WO1997034850A1 - Method for fabricating painted bumper - Google Patents

Method for fabricating painted bumper Download PDF

Info

Publication number
WO1997034850A1
WO1997034850A1 PCT/US1997/003824 US9703824W WO9734850A1 WO 1997034850 A1 WO1997034850 A1 WO 1997034850A1 US 9703824 W US9703824 W US 9703824W WO 9734850 A1 WO9734850 A1 WO 9734850A1
Authority
WO
WIPO (PCT)
Prior art keywords
preform
paint film
mold
article
set forth
Prior art date
Application number
PCT/US1997/003824
Other languages
French (fr)
Inventor
Josh Kelman
Bruce A. Batchelder
Scott M. Filion
Original Assignee
Textron Automotive Company Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Textron Automotive Company Inc. filed Critical Textron Automotive Company Inc.
Publication of WO1997034850A1 publication Critical patent/WO1997034850A1/en

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/78Moulding material on one side only of the preformed part
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28Shaping operations therefor
    • B29C70/40Shaping or impregnating by compression not applied
    • B29C70/42Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/48Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86Incorporated in coherent impregnated reinforcing layers, e.g. by winding

Definitions

  • the invention relates to articles molded with reinforcement material, such as automotive bumpers, and more particularly toward reinforced resin molded articles with a painted surface formed thereon.
  • U.S. Patent No. 3,493,257 issued February 3, 1970 discloses a resilient microcellular foam bumper.
  • the patent discloses the use of a sprayed paint pigment layer in a mold used.in resin molding of a bumper.
  • United States Patent No. 4,762,352 issued August 9, 1988 and United States Patent No. 5,290,079 issued March 1, 1994 disclose fiber reinforced resin bumper beams.
  • United States Patent No. 4,545,105 issued October 8, 1985 discloses a stretched material metal film on underlying bumper formation wherein the stretching step occurs without vacuum application.
  • 5,009,821 discloses a method in which a surface film is formed into the mold cavity surface simultaneously with resin impregnation of a fiber preform. Surface films are listed, though none are comprised of a paint film.
  • the patent also discloses resin transfer molding (RTM) and reinforced reaction injection molding (RRIM or SRIM) . These processes use a fiber reinforced mat or preform placed in a mold cavity into which reactive polymeric precursor materials are subsequently injected. The polymeric precursor materials react to form a molded plastic article having fiber reinforcement throughout.
  • RTM resin transfer molding
  • RRIM or SRIM reinforced reaction injection molding
  • the invention provides a method of making a painted, formed article for use in a vehicle.
  • the method includes the steps of forming a preform -of reinforcement material, placing a paint film and the preform in a mold, molding the preform with the paint film forming the article by injecting plastic material into the mold, and curing and removing the article from the mold.
  • the invention also includes a painted formed article for use on a vehicle.
  • the article comprises a preform of predefined contour including reinforcement material, a paint film formed of the predetermined contour complementary with the preform and resinous molding material molded within the preform securing the paint film to the preform molding the article.
  • Figure 1 is a partially cut away perspective view of an article comprising a composite bumper
  • Figure 2 illustrates the process of a first embodiment showing the step of forming a preform by a vacuum process
  • Figure 3 diagrammatically illustrates the step of vacuum forming the paint sheet to a mold and placing the preform thereover;
  • Figure 4 illustrates the step of injecting resinous material into the mold
  • Figure 5 illustrates the second embodiment of the step of forming the paint film against the preform.
  • a fiber-reinforced molded plastic article 10 is generally shown in Figure 1. Such an article 10 is suitable for installation on an automotive vehicle as in a bumper assembly. It will be readily appreciated that the fiber-reinforced plastic article 10 made by the process discussed herein may likewise be of a different shape for other automotive body panels or parts, as well as various types of fiber-reinforced molded plastic articles.
  • the article 10 is produced by resin transfer molding (RTM) or structural reaction injection molding (SRIM) processes wherein plastic or resin, namely polymeric precursor materials, is metered or injected into a mold cavity 12 of a mold 14.
  • RTM resin transfer molding
  • SRIM structural reaction injection molding
  • plastic or resin namely polymeric precursor materials
  • Such general molding process is known -in the art by including the mold cavity 12 supporting and containing a preform 16 of reinforcement fiber material.
  • the resinous material 20 is injected or provided into the mold cavity 12 to impregnate the fiber preform 16 to form the article 10.
  • the subject invention improves this process by use of a paint film 18.
  • the paint film 18 is molded to the desired shape, placed in the mold 14 with the preform 16 so that during resin molding the paint film
  • the preform 16 is formed of reinforcement material, such as fiberglass 22, which is held in place by an applied binder 23, as commonly known in the art. Such preform may be manufactured as disclosed in U.S. Patent No. 5,009,821 set forth in the Background of the Invention.
  • the preform 16 is formed on a shaped perforated screen 26 of the desired contour, and a vacuum 28 is applied to draw the fibers 22 against the screen 26.
  • the fibers 22 may include binder 23 thereon so that when the screen 26 is heated, the binder 23 melts to bind the fibers to one another. Alternatively, the binder 23 may be subsequently sprayed over the vacuum formed fibers 22 to retain the shape of the preform 16, as illustrated in Figure 2.
  • the preform 16 is utilized in the first embodiment of forming the article 10.
  • the mold 14 includes a lower mold half 14a providing a contoured surface 15 complementing the contour of the preform 16.
  • the paint film 18 is placed in the lower mold 14 and vacuum-formed thereagainst by a vacuum 30, as illustrated in Figure 3. It is also possible to vacuum-form the paint film 18 in a separate mold or the same mold 14.
  • the paint film 18 is heated and vacuum- formed to mold or deform to the contour of the mold 14 and therefore preform 16 at opposed surfaces 16a, 16b as shown in Figure 3. Heating of the paint film 18 may be by steam or conductive heating of the mold 14.
  • the preform 16 With the paint film 18 formed and placed in the lower mold 14, the preform 16 is placed thereover and the upper mold half 14b is closed to enclose the mold cavity 12. Thereafter, resin material 22 such as polymeric precursor material, is provided into the mold cavity 12 to impregnate the preform 16 and contact the paint film 18. The article 10 is cured within the mold 14 and then removed therefrom to provide an article 10 with the paint film 18 on an exterior surface.
  • resin material 22 such as polymeric precursor material
  • the paint film 18 is vacuum-formed against the preform 16 while on the screen 26 as illustrated in Figure 5.
  • a heated paint film 18 is placed over the preform and the vacuum draws the paint film 18 against the preform 16 molding it to the predetermined shape.
  • the combination preform 16 and paint film 18 may be placed in the mold 14 for the injection of resin material 20 therein.
  • the molding with the resin material 20 may be with RTM or SRIM, as previously discussed.
  • the reinforcement material 22 may be comprised of fiberglass or other reinforced fibers.
  • the paint film is commonly available, such as from 3M and Avery Dennis.

Abstract

A method of making a painted article (10) includes use of a fiber preform (16) and paint film (18). The preform (16) is formed to the desired shape, and the paint film (18) is heat deformed to a complimenting shape. The paint film (18) is placed in a mold (14) and the preform (16) is placed thereover. The mold (14) is closed and resin metered therein. The cured article (10) is removed with a reinforced substrate and painted film surface thereover.

Description

METHOD FOR FABRICATING PAINTED BUMPER
TECHNICAL FIELD
The invention relates to articles molded with reinforcement material, such as automotive bumpers, and more particularly toward reinforced resin molded articles with a painted surface formed thereon.
BACKGROUND OF THE INVENTION
Current automotive bumper systems have consisted of metal or plastic substrates, energy absorbers and external surface facie. U.S. Patent No. 3,493,257 issued February 3, 1970 discloses a resilient microcellular foam bumper. The patent discloses the use of a sprayed paint pigment layer in a mold used.in resin molding of a bumper. United States Patent No. 4,762,352 issued August 9, 1988 and United States Patent No. 5,290,079 issued March 1, 1994 disclose fiber reinforced resin bumper beams. United States Patent No. 4,545,105 issued October 8, 1985 discloses a stretched material metal film on underlying bumper formation wherein the stretching step occurs without vacuum application. United States Patent No. 5,009,821 discloses a method in which a surface film is formed into the mold cavity surface simultaneously with resin impregnation of a fiber preform. Surface films are listed, though none are comprised of a paint film. The patent also discloses resin transfer molding (RTM) and reinforced reaction injection molding (RRIM or SRIM) . These processes use a fiber reinforced mat or preform placed in a mold cavity into which reactive polymeric precursor materials are subsequently injected. The polymeric precursor materials react to form a molded plastic article having fiber reinforcement throughout. Other U.S. patents relating to general molding processes are cited in the patent.
SUMMARY OF THE INVENTION
The invention provides a method of making a painted, formed article for use in a vehicle. The method includes the steps of forming a preform -of reinforcement material, placing a paint film and the preform in a mold, molding the preform with the paint film forming the article by injecting plastic material into the mold, and curing and removing the article from the mold.
The invention also includes a painted formed article for use on a vehicle. The article comprises a preform of predefined contour including reinforcement material, a paint film formed of the predetermined contour complementary with the preform and resinous molding material molded within the preform securing the paint film to the preform molding the article.
BRIEF DESCRIPTION OF THE DRAWINGS
Advantages of the invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: Figure 1 is a partially cut away perspective view of an article comprising a composite bumper;
Figure 2 illustrates the process of a first embodiment showing the step of forming a preform by a vacuum process; Figure 3 diagrammatically illustrates the step of vacuum forming the paint sheet to a mold and placing the preform thereover;
Figure 4 illustrates the step of injecting resinous material into the mold; and Figure 5 illustrates the second embodiment of the step of forming the paint film against the preform. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
A fiber-reinforced molded plastic article 10 is generally shown in Figure 1. Such an article 10 is suitable for installation on an automotive vehicle as in a bumper assembly. It will be readily appreciated that the fiber-reinforced plastic article 10 made by the process discussed herein may likewise be of a different shape for other automotive body panels or parts, as well as various types of fiber-reinforced molded plastic articles.
As illustrated in Figures 3-4, the article 10 is produced by resin transfer molding (RTM) or structural reaction injection molding (SRIM) processes wherein plastic or resin, namely polymeric precursor materials, is metered or injected into a mold cavity 12 of a mold 14. Such general molding process is known -in the art by including the mold cavity 12 supporting and containing a preform 16 of reinforcement fiber material. In general, the resinous material 20 is injected or provided into the mold cavity 12 to impregnate the fiber preform 16 to form the article 10.
The subject invention improves this process by use of a paint film 18. The paint film 18 is molded to the desired shape, placed in the mold 14 with the preform 16 so that during resin molding the paint film
18 will be molded with and adhered to the external surface of the preform 16 to form the article 10.
The preform 16 is formed of reinforcement material, such as fiberglass 22, which is held in place by an applied binder 23, as commonly known in the art. Such preform may be manufactured as disclosed in U.S. Patent No. 5,009,821 set forth in the Background of the Invention. The preform 16 is formed on a shaped perforated screen 26 of the desired contour, and a vacuum 28 is applied to draw the fibers 22 against the screen 26. The fibers 22 may include binder 23 thereon so that when the screen 26 is heated, the binder 23 melts to bind the fibers to one another. Alternatively, the binder 23 may be subsequently sprayed over the vacuum formed fibers 22 to retain the shape of the preform 16, as illustrated in Figure 2.
There are two embodiments of the process for making the article 10 according to the general teachings hereinabove. In the first embodiment of forming the article 10, the preform 16 is utilized. The mold 14 includes a lower mold half 14a providing a contoured surface 15 complementing the contour of the preform 16. The paint film 18 is placed in the lower mold 14 and vacuum-formed thereagainst by a vacuum 30, as illustrated in Figure 3. It is also possible to vacuum-form the paint film 18 in a separate mold or the same mold 14. The paint film 18 is heated and vacuum- formed to mold or deform to the contour of the mold 14 and therefore preform 16 at opposed surfaces 16a, 16b as shown in Figure 3. Heating of the paint film 18 may be by steam or conductive heating of the mold 14. With the paint film 18 formed and placed in the lower mold 14, the preform 16 is placed thereover and the upper mold half 14b is closed to enclose the mold cavity 12. Thereafter, resin material 22 such as polymeric precursor material, is provided into the mold cavity 12 to impregnate the preform 16 and contact the paint film 18. The article 10 is cured within the mold 14 and then removed therefrom to provide an article 10 with the paint film 18 on an exterior surface.
In the second embodiment of the method, the paint film 18 is vacuum-formed against the preform 16 while on the screen 26 as illustrated in Figure 5. A heated paint film 18 is placed over the preform and the vacuum draws the paint film 18 against the preform 16 molding it to the predetermined shape. Thereafter, the combination preform 16 and paint film 18 may be placed in the mold 14 for the injection of resin material 20 therein.
The molding with the resin material 20 may be with RTM or SRIM, as previously discussed. The reinforcement material 22 may be comprised of fiberglass or other reinforced fibers. The paint film is commonly available, such as from 3M and Avery Dennis.

Claims

WHAT IS CLAIMED IS:
1. A method of making a painted, formed article for use in a vehicle, the method including the steps of: forming a preform of reinforcement material; placing a paint film and the preform in a mold so that the paint film engages the preform along opposed suraces thereon; injecting polymeric precursor material behind the fiber preform such that the polymeric precursor material impregnates the fiber preform and contacts the paint film at the opposed surfaces; and curing and removing the article from the mold.
2. The method as set forth in claim- 1 further including vacuum forming the paint film prior to the molding step.
3. The method as set forth in claim 2 wherein the vacuum forming includes vacuum forming the paint film in the mold prior to placing the preform in the mold.
4. The method as set forth in claim 2 wherein the vacuum forming includes vacuum forming the paint film against the preform prior to placing in the mold.
5. The method as set forth in claim 2 including drawing reinforcement fibers against a screen form with binder to form the preform.
6. The method as set forth in claim 2 wherein the molding includes metering resin into the mold through the preform.
7. The method as set forth in claim 3 further including the forming of the preform with fiberglass .
8. The painted, formed article for use on a vehicle, the article comprising: a preform of a predefined contour including reinforcement material; a paint film formed of said predetermined contour complimentary with said preform; resinous molding material molded within said preform; and securing said paint film to said preform molding to the article.
PCT/US1997/003824 1996-03-22 1997-03-12 Method for fabricating painted bumper WO1997034850A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US62022296A 1996-03-22 1996-03-22
US08/620,222 1996-03-22

Publications (1)

Publication Number Publication Date
WO1997034850A1 true WO1997034850A1 (en) 1997-09-25

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1997/003824 WO1997034850A1 (en) 1996-03-22 1997-03-12 Method for fabricating painted bumper

Country Status (1)

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WO (1) WO1997034850A1 (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6383320B1 (en) 1999-12-03 2002-05-07 Lear Corporation Method of forming a headliner
US6440546B1 (en) 1999-10-13 2002-08-27 Ream Industries Corp. Gloss-adjusting mask layer with particulate filler
DE102011108289A1 (en) 2011-07-21 2012-08-16 Daimler Ag Fiber reinforced plastic (FRP) motor vehicle component has fiber layer and differently colored matrix materials that together form component areas, so that visible side of components areas are provided with different colored surfaces

Citations (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3493257A (en) * 1967-03-22 1970-02-03 Gen Motors Corp Resilient microcellular foam bumper
JPS54127472A (en) * 1978-03-27 1979-10-03 Sanpo Jiyushi Kougiyou Kk Three dimensional surface decorative vacuum forming of thermoplastic resin sheet
US4545105A (en) * 1981-10-13 1985-10-08 Autodynamics Corporation Of America Method of making bright-faced reinforced plastic bumper
JPS6195998A (en) * 1984-10-18 1986-05-14 釜屋化学工業株式会社 Manufacture of conductive plastic molded shape
EP0247359A2 (en) * 1986-04-25 1987-12-02 Inoac Corporation Interior material for vehicles and method for its manufacture
US4762352A (en) * 1985-11-29 1988-08-09 Honda Giken Kogyo Kabushiki Kaisha Synthetic resin bumper assembly
US4952358A (en) * 1986-09-05 1990-08-28 Inoue Mtp Kabushiki Kaisha Method of manufacturing an interior member for vehicles
US4965037A (en) * 1989-07-17 1990-10-23 Libbey-Owens-Ford Co. Method of molding a composite
US5000903A (en) * 1989-04-06 1991-03-19 Libbey-Owens-Ford Co. Method of molding plastic products having chemically bonded protective coatings
US5009821A (en) * 1989-02-23 1991-04-23 Libbey-Owens-Ford Co. Molding method for eliminating fiber readout
EP0423676A2 (en) * 1989-10-16 1991-04-24 Sumitomo Chemical Company, Limited Method for producing molded article of fiber-reinforced thermoplastic resin
US5041260A (en) * 1989-10-30 1991-08-20 Ford Motor Company Resin transfer molding method
US5064707A (en) * 1989-07-17 1991-11-12 Libbey-Owens-Ford Co. Molded composites
US5068076A (en) * 1988-07-28 1991-11-26 Libbey-Owens-Ford Co. Method of forming an encapsulated glazing unit
US5290079A (en) * 1992-12-22 1994-03-01 General Motors Corporation Reinforced composite impact beam for a bumper assembly and method
US5328494A (en) * 1992-04-08 1994-07-12 Davidson Textron Inc. Method of forming a preform by precoating glass fibers prior to chopping and preforming
US5401457A (en) * 1992-08-04 1995-03-28 Valyi; Emery I. Process for forming a color coated article
US5407631A (en) * 1993-10-28 1995-04-18 Davidson Textron Inc. Casting process for making glass fiber preforms

Patent Citations (18)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3493257A (en) * 1967-03-22 1970-02-03 Gen Motors Corp Resilient microcellular foam bumper
JPS54127472A (en) * 1978-03-27 1979-10-03 Sanpo Jiyushi Kougiyou Kk Three dimensional surface decorative vacuum forming of thermoplastic resin sheet
US4545105A (en) * 1981-10-13 1985-10-08 Autodynamics Corporation Of America Method of making bright-faced reinforced plastic bumper
JPS6195998A (en) * 1984-10-18 1986-05-14 釜屋化学工業株式会社 Manufacture of conductive plastic molded shape
US4762352A (en) * 1985-11-29 1988-08-09 Honda Giken Kogyo Kabushiki Kaisha Synthetic resin bumper assembly
EP0247359A2 (en) * 1986-04-25 1987-12-02 Inoac Corporation Interior material for vehicles and method for its manufacture
US4952358A (en) * 1986-09-05 1990-08-28 Inoue Mtp Kabushiki Kaisha Method of manufacturing an interior member for vehicles
US5068076A (en) * 1988-07-28 1991-11-26 Libbey-Owens-Ford Co. Method of forming an encapsulated glazing unit
US5009821A (en) * 1989-02-23 1991-04-23 Libbey-Owens-Ford Co. Molding method for eliminating fiber readout
US5000903A (en) * 1989-04-06 1991-03-19 Libbey-Owens-Ford Co. Method of molding plastic products having chemically bonded protective coatings
US5064707A (en) * 1989-07-17 1991-11-12 Libbey-Owens-Ford Co. Molded composites
US4965037A (en) * 1989-07-17 1990-10-23 Libbey-Owens-Ford Co. Method of molding a composite
EP0423676A2 (en) * 1989-10-16 1991-04-24 Sumitomo Chemical Company, Limited Method for producing molded article of fiber-reinforced thermoplastic resin
US5041260A (en) * 1989-10-30 1991-08-20 Ford Motor Company Resin transfer molding method
US5328494A (en) * 1992-04-08 1994-07-12 Davidson Textron Inc. Method of forming a preform by precoating glass fibers prior to chopping and preforming
US5401457A (en) * 1992-08-04 1995-03-28 Valyi; Emery I. Process for forming a color coated article
US5290079A (en) * 1992-12-22 1994-03-01 General Motors Corporation Reinforced composite impact beam for a bumper assembly and method
US5407631A (en) * 1993-10-28 1995-04-18 Davidson Textron Inc. Casting process for making glass fiber preforms

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6440546B1 (en) 1999-10-13 2002-08-27 Ream Industries Corp. Gloss-adjusting mask layer with particulate filler
US6383320B1 (en) 1999-12-03 2002-05-07 Lear Corporation Method of forming a headliner
US6736915B2 (en) 1999-12-03 2004-05-18 Lear Corporation Method of forming a headliner
DE102011108289A1 (en) 2011-07-21 2012-08-16 Daimler Ag Fiber reinforced plastic (FRP) motor vehicle component has fiber layer and differently colored matrix materials that together form component areas, so that visible side of components areas are provided with different colored surfaces

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