover assembly |
US3517968A (en) * | 1968-10-09 | 1970-06-30 | Motor Wheel Corp | Wheel rim trim ring |
US3567285A (en) * | 1969-02-10 | 1971-03-02 | Sheller Globe Corp | Simulated magnesium bicycle wheel and method |
US3669501A (en) * | 1970-03-03 | 1972-06-13 | Motor Wheel Corp | Vehicle wheel construction |
US3756658A (en) * | 1969-09-15 | 1973-09-04 | Motor Wheel Corp | Composite styled wheel construction |
US3762677A (en) * | 1971-10-14 | 1973-10-02 | Motor Wheel Corp | Molding apparatus |
US3794529A (en) * | 1971-12-15 | 1974-02-26 | Goodyear Tire & Rubber | Method of making a metal laminate |
US3815200A (en) * | 1971-10-14 | 1974-06-11 | Motor Wheel Corp | Method of making mold |
US3823982A (en) * | 1973-08-02 | 1974-07-16 | S & S Prod Eng Service Inc | Hub cap for molded vehicle wheel |
US3891276A (en) * | 1973-08-02 | 1975-06-24 | S & S Product Engineering Serv | Wheel and wheel trim assembly |
US3918762A (en) * | 1974-03-29 | 1975-11-11 | Goodyear Tire & Rubber | Vehicle wheel cover |
US3935291A (en) * | 1973-08-28 | 1976-01-27 | The Goodyear Tire & Rubber Company | Method of molding polyurethane articles in a mold coated with three mold release agents |
US3956451A (en) * | 1971-10-14 | 1976-05-11 | Motor Wheel Corporation | Method of making an ornamental styled wheel |
US4000926A (en) * | 1975-10-31 | 1977-01-04 | Wlcox Raymond J | Wheel with individually formed ribs |
US4017239A (en) * | 1976-06-07 | 1977-04-12 | The Goodyear Tire & Rubber Company | Molding apparatus |
US4076788A (en) * | 1976-12-02 | 1978-02-28 | General Motors Corporation | Mold coating of freshly molded articles |
DE2457907B2 (en) * | 1974-12-04 | 1978-09-28 | Kronprinz Ag, 5650 Solingen | Vehicle wheel and process for its manufacture |
US4153657A (en) * | 1976-03-10 | 1979-05-08 | Wilcox Raymond J | Method for making a vehicle wheel with a foamed resin core |
US4251476A (en) * | 1979-03-16 | 1981-02-17 | Motor Wheel Corporation | Manufacture of ornamental vehicle wheels |
US4397504A (en) * | 1980-04-14 | 1983-08-09 | James Connell | Wheel cover simulating a wire spoke wheel |
US4398770A (en) * | 1981-02-23 | 1983-08-16 | Motor Wheel Corporation | Wire spoke vehicle wheel and method of manufacture |
US4408804A (en) * | 1979-11-13 | 1983-10-11 | Rockwell International Corporation | Composite wheel cover |
US4659148A (en) * | 1985-09-23 | 1987-04-21 | Motor Wheel Corporation | Vehicle wheel construction |
US4682820A (en) * | 1985-10-16 | 1987-07-28 | Motor Wheel Corporation | Vehicle wheel with an ornamental plastic overlay |
US4786027A (en) * | 1987-02-17 | 1988-11-22 | Motor Wheel Corporation | Apparatus for molding composite metal-elastomer wheels |
US4790605A (en) * | 1987-02-27 | 1988-12-13 | Motor Wheel Corporation | Vehicle wheel with ornamental plastic overlay |
US4847030A (en) * | 1985-10-16 | 1989-07-11 | Motor Wheel Corporation | Method and apparatus for making a composite wheel |
Family Cites Families (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3952786A (en) * | 1974-07-01 | 1976-04-27 | Plasco, Inc. | Unitary wheel and tire assembly |
EP0180383A3 (en) * | 1984-10-26 | 1987-06-03 | Aronkasei Co., Limited | A manufacturing method for housings with a two-layer structure |
-
1990
- 1990-11-13 CA CA002044624A patent/CA2044624A1/en not_active Abandoned
- 1990-11-13 EP EP19900917664 patent/EP0453553A4/en not_active Withdrawn
- 1990-11-13 WO PCT/US1990/006624 patent/WO1991007289A1/en not_active Application Discontinuation
- 1990-11-13 JP JP3500566A patent/JPH0628878B2/en not_active Expired - Lifetime
- 1990-11-13 KR KR1019910700724A patent/KR920700890A/en not_active Application Discontinuation
Patent Citations (30)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2266432A (en) * | 1939-02-28 | 1941-12-16 | Whitchall Patents Corp | Method of die casting heads on pins |
US2977151A (en) * | 1956-06-06 | 1961-03-28 | Jr Frank W Ford | Wheel flange protectors |
US3062254A (en) * | 1959-10-20 | 1962-11-06 | Keefe Arthur | Molded wheel having internal reinforcing |
US3356421A (en) * | 1966-07-28 | 1967-12-05 | Kelsey Hayes Co | Wheel and wheel cover assembly |
US3517968A (en) * | 1968-10-09 | 1970-06-30 | Motor Wheel Corp | Wheel rim trim ring |
US3567285A (en) * | 1969-02-10 | 1971-03-02 | Sheller Globe Corp | Simulated magnesium bicycle wheel and method |
US3756658A (en) * | 1969-09-15 | 1973-09-04 | Motor Wheel Corp | Composite styled wheel construction |
US3669501A (en) * | 1970-03-03 | 1972-06-13 | Motor Wheel Corp | Vehicle wheel construction |
US3762677A (en) * | 1971-10-14 | 1973-10-02 | Motor Wheel Corp | Molding apparatus |
US3815200A (en) * | 1971-10-14 | 1974-06-11 | Motor Wheel Corp | Method of making mold |
US3956451A (en) * | 1971-10-14 | 1976-05-11 | Motor Wheel Corporation | Method of making an ornamental styled wheel |
US3794529A (en) * | 1971-12-15 | 1974-02-26 | Goodyear Tire & Rubber | Method of making a metal laminate |
US3823982A (en) * | 1973-08-02 | 1974-07-16 | S & S Prod Eng Service Inc | Hub cap for molded vehicle wheel |
US3891276A (en) * | 1973-08-02 | 1975-06-24 | S & S Product Engineering Serv | Wheel and wheel trim assembly |
US3935291A (en) * | 1973-08-28 | 1976-01-27 | The Goodyear Tire & Rubber Company | Method of molding polyurethane articles in a mold coated with three mold release agents |
US3918762A (en) * | 1974-03-29 | 1975-11-11 | Goodyear Tire & Rubber | Vehicle wheel cover |
DE2457907B2 (en) * | 1974-12-04 | 1978-09-28 | Kronprinz Ag, 5650 Solingen | Vehicle wheel and process for its manufacture |
US4000926A (en) * | 1975-10-31 | 1977-01-04 | Wlcox Raymond J | Wheel with individually formed ribs |
US4153657A (en) * | 1976-03-10 | 1979-05-08 | Wilcox Raymond J | Method for making a vehicle wheel with a foamed resin core |
US4017239A (en) * | 1976-06-07 | 1977-04-12 | The Goodyear Tire & Rubber Company | Molding apparatus |
US4076788A (en) * | 1976-12-02 | 1978-02-28 | General Motors Corporation | Mold coating of freshly molded articles |
US4251476A (en) * | 1979-03-16 | 1981-02-17 | Motor Wheel Corporation | Manufacture of ornamental vehicle wheels |
US4408804A (en) * | 1979-11-13 | 1983-10-11 | Rockwell International Corporation | Composite wheel cover |
US4397504A (en) * | 1980-04-14 | 1983-08-09 | James Connell | Wheel cover simulating a wire spoke wheel |
US4398770A (en) * | 1981-02-23 | 1983-08-16 | Motor Wheel Corporation | Wire spoke vehicle wheel and method of manufacture |
US4659148A (en) * | 1985-09-23 | 1987-04-21 | Motor Wheel Corporation | Vehicle wheel construction |
US4682820A (en) * | 1985-10-16 | 1987-07-28 | Motor Wheel Corporation | Vehicle wheel with an ornamental plastic overlay |
US4847030A (en) * | 1985-10-16 | 1989-07-11 | Motor Wheel Corporation | Method and apparatus for making a composite wheel |
US4786027A (en) * | 1987-02-17 | 1988-11-22 | Motor Wheel Corporation | Apparatus for molding composite metal-elastomer wheels |
US4790605A (en) * | 1987-02-27 | 1988-12-13 | Motor Wheel Corporation | Vehicle wheel with ornamental plastic overlay |
Non-Patent Citations (1)
Title |
---|
See also references of EP0453553A4 * |
Cited By (11)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2678366A1 (en) * | 1991-06-27 | 1992-12-31 | France Etat Armement | Multi-spectral camouflage for a roller of the undercarriage of a vehicle |
EP0648661A1 (en) * | 1993-10-15 | 1995-04-19 | GERSTEEN exerçant ses activités sous la dénomination ISODELTA | Steering wheel for motor vehicles, mounting piece and steering column adopted to cooperate with this steering wheel, and process for its fabrication |
WO1995010440A1 (en) * | 1993-10-15 | 1995-04-20 | Gersteen | Steering wheel for motor vehicles, mounting component and steering column cooperating with said steering wheel, and method of manufacture |
WO1995025019A1 (en) * | 1994-03-17 | 1995-09-21 | Hayes Wheels International, Inc. | Vehicle wheel |
FR2717424A1 (en) * | 1994-03-17 | 1995-09-22 | Hayes Wheel Int Inc | Vehicle wheel. |
US5591386A (en) * | 1994-03-17 | 1997-01-07 | Hayes Wheels International, Inc. | Vehicle wheel with filler ring |
US5597213A (en) * | 1995-06-06 | 1997-01-28 | Lacks Industries, Inc. | Wheel and overlay assembly |
US5779951A (en) * | 1996-05-16 | 1998-07-14 | Hayes Lemmerz International, Inc. | Method of forming a vehicle wheel having injection molded annular filler ring in wheel cavity |
FR2836865A1 (en) * | 2002-03-11 | 2003-09-12 | Michelin Soc Tech | WHEEL WITH COMPOSITE RIM MADE BY RTM PROCESS |
WO2003076212A1 (en) * | 2002-03-11 | 2003-09-18 | Societe De Technologie Michelin | Wheel comprising a composite rim which is produced using the rtm method |
US7309110B2 (en) | 2002-03-11 | 2007-12-18 | Michelin Recherche Et Technique S.A. | Wheel with composite rim produced by resin transfer molding |
Also Published As
Publication number | Publication date |
---|---|
EP0453553A1 (en) | 1991-10-30 |
EP0453553A4 (en) | 1992-04-08 |
JPH04503641A (en) | 1992-07-02 |
KR920700890A (en) | 1992-08-10 |
CA2044624A1 (en) | 1991-05-14 |
JPH0628878B2 (en) | 1994-04-20 |
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