WO2019200467A1 - Appareil et procédé de surmoulage par injection d'articles comprenant des structures sensibles au processus de moulage par injection - Google Patents

Appareil et procédé de surmoulage par injection d'articles comprenant des structures sensibles au processus de moulage par injection Download PDF

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Publication number
WO2019200467A1
WO2019200467A1 PCT/CA2019/050466 CA2019050466W WO2019200467A1 WO 2019200467 A1 WO2019200467 A1 WO 2019200467A1 CA 2019050466 W CA2019050466 W CA 2019050466W WO 2019200467 A1 WO2019200467 A1 WO 2019200467A1
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Prior art keywords
mold
injection
molded
fibers
fiber
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Ceased
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PCT/CA2019/050466
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English (en)
Inventor
Yannick Longpré
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Mi Integration SENC
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Mi Integration SENC
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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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced 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
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14336—Coating a portion of the article, e.g. the edge of the article
    • B29C45/14409—Coating profiles or strips by injecting end or corner or intermediate parts
    • 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
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14336—Coating a portion of the article, e.g. the edge of the article
    • B29C45/14418—Sealing means between mould and article
    • 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
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14836—Preventing damage of inserts during injection, e.g. collapse of hollow inserts, breakage
    • 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
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/37—Mould cavity walls, i.e. the inner surface forming the mould cavity, e.g. linings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2023/00—Use of polyalkenes or derivatives thereof as moulding material
    • B29K2023/16—EPM, i.e. ethylene-propylene copolymers; EPDM, i.e. ethylene-propylene-diene copolymers; EPT, i.e. ethylene-propylene terpolymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2623/00—Use of polyalkenes or derivatives thereof for preformed parts, e.g. for inserts
    • B29K2623/16—EPM, i.e. ethylene-propylene copolymers; EPDM, i.e. ethylene-propylene-diene copolymers; EPT, i.e. ethylene-propylene terpolymers

Definitions

  • the present invention relates generally to injection molding of articles and, more specifically, to apparatuses and methods for injection molding of articles comprising textured components.
  • Injection molding is a manufacturing process in which a molten plastic or rubber material is injected into a mold cavity where it solidifies into a shape that conforms to the interior of the mold cavity.
  • molded articles are manufactured by over-molding or joint-molding parts that have been manufactured separately.
  • an extruded ethylene propylene diene methylene (EPDM) rubber or thermoplastic elastomer (TPE) part may be inserted in an injection mold wherein EPDM or TPE is injected to over-mold or joint-mold the extrusions.
  • the part to be over-molded or joint-molded may comprise a textured surface or component.
  • the texture can be in the form of a substrate on the surface of the article being over-molded such as flock (flock fibers).
  • Flock is frequently used on parts incorporated in the manufacture of vehicles such as window seals for example.
  • the flock fibers may play an aesthetic, textural and/or functional role.
  • flock is an important material in the manufacture of sealing parts of automotive vehicles.
  • the incorporation of flock fibers onto a surface is a relatively complex process.
  • Flock fibers can be deposited directly on the surface of an article or can be incorporated on an adhesive substrate such as tape to produce so-called flock tape which is then applied to the article.
  • the flock fibers are retained on the substrate by an adhesive.
  • the nature of the adhesive, its properties and uniformity influence the strength of the bond between the fibers and the substrate and the orientation and density of the fibers all of which influence in turn the aesthetic and functionality of the flocked article. Therefore, when flocked surfaces are subjected to harsh conditions, it is not only the fibers that can be affected but also the adhesive and underlying substrate.
  • Over-molding or joint-molding of articles comprising flocked surfaces can therefore compromise the integrity and functionality of these surfaces.
  • flocked surfaces present on or near the part to be over-molded/joint-molded can suffer temperature damage.
  • the textured surface may also be sensitive to pressure. Indeed, the part(s) to be over- molded/joint-molded must be secured within the mold to prevent its displacement during the injection cycle.
  • the structures within the injection mold required to position and immobilize the extrusion to ensure a good sealing of the injection cavity can be complex and can impart pressure stress on the extrusions. The immobilization sometimes requires clamping that can further damage the substrate.
  • the process of over-molding/joint-molding implies binding affinity between the injected molten thermoplastic and the article being over-molded.
  • the presence of flocked surfaces near the boundaries of the over-molded/joint-molded surface(s) may compromise binding and prevents the design of articles with flocked surfaces near or on the over- molded/joint-molded sections of the finished article.
  • an injection mold for manufacturing an injection over-molded article comprising one or more existing part having a textured surface characterized by a plurality of fibers, the injection mold comprising: a first mold component and a second mold component together defining existing part positioning members and a cavity into which a molten material is injected to form additional structure on the one or more existing part to form the injection over-molded article; and a texture conforming structure comprising a plurality of fiber receiving channels for receiving and protecting the fibers during over-molding.
  • a method of manufacturing an injection-molded article comprising at least one part that is over-molded and wherein said part comprises a process-sensitive substrate, the method comprising: providing a first mold component and a second mold component together defining a cavity; providing a substrate protection structure to protect the process sensitive substrate; positioning the part to be over molded within the mold such that the process sensitive substrate is protected by the substrate protection structure; and injecting a molten material into the cavity to form the article.
  • Figure 1 is a cross-sectional view of an injection mold having a substrate protection structure in accordance with another embodiment of the present invention.
  • Figure 2A is a cross-sectional view of an injection mold having a plurality of fiber-receiving channels in accordance with another embodiment of the invention.
  • Figure 2B is a cross-sectional view of another injection mold having a plurality of fiber receiving channels in accordance with another embodiment of the invention.
  • Figure 3 is a top view of fiber-receiving channels.
  • Figure 4A is a side view of the fiber-receiving channels.
  • Figure 4B is a photomicrograph of a cross-section of a part of a mold showing two laser- cut fiber-receiving channels.
  • Figure 4C is a photograph showing a mold part with texture conforming structures (top) and a part comprising a flocked surface (bottom) comprising gray areas corresponding to a flocked surface that has been burnt and flattened and also showing dark areas corresponding to a flocked surface that has been protected.
  • Figure 5 is a perspective view of a mesh structure in accordance with another embodiment of the invention.
  • Figure 6 is a cross-sectional view of an injection mold having a mesh structure that provides the fiber-receiving channels.
  • Figure 7 is a cross-sectional view of an injection mold having a mesh structure that provides the fiber-receiving channels in which strands of the mesh are rounded at the top.
  • Figure 8 is a perspective view of an embodiment of the lower part of a mold with texture- conforming structures.
  • Figure 9 is a perspective view of an embodiment of the lower part of a mold with extrusions to be joint-molded.
  • Figure 10 is a cross-sectional view of an embodiment of a mold with an extrusion.
  • textured surface it is meant a surface characterized by having projections, strands, filaments, or fibers such as but not limited to flock fibers.
  • the strands, filaments or fibers are elongated, slender and omnidirectionally flexible relative to the substrate to which they are attached.
  • An example of a textured surface is a flocked surface which comprises fibers such as polyester or nylon fibers for example.
  • the fibers are attached to a substrate by an adhesive.
  • An example of a substrate/adhesive/fibers arrangement is flock tape.
  • the novel injection mold is useful for manufacturing an article that comprises at least one part, section or a surface having a substrate such as a textured surface thereon and which article is an over-molded article.
  • over-molding it is meant the process by which a molten thermosetting plastic or rubber is injected onto an existing article(s) placed within an injection mold to add additional layers or shape or structure to the existing article(s).
  • the process may in particular be used to permanently join existing articles together. This latter process may be termed joint-molding. It will be understood that the term over-molding may encompass joint-molding.
  • the novel mold of the invention can be a thermoplastic elastomer (TPE) or ethylene propylene diene methylene (EPDM) injection mold for over-molding or joint-molding a part or parts such as an extruded thermoplastic part comprising a flocked surface.
  • TPE thermoplastic elastomer
  • EPDM ethylene propylene diene methylene
  • the flocked surface may have been applied to the part(s) to be over-molded/joint-molded in the form of flock tape for example.
  • the novel injection mold is particularly useful for, although not limited to, EPDM (rubber) injection over-molding/joint-molding of a part (or parts) with a textured surface such as a flocked surface.
  • EPDM rubber
  • the conditions within the mold for TPE or EPDM injection can be harsh for the textured surface as a result of the high pressures and high temperatures involved. These harsh conditions may result in damage to functional structures of textured surfaces.
  • damage can be in the form of flattening of the fibers as a result of the pressure exerted by the insertion of the part(s) in the mold.
  • the mold must be heated as part of the curing process of the EPDM.
  • Mold temperatures in typical heating cycles may reach 100 to 200°C.
  • the following parameters may be used: injection pressure of 165 psi, injection speed of 25 mm/s, decompression pressure of 35 psi, decompression speed 15 mm/s, screw rotation pressure 20 Nm, screw rotation speed 30 RPM, curing time (cooling) 120 sec, holding time 6 sec, injection time 1.2 sec, lower mold part temperature 190°C, upper mold part 190°C, Head/screw heater 50°C.
  • Temperature-sensitive substrates such as flocked surfaces may be damaged during the heating cycle. Not only are the flocked fibers susceptible to temperature but also the adhesive that anchors the fibers on their attachment substrate.
  • an injection mold comprising a texture conforming structure having fiber-receiving channels.
  • an injection mold system 2 shown in FIG. 1 having a cavity 14 formed by a first mold component 14A and a second (lower) mold component 14B, there is provided a texture conforming structure 100 located under the region of the part 101 to be over-molded or joint- molded that comprises the textured surface 20.
  • the mold is shown in cross-section and the flow of molten material such as molten rubber 18 is schematically represented with its front 19.
  • the texture conforming structure 100 comprises a plurality of fiber receiving channels 70.
  • the fiber receiving channels have walls 72 defining a textured surface supporting tip 73.
  • the fiber receiving channels provides a multi-function protective structure including fiber protection, temperature control and lateral stabilizing of part 101.
  • Texture such as flock fibers are substantially protected from flattening and/or from heat damage while sufficient support is provided to prevent the part that is being over-molded/joint-molded from bending under the pressure of immobilizing structures or during injection.
  • the insertion of fibers in the fiber-receiving channels also contributes to stabilizing part 101 in the mold by creating a resistance to lateral displacement of part 101 during injection.
  • the fiber-receiving channels 70 are embedded in lower mold component 14B just underneath a flocked surface comprising flock fibers 71.
  • the fiber-receiving channels 70 are dimensioned to accommodate the length of flocking fibers 71 optionally with some extra space at the bottom to allow for variations in length of the fibers and/or slight downwards displacement when subjected to the pressure of mold components or the flow of melted material.
  • the depth of the fiber-receiving channels 70 may be, for example, between about 0.2 and 1 mm, a range comprising typical length of flock fibers.
  • the extra space at the bottom may be of the order of about 10-20% of the length of the flock fibers.
  • Figure 2A represents an embodiment in which there is an indentation 21 in the mold surface to accommodate the substrate to which the fibers are bonded, this indentation need not be present.
  • Figure 2B exemplifies an embodiment in which the textured surface contacting tips 73 of the fiber-receiving channels are at the same level as the surface of the mold.
  • the fiber-receiving channels 70 also provide thermal shielding for the flock fibers 71 (or any type of fibers that could be damaged at temperatures used in rubber injection molding).
  • the thermal shielding is in part due to the minimization of contact surface between the fibers and the surface of the mold provided by the positioning of the fibers within the channels.
  • other thermal mechanisms may be at play.
  • the fibers located near the walls of the channels may insulate the fibers that are more centrally located.
  • the ratio of channel wall surface to density of fibers may be adjusted to optimize this thermal shielding mechanism.
  • each fiber receiving channel 70 is separated from its neighbors by a distance commensurate with minimizing flattening of fibers and minimizing heating of the fibers and of the adhesive layer while still providing an adequate support of the flocked surface. That is to say, the walls 72 of the lower mold component 14B between the channels contribute to flattening of the flock fibers (or substantial displacement from their original generally vertical arrangement).
  • the area, defined by the textured surface contacting tip surface 73, occupied by these sections is preferably minimized while retaining sufficient supportive strength to withstand the pressure generated on the part 101 by the mold components used to maintain the part in position during injection.
  • Figure 3 exemplifies a regular pattern of disposition of fiber receiving channels 70 with rounded-corners squares openings but it will be appreciated that other patterns may also be used such as a honeycomb pattern (see Figure 5) or a pattern where the openings for fiber receiving channels 70 are round for example. Also, the pattern need not necessarily be regular and may be designed to adapt to the shape of the textured surface for example. Furthermore, the edges of surface 73 between channels 70 may be rounded so that the top of walls 72 is dome shaped. Such a shape may advantageously force flock fibers to deviate into one or another flock receiving channel 70 thereby further reducing flattening of the fibers.
  • the thickness of walls 72 may be optimized to minimize heat buildup near the fibers and/or to maximize cooling rate during the curing process to eliminate or reduce thermal damage to the fibers and the adhesive layer to which the fibers are bonded.
  • the mold may comprise a cooling system including built-in cooling channels that are thermally coupled to the fiber-receiving channels 70.
  • the fiber-receiving channels 70 can be created with a laser.
  • the channels may have a generally conical shape as illustrated in Figure 2A.
  • the shape may be obtained by laser engraving.
  • the tapering can be designed to provide sufficient volume to accommodate the fibers.
  • the fibers may tolerate a certain level of crowding within the channel to the extent that they are resilient enough to regain their original orientation once the molded object is removed from the mold.
  • An exemplary set of laser parameters to manufacture the channels in a stainless-steel mold may comprise: Frequency 100 kHz; Power: 20 W for an initial hatching of the channels followed by 30 W for fine tuning the shape of the channels; laser beam displacement speed 3mm/sec for initial hatching and 75 mm/sec for fine tuning.
  • the laser may be, for example, a LXQ-100 (Laserax) with a source fiber IPG YLP-HP with nominal power of 100 W with a scanning type laser head.
  • Other geometries for the fiber-receiving channels 70 are also contemplated such as cylindrical, cubic and the like.
  • the orientation of the channels 70 within the lower mold component 14B may depend on the shape of part 101 in the region comprising the textured surface.
  • channels 70 include, without being limited to, electrical discharge machining (EDM), plasma cutting and the like.
  • EDM electrical discharge machining
  • FIGs 3 and 4A are illustrations of a mold having a plurality of conically shaped flock receiving channels 70 that have been engraved, such as by laser engraving, into the lower mold component 14B.
  • the flock-receiving channels 70 are paraboloid as exemplified in Figure 4B which is photomicrograph of a cross-section of part of a mold showing two fiber receiving channels 70.
  • the textured surface contacting tip 73 is shown having a dome or partially domed shape when viewed in cross-section. In other words, they are shown with rounded edges.
  • the width (0.23 mm) and depth (0.59 and 0.58 mm) are also shown.
  • the configuration (in terms of size and spacing) of the channels 70 is merely illustrative of the concept and may be varied for different operating parameters, materials, pressures, etc. and/or to achieve different results.
  • the height (or length) of the paraboloid-shaped channels is 0.3-1 mm and the width is 0.05-0.3 mm.
  • the dimensions of the fiber receiving channels 70 are more preferably approximately 0.6 mm in height (or length) and approximately 0.25 mm in width. Other geometries and dimensions may be used as further described below.
  • the density of fibers on flocked surfaces required by the automotive industry is typically of the order of about 10 4 fibers/cm 2 . It has been discovered that a texture conforming structure configured to receive between about 10 to 50 fibers per fiber-receiving channel 70 provides good results.
  • Figure 4C provides an example of the efficacy of an embodiment of the texture conforming structure of the invention. A partial section of a mold having two sections of texture conforming structure 100 of fibers receiving channels 70 with dimensions and shape similar to those shown in Figure 4B and areas 80 without fiber receiving channels is shown at the top of the figure.
  • the sections 82 and 83 of the part 101 which were facing the mold texture conforming structure 100 comprising the fiber receiving channels 70 during molding are clearly darker than areas 84.
  • the gray areas 84 correspond to flocked surface that has been burnt and flattened while the dark areas 82 and 83 correspond to flocked surface that has been protected and exhibit no difference from a flocked surface that has not been subjected to over- molding/joint-molding mold conditions.
  • the fiber-receiving channels may be created with a mesh structure 76 superimposed (as an insert or replaceable insert) on the lower mold component 14B or inserted in a cavity 17.
  • the fiber-receiving channels 70 are the pores or sieves of the mesh while walls 72 represent the scaffold of the mesh.
  • the mesh structure may be removed and replaced by a mesh of different dimension allowing the same mold to be re-used for substrates and/or flocking fibers of different dimensions.
  • the mesh for use in EPDM injection molding, may be made of any suitable material such as stainless steel, titanium, carbon nanotubes and the like provided the material has a melting point that is higher than the maximum temperature reached inside the mold during the curing cycle and has a strength sufficient to withstand pressures exerted in the area of the insert.
  • One advantageous material that can be used in the present invention for TPE injection over molding (in which no heating of the mold is required) is acrylonitrile butadiene styrene (ABS).
  • ABS acrylonitrile butadiene styrene
  • the material is one that does not bind to the rubber material used for the injection. Thus, in case of infiltration of the rubber in the mesh, it is easily cleanable.
  • Mesh structures can be made by methods known to persons skilled in the art. More recent technologies such as 3D printing can advantageously be used.
  • the material may be chosen to minimize thermal conductivity to reduce as much as possible heating of the textured surface.
  • the dimensions of the pores or sieves are in the same ranges as described for the fiber receiving channels 70 created in the lower mold component 14B.
  • the mesh size is preferably between about 45 to 300 mesh and more preferably about 60 mesh which corresponds to a pore or sieve aperture size of about 0.05 mm to about 0.35 mm and more preferably about 0.25 mm.
  • the textured surface supporting tip 73 of the walls 72 of the mesh may be rounded as was described above in the case where the fiber-receiving channels 70 are made directly in lower mold component 14B.
  • the insert or mesh structure 76 may advantageously be made of a different material than the mold itself to provide thermal insulation.
  • the mesh structure 76 may provide at least two mechanisms of heat protection for the fibers by providing a space 70 that reduces surface contact and by insulating the fibers by preventing all or part of the heat generated in the mold from propagating into the mesh structure 76.
  • the mesh structure may be retained by retaining means to avoid displacement and/or facilitate the positioning of the substrate thereon.
  • the cavity 17 alone may be enough to achieve that effect or it may cooperate with additional retention structures.
  • FIG. 8 An exemplary embodiment of the invention is depicted in Figure 8 in which the lower mold part 14B used to joint-mold a corner on two extrusions having flock on one of their surfaces is shown in a simplified schematic representation.
  • the mold comprises extrusions receiving grooves 300 and 301 to bring the extremities in the molding cavity 14 in position to mold the corner between them.
  • the extrusion-receiving grooves comprise texture conforming structures 100 which, in turn, comprise fiber-receiving channels 70.
  • FIG. 9 A more detailed perspective view is shown in Figure 9.
  • the extrusions 302 and 303 are inserted in their respective extrusion receiving grooves 300 and 301.
  • the extrusion-receiving grooves are configured according to the shape and size of the extrusions and comprise a number of positioning members.
  • Such positioning members are well known in the art.
  • a moveable clamping mold insert 306 which comprises clamping teeth 308 which are shown in cross-section in Figure 10.
  • Over-molding or joint-molding of parts often requires clamping of the part in the mold to avoid displacement of the latter during injection. This clamping generates additional pressure, which can be a localized pressure, that can further damage substrate like flock fibers.
  • the texture conforming structure 100 described above can provide protection against this type of damage as well.
  • the shaded gray area indicates the general position of the texture conforming structures
  • FIG. 10 A cross-sectional view of the mold from Figure 9 with the extrusion and top mold part 14A in addition to the bottom mold part 14B is shown in Figure 10.
  • the extrusion is maintained held in place by positioning member 305 and top mold part 14A as well as the moveable clamping mold insert 306 which comprises clamping teeth 308.
  • the fiber-receiving channels 70 are shown underneath extrusion lip 304 of extrusion 302.
  • the mold may also comprise a cooling system, a part of which is shown at 310 and insulating air gaps 320.
  • the fiber-receiving channels 70 can also contribute to the stabilization of the part to be over-molded.
  • the fibers once inserted in the fiber-receiving channels 70 contribute to resist lateral displacement of the part to be over-molded.
  • a method of manufacturing an injection-molded article comprising at least one part that is over-molded and wherein said part comprises a process-sensitive substrate, the method comprising: providing a first mold component and a second mold component together defining a cavity; providing a texture-conforming structure to protect the process sensitive substrate; positioning the part to be over-molded within the mold such that the process sensitive substrate is protected by the texture-conforming structure; and injecting a molten material into the cavity to form the article.
  • the method may be applied to over-molding existing parts comprising fibers such as flocked surfaces. In this case the method comprises the step to positioning the fibers into fiber-receiving channels.
  • the method may be related to rubber injection molding and may comprise a curing cycle involving heating and cooling of the mold. It can also relate to thermoplastics injection molding in which the mold does not require heating.
  • the texture conforming structure can create molded projections that have properties similar to flock fibers.
  • One of the problems with over-molding/joint-molding articles having flocked surfaces is that the over-molded/joint-molded section of the article does not have flock. This may create a flocked surface discontinuity. These unflocked surfaces often have an intricate geometry, such as a corner of a sealing frame for automobile windows and post-molding application of flock is often forgone because it is too difficult.
  • fiber receiving channels are provided within the molding cavity in areas free existing parts.
  • the thermoplastic is injected in the cavity comprising fiber receiving channels 70 that are not occupied by a textured surface
  • the molten thermoplastic penetrates in the channels and it has been surprisingly found that the resulting molded projections exhibit properties similar to flock fibers.
  • the appearance and the tactile properties are nearly identical. These properties are obtained despite the fact that the density of molded fibers is lower than the density of flock fibers acceptable for automobile sealing applications for example.
  • EPDM molded fibers having flock-like properties can be obtained using fiber receiving channels 70 having densities, shapes and sizes as described above. Therefore, the mold of the invention may be used to manufacture articles with molded fibers surfaces.
  • the mold comprises fiber-receiving channels not only in the regions where the flocked surface of the over-molded article is located but also elsewhere in the mold and especially in the molding cavity to allow molding of fibers to take place.
  • the fiber-receiving channels 70 used to manufacture molded flock fibers have shapes and dimensions similar to those shown in Figure 4B.
  • TPE or EPDM extrusions for automobile window sealing comprising flocked surfaces are joint-molded to create a corner between the two extrusions.
  • the mold comprises fiber receiving channels 70 that are positioned in the molding cavity 14 so that molded fibers will be created on the joint-molded corner and contiguous to the flocked surface of the extrusions.
  • the dimensions of the fiber-receiving channels can be adjusted to create molded fibers with the desired functional and aesthetic properties.
  • an automotive window sealing article comprising two extrusions such as EPDM and TPE extrusions and a joint molded corner, the article further comprising one or more flocked surface on at least one extrusion and molded fibers on the joint molded corner.
  • the flocked surface substantially free of heat damaged flocked surface or flattened flock fibers.
  • the molded fibers on the joint molded corner in the flocked extrusion(s) creating a continuous fiber comprising surface that is substantially visually uniform. That is to say, the flocked surface and the surface with molded fibers are visually substantially uniform.
  • the continuous fiber comprising surface has a substantially uniform tactile properties.
  • tactile properties it is meant bending, compression, friction, thermal transfer and the like.
  • substantially uniform it is meant that one or more of these properties for flocked surface and molded fibers, such as EPDM molded fibers, are similar.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

L'invention concerne un moule d'injection, conçu pour fabriquer un article surmoulé par injection, qui comprend une ou plusieurs parties existantes ayant une surface texturée caractérisée par une pluralité de fibres. Le moule d'injection comprend un premier composant de moule et un second composant de moule définissant ensemble des éléments de positionnement de partie existante et une cavité dans laquelle un matériau fondu est injecté pour former une structure supplémentaire sur la ou les parties existantes pour former l'article surmoulé par injection et une structure de conformation de texture comprenant une pluralité de canaux de réception de fibre pour recevoir et protéger les fibres pendant le surmoulage.
PCT/CA2019/050466 2018-04-16 2019-04-16 Appareil et procédé de surmoulage par injection d'articles comprenant des structures sensibles au processus de moulage par injection Ceased WO2019200467A1 (fr)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US12240300B2 (en) 2021-01-12 2025-03-04 Henniges Automotive Sealing Systems North America, Inc. Below belt seal assembly, associated window sealing system, and method for manufacturing same

Citations (8)

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CA2187095A1 (fr) * 1994-04-07 1995-10-19 Bart Gerard Boucherie Procede de moulage par injection de brosses
JPH0857880A (ja) * 1994-08-29 1996-03-05 Araco Corp 加飾体を備えた積層体の製造方法及び製造装置
US5540970A (en) * 1991-05-03 1996-07-30 Velcro Industries B.V. Die cut mold-in
US5606781A (en) * 1995-02-17 1997-03-04 Velcro Industries, B.V. Separable fastener having a bald perimeter rib bounded by fastening elements
US20020079605A1 (en) * 2000-08-26 2002-06-27 Pearson Lee S. Method of manufacturing a plastics molded part with a soft-feel surface and a manufacturing tool to use in the method
US20080150186A1 (en) * 2000-07-24 2008-06-26 High Voltage Graphics, Inc. Co-molded direct flock and flock transfer and methods of making same
EP2248649A1 (fr) * 2009-05-07 2010-11-10 Industrias Tapla, S.L. Article floqué et son procédé de fabrication
WO2018213914A1 (fr) * 2017-05-23 2018-11-29 Mi Intégration S.E.N.C. Appareil et procédé de liaison d'un substrat dans le moule à des articles fabriqués par moulage par injection

Patent Citations (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5540970A (en) * 1991-05-03 1996-07-30 Velcro Industries B.V. Die cut mold-in
CA2187095A1 (fr) * 1994-04-07 1995-10-19 Bart Gerard Boucherie Procede de moulage par injection de brosses
JPH0857880A (ja) * 1994-08-29 1996-03-05 Araco Corp 加飾体を備えた積層体の製造方法及び製造装置
US5606781A (en) * 1995-02-17 1997-03-04 Velcro Industries, B.V. Separable fastener having a bald perimeter rib bounded by fastening elements
US20080150186A1 (en) * 2000-07-24 2008-06-26 High Voltage Graphics, Inc. Co-molded direct flock and flock transfer and methods of making same
US20020079605A1 (en) * 2000-08-26 2002-06-27 Pearson Lee S. Method of manufacturing a plastics molded part with a soft-feel surface and a manufacturing tool to use in the method
EP2248649A1 (fr) * 2009-05-07 2010-11-10 Industrias Tapla, S.L. Article floqué et son procédé de fabrication
WO2018213914A1 (fr) * 2017-05-23 2018-11-29 Mi Intégration S.E.N.C. Appareil et procédé de liaison d'un substrat dans le moule à des articles fabriqués par moulage par injection

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US12240300B2 (en) 2021-01-12 2025-03-04 Henniges Automotive Sealing Systems North America, Inc. Below belt seal assembly, associated window sealing system, and method for manufacturing same

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