Stock material or miscellaneous articles – Sheets or webs edge spliced or joined – Sheets or webs coplanar
Patent
1991-05-20
1993-07-06
Robinson, Ellis P.
Stock material or miscellaneous articles
Sheets or webs edge spliced or joined
Sheets or webs coplanar
428 31, 264245, 296146R, 296146B, 296146F, B32B 302, B29C 3912
Patent
active
052252612
ABSTRACT:
A two tone plastic vehicle door shell (10), FIG. 1 has a front surface (12) and a side surface (14) separated into two tone segments (18, 20) (18a, 20a) by an integral two tone trim line (22). The shell's side surface is joined to a return flange (16). The return flange is arranged generally parallel to the front of the shell and includes a side flap (26) thereon which covers a cut-out opening (24) in the return flange on either side of the trim line at the side of the door. The cut-out opening (24) is provided for removing a seal and divider wall assembly from the door shell when thermoplastic powder is cast on a heated mold to form the shell. A tool FIG. 2 for manufacturing the two tone plastic shell includes an electroformed mold (28) having a first surface (29) for forming a front of a shell; a second surface (32) for forming the side edge portion of a shell; and a third surface segment (34) for forming a return flange on a door shell and the third surface segment has a cut-out opening (36) therein and a runout surface (40) providing for entry and removal of a seal and divider wall assembly to seal against a sealing rib (38) in the mold which separates the first, second and third segments into first and second casting surfaces. The divider rib and runout surface are sprayed with thermoplastic material to form a joint between material cast on the first and second casting surfaces and a skin return flap for sealing the cut-out opening.
REFERENCES:
patent: 4610620 (1986-09-01), Gray
patent: 4780345 (1988-10-01), Gray
patent: 4894004 (1990-01-01), Brault
patent: 4925151 (1990-04-01), Gray
patent: 4945682 (1990-08-01), Altman et al.
Davidson Textron Inc.
Nold Charles R.
Robinson Ellis P.
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