Adhesive bonding and miscellaneous chemical manufacture – Methods – Surface bonding and/or assembly therefor
Reexamination Certificate
1993-09-20
2001-01-16
Johnstone, Adrienne C. (Department: 1733)
Adhesive bonding and miscellaneous chemical manufacture
Methods
Surface bonding and/or assembly therefor
C156S212000, C156S214000, C156S215000
Reexamination Certificate
active
06174396
ABSTRACT:
BACKGROUND OF THE INVENTION
This invention relates generally to the manufacture of composite thermoplastic parts such as trim panels for automobile doors and more particularly to a method of manufacturing a composite thermoplastic part that has an integral 360 degree handle.
U.S. Pat. No. 4,459,331 granted to James M. Brix et al Jul. 10, 1984 discloses a composite thermoplastic trim panel for an automobile door that includes an integral loop portion for a 360 degree door handle. The trim panel comprises a molded thermoplastic shell that is fitted with an insert that includes a reinforcement for the loop portion. This subassembly is then filled with a cellular material such as reaction injected foam in a secondary operation to provide a composite trim panel that has a partially formed loop. The loop is completed by cutting an endless hole in the composite trim panel and then attaching plates to cover the foam exposed around the periphery of the hole to provide a finished appearance for the door panel.
While this process is suitable for its intended purpose, the process requires the fabrication of cover plates and the attachment of these cover plates to the trim panel after the endless hole is cut to form the loop.
U.S. Pat. No. 5,173,228 granted to Reza Kargarzadeh, Ken E. Tuttle and John A. Grimes Dec. 22, 1992 discloses another foam in place type method that uses a precast skin shell for forming a 360 degree handle in a composite thermoplastic part such as an automobile door trim panel. In this latter method, the molded thermoplastic shell itself is formed with an integral 360 degree handle in a special mold. The molded thermoplastic shell is then fitted with an insert that includes a reinforcement for the integral 360 degree door handle. The subassembly is then filled with a foam material in a secondary operation to provide the composite door trim panel.
This process is also suitable for its intended purpose. However, the process requires complicated equipment for molding the shell with a 360 degree handle and then a difficult assembly of the handle reinforcement in preparation for the foaming operation.
Automobile interior trim door panels can also be made a vacuum forming process as disclosed in U.S. Pat. No. 4,740,417 granted to Roger Tornero Apr. 26, 1988. In this process, a porous foam backed fabric is loosely positioned over a female mold. A substrate is heated sufficiently to sag and then deposited over the female mold so that the sagging substrate contacts the fabric around an effective mold perimeter. Vacuum applied through the female mold is transmitted through the porous foam backed fabric and attracts the sagging substrate into the mold causing contact and adhesion of the heated substrate and the foam backed fabric. This method produces a contoured door panel that has sizeable functional protrusions, such as an arm rest and ridges or depressions that enhance the decorative appearance of the door. However, the door panel does not have any integral loop portions that provide a 360 degree handle.
It is also known from U.S. Pat. No. 3,467,741 granted to Keith K. Kesling Sep. 16, 1969 to vacuum form an inner panel of a refrigerator door so that wooden reinforcing sticks are embedded in the plastic sheet at the tops of integral plastic shelf fronts. This door panel likewise does not have any integral loop portions that provide a 360 degree door handle or any other portions capable of doing so.
SUMMARY OF THE INVENTION
The object of this invention is to provide a method for making a composite thermoplastic article having an integral 360 degree handle that uses vacuum forming techniques for forming the decorative skin of the article.
A feature of the invention it that the method provides a composite plastic molded article that has a 360 degree handle without any need for a cutting a hole through the article after the final molding operation.
Another feature of the invention it that the method provides a composite plastic molded article that has a 360 degree handle that does not require attachment of any plates or other components to provide a finished appearance.
Another feature of the invention is that the method provides a composite plastic molded article that has a 360 degree door handle that does not require any special molds and complicated molding equipment for molding a thermoplastic shell.
Still another feature of the invention is that the method provides a composite plastic molded article that has a 360 degree door handle and a handle frame inside the door handle that is attached to a structural substrate easily.
Yet another feature of the invention it that the method provides a composite plastic molded article that has a 360 degree handle that is completely wrapped by the same facing material that covers the rest of the article.
Still yet another feature of the invention is that the method provides a composite plastic molded article that has a 360 degree door handle that is completely wrapped by a facing material having cut ends that are tucked neatly into a longitudinal slot in the underside of the handle.
REFERENCES:
patent: 2656294 (1953-10-01), Hunt
patent: 2876498 (1959-03-01), Nason
patent: 3068044 (1962-12-01), Wilfert
patent: 3467741 (1969-09-01), Kesling
patent: 3875280 (1975-04-01), Story
patent: 3895475 (1975-07-01), Wolfelsperger
patent: 4016230 (1977-04-01), Michel
patent: 4568404 (1986-02-01), Herring
patent: 4740417 (1988-04-01), Tornero
patent: 4890877 (1990-01-01), Ashtiani-Zarandi
patent: 5252164 (1993-10-01), Mills
patent: 0117077 (1978-10-01), None
Casteel Donald
Muller John
Davidson Textron Inc.
Johnstone Adrienne C.
Reising Ethington Barnes Kisselle Learman & McCulloch PC
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