Patent Application
20220097488
The present disclosure relates to molding processes, and more particularly to molding processes for the manufacture of air register vanes in automotive interiors.
The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.
Automotive interiors have become increasingly more stylish and unique in recent years, as automotive manufacturers seek to appeal to more discerning customers. In one example, specific surfaces in automotive interiors are treated with overlays or trim pieces of a variety of materials (or faux materials), including wood grain, brushed aluminum, carbon fiber, or chrome, among others. Surfaces that have been popular to treat are air register vanes, and more specifically, edges of these air register vanes.
However, attaching overlays to underlying surfaces can be a challenge when different materials are being used. Proper adhesion, in order to achieve both surface finish and long-term durability, can be difficult with a wide variety of materials and underlying part fabrication processes. As a result, the selection of materials for both the underlying component and the overlay is limited, thus limiting design flexibility for automotive interior designers.
These issues related to the use of different materials in overlays for automotive materials, among other issues related to manufacturing such overlays, are addressed by the present disclosure.
This section provides a general summary of the disclosure and is not a comprehensive disclosure of its full scope or all of its features.
In one form, a method of manufacturing a vane assembly for an air vent is provided that includes molding an intermediate member in a molding die, the intermediate member comprising a head portion and a stem portion extending distally from the head portion, the stem portion defining a gate for the molding, the intermediate member consisting of an unreinforced polymer material. Subsequently, a vane body is molded over the stem portion of the intermediate member in the molding die, the vane body comprising a reinforced polymer material. After molding the vane body over the stem portion of the intermediate member, a facia is secured to the head portion of the intermediate member to form the vane assembly.
In variations of this method, which may be employed separately or in any combination: the vane body is reinforced with glass fibers; the facia comprises a layered film comprising an adhesive layer, a polymer layer adjacent to the adhesive layer, a metal flake layer adjacent to the polymer layer, and a protective layer adjacent to the metal flake layer, wherein the adhesive layer is secured to the head portion of the intermediate member; at least one of the vane body and the intermediate member comprises at least one mechanical interlock configured to secure the vane body to the intermediate member; the mechanical interlock comprises a tab and a groove; the stem portion of the intermediate member defines a tapered profile; the facia covers a portion of the head portion; the facia covers an entirety of the head portion; and the vane body is molecularly bonded to the intermediate member after the subsequent molding.
In another form, a vane assembly for an air vent is manufactured according to a method of: molding an intermediate member in a molding die, the intermediate member comprising a head portion and a stem portion extending distally from the head portion, the stem portion defining a gate for the molding; subsequently molding a vane body over the stem portion of the intermediate member in the molding die; and after molding the vane body over the stem portion of the intermediate member, securing a facia to the head portion of the intermediate member to form the vane assembly, wherein the vane body is molecularly bonded to the intermediate member after the subsequent molding.
In variations of this vane assembly, which may be employed individually or in any combination: the vane body is reinforced with glass fibers; the intermediate member consists of an unreinforced polymer material; the facia comprises a layered film comprising an adhesive layer, a polymer layer adjacent to the adhesive layer, a metal flake layer adjacent to the polymer layer, and a protective layer adjacent to the metal flake layer, wherein the adhesive layer is secured to the head portion of the intermediate member; the facia covers a portion of the head portion; the facia covers an entirety of the head portion.
In still another form of the present disclosure, a vane assembly for an air vent is manufactured according to a method of: molding an intermediate member in a molding die, the intermediate member comprising a head portion and a stem portion extending distally from the head portion, the stem portion defining a gate for the molding, the intermediate member consisting of an unreinforced polymer material; subsequently molding a vane body over the stem portion of the intermediate member in the molding die, the vane body comprising a reinforced polymer material; and after molding the vane body over the stem portion of the intermediate member, securing a facia to the head portion of the intermediate member to form the vane assembly.
In variations of this vane assembly, which may be employed individually or in any combination: at least one of the vane body and the intermediate member comprises at least one mechanical interlock configured to secure the vane body to the intermediate member; the mechanical interlock comprises a tab and a groove; the facia covers a portion of the head portion; and the facia covers an entirety of the head portion.
Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure.
In order that the disclosure may be well understood, there will now be described various forms thereof, given by way of example, reference being made to the accompanying drawings, in which:
The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.
The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
Referring to
The intermediate member 24 comprises a head portion 30 and a stem portion 32 extending distally from the head portion 30. The stem portion 32 is received by the vane body 22, and more specifically within the slot 34. Accordingly, both the stem portion 32 and the slot 34 have a tapered as shown for both molding purposes as described in greater detail below and to better secure the intermediate member 24 to the vane body 22 after molding. If the materials/polymers for each of the intermediate member 24 and vane body 22 are not compatible enough to form a molecular bond during molding, to further improve the mechanical connection between the intermediate member 24 and vane body 22 after molding, locking features may be employed, such as by way of example, a tab 36 and a groove 38. While the tab 36 is shown on the intermediate member 24 and the groove 38 is shown on the vane body 22, it should be understood that the tab 36 and groove 38 may be disposed on one or the other of the intermediate member 24 and vane body 22 while remaining within the scope of the present disclosure. In another form, the intermediate member 24 and vane body 22 are secured together via friction from the molding process and may include surface texturing, or a grain to their surfaces, in order to increase the strength of the interface.
Referring to
Referring now to
After the intermediate member 24 is molded, a second “shot” is made in the same mold and subsequently molding the vane body 22 over the stem portion of 32 the intermediate member in 24 the molding die. Because the vane body 22 is molded with the intermediate member 24 in the same molding die, while the materials of both parts are heated and generally at or past their glass transition temperature, the vane body 22 is molecularly bonded to the intermediate member 24 after the subsequent molding. After molding the vane body 22 over the stem portion 32 of the intermediate member 24, the facia 26 is secured to the head portion 30 of the intermediate member 24 to form the vane assembly 20. As set forth above, the facia 26 includes an adhesive layer 40, which provides a bonding interface between the intermediate member 24 and the facia 26.
Referring to
Unless otherwise expressly indicated herein, all numerical values indicating mechanical/thermal properties, compositional percentages, dimensions and/or tolerances, or other characteristics are to be understood as modified by the word “about” or “approximately” in describing the scope of the present disclosure. This modification is desired for various reasons including industrial practice, material, manufacturing, and assembly tolerances, and testing capability.
As used herein, the phrase at least one of A, B, and C should be construed to mean a logical (A OR B OR C), using a non-exclusive logical OR, and should not be construed to mean “at least one of A, at least one of B, and at least one of C.”
The description of the disclosure is merely exemplary in nature and, thus, variations that do not depart from the substance of the disclosure are intended to be within the scope of the disclosure. Such variations are not to be regarded as a departure from the spirit and scope of the disclosure.
