TOOLING AND METHODS FOR FORMING A COMPONENT WITH AN OVERMOLD LAYER

Abstract

A method for forming an overmolded component includes arranging a first mold part and a second part with at least a portion of a first mold cavity defined by the first mold part and the second mold part, supplying material to form a substrate in the first mold cavity, supplying an overmold cavity that is defined at least in part by the substrate, one or both of the first mold part and the second mold part, and a seal that engages with the substrate and also engages with one or both of the first mold part and the second mold part, and supplying material for an overmolded layer in the overmold cavity.The overmold layer can be formed from a material with low viscosity and the seal inhibits or prevents the overflow of the overmold material to reduce or eliminate the formation of burrs at parting or junction lines in the molding process.

Description

Title of the invention: TOOLING AND METHODS FOR FORMING A COMPONENT WITH AN OVERMOLDED LAYER DOMAIN

[0001] The present invention relates to a component with an integrated seal and methods for manufacturing the component with the integrated seal. CONTEXT

[0002] Certain components, such as automotive doors and tailgates and the like, include perimeter seals or gaskets that reduce the intrusion of noise, wind, and contaminants into the vehicle. Some trim panels have molded gaskets on a portion of the panel. Low-viscosity materials used to form the gaskets, such as polyurethane, are difficult to mold without overflowing into the molding tooling, leading to burrs that must then be trimmed. The size of the material can affect the surface finish, appearance, and durability of the part, and the trimming operation adds time and cost to forming a part, requiring more material to form the gasket along with the burrs. SUMMARY

[0003] A method for forming an overmolded component includes arranging a first mold piece and a second piece with at least a portion of a first mold cavity defined by the first mold piece and the second mold piece, supplying material to form a substrate in the first mold cavity, supplying an overmold cavity that is defined at least in part by the substrate, one or both of the first mold piece and the second mold piece, and a seal that engages with the substrate and also engages with one or both of the first mold piece and the second mold piece, and supplying material for an overmolded layer in the overmold cavity.The overmold layer can be formed from a material with low viscosity, and the seal inhibits or prevents the overflow of the overmold material to reduce or eliminate the formation of burrs at parting or junction lines in the molding process.

[0004] In at least some embodiments, the seal is carried by the first mold piece and engages with the second mold piece and the substrate. In at least some embodiments, the overmold cavity is defined by the substrate, the second mold part and seal. In at least some implementations, the first mold part includes a cavity and the seal is located in the cavity.

[0005] In at least some embodiments, the method also includes providing a third mold piece to define a portion of the overmold cavity, and in which the seal is fixed to the third mold piece. In at least some embodiments, the seal carried by the third mold piece is compressed during the formation of the overmolded layer, and the seal comes into contact with the second mold piece and the substrate. In at least some embodiments, the seal carried by the third mold piece comes into contact with the first mold piece, the second mold piece, and the substrate.In at least some implementations, a portion of the third mold piece spaced from the joint defines a part of the first mold cavity such that the joint does not define a part of the first mold cavity, and the method includes moving the third mold piece from a first position in which the third mold piece defines a part of the first mold cavity to a second position in which the joint defines a part of the overmold cavity.

[0006] In at least some embodiments, the joint is compressed during the formation of the overmolded layer.

[0007] In at least some embodiments, the method also includes providing a third mold piece wherein the seal is fixed to the third mold piece, and the seal defines a portion of the first mold cavity. In at least some embodiments, the third mold piece can be moved from a first position in which the seal defines a portion of the first mold cavity to a second position in which the seal defines a portion of the overmold cavity.

[0008] In at least some implementations, the method also includes the provision of a third mold piece and a fourth mold piece, in which the method includes positioning the third mold piece so that the third mold piece defines a portion of the first mold cavity, and after the material for the substrate is provided into the first mold cavity, moving the third mold piece and providing a fourth mold piece that includes the seal to define a portion of the overmold cavity.

[0009] In at least some embodiments, a method for forming an overmolded component includes defining a first mold cavity, a gasket mold cavity, and an overmold cavity. The method includes: arranging a first mold piece, a second mold piece, and a third mold piece to define at least a portion of a first mold cavity; the supply of material to form a substrate in the first mold cavity; the arrangement of the first mold piece, the second mold piece and the third mold piece to define a joint mold cavity, where the joint cavity is defined in part by the substrate; the supply of material for a seal in the seal mold cavity; the provision of an overmold cavity which is defined at least in part by the joint and the substrate; and the supply of material for an overmolded layer in the overmold cavity.

[0010] In at least some embodiments, the overmold cavity is partly defined by a fourth mold piece that is different from the first, second, and third mold pieces. In at least some embodiments, the seal is compressed by the fourth mold piece to close a portion of the overmold cavity.

[0011] In at least some implementations, the third mold piece can be moved relative to the first mold piece and the second mold piece from a first position in which the third mold piece defines a portion of the first mold cavity to a second position in which the third mold piece defines a portion of the joint mold cavity.

[0012] In at least some implementations, the joint mold cavity is defined by the first mold piece, the second mold piece, the third mold piece and the substrate.

[0013] In at least some embodiments, the first mold part defines a portion of the first mold cavity that defines at least a part of an internal surface of the substrate, the second mold part defines a portion of the first mold cavity that defines at least a part of an external surface of the substrate, and the third mold part defines a part of the first mold cavity that defines at least a part of a peripheral edge of the substrate between the internal surface and the external surface.

[0014] In at least some embodiments, the joint mold cavity is defined in part by the peripheral edge of the substrate.

[0015] In at least some implementations, the seal is compressed by one or more of the first mold piece, the second mold piece and the third mold piece to close a portion of the overmold cavity. Brief description of the drawings

[0016] Fig. 1 is a cross-sectional view of part of a mold system intended to form a substrate with an overmolded layer, the substrate being shown in a first mold cavity;

[0017] [Fig.2] is a view similar to [Fig.1] and showing the overmolded layer formed in an overmold cavity;

[0018] [Fig.3] is a cross-sectional view of part of a mold system showing a substrate in a first mold cavity;

[0019] [Fig.4] is a view similar to [Fig.3] and showing the overmolded layer formed in an overmold cavity;

[0020] [Fig.5] is a view similar to [Fig.4] showing an overmolded layer deployed;

[0021] [Fig.6] and [Fig.7] are cross-sectional views of part of a mold system showing the formation of a substrate in a first mold cavity and an overmolded layer in an overmold cavity;

[0022] [Fig.8] and [Fig.9] are cross-sectional views of part of a mold system showing the formation of a substrate in a first mold cavity and an overmolded layer in an overmold cavity;

[0023] [Fig. 10] is a view similar to [Fig. 9] showing an overmolded layer deployed;

[0024] [Fig.1 1] is a view similar to [Fig. 10] showing an overmolded layer deployed and an overflow joint;

[0025] [Fig.12] and [Fig.13] are cross-sectional views of part of a mold system showing the formation of a substrate in a first mold cavity and an overmolded layer in an overmold cavity;

[0026] [Fig.14], [Fig.15], [Fig.16] and [Fig.17] are cross-sectional views of part of a mold system showing the formation of a substrate in a first mold cavity and an overmolded layer in an overmold cavity;

[0027] [Fig. 18] is a view showing a modified overflow joint and a substrate thus formed;

[0028] [Fig.19], [Fig.20] and [Fig.21] are cross-sectional views of part of a mold system showing the formation of a substrate in a first mold cavity, an overmolded layer in an overmold cavity and a seal in a third mold cavity;

[0029] [Fig.22], [Fig.23] and [Fig.24] are cross-sectional views of part of a mold system showing the formation of a substrate in a first mold cavity, an overmolded layer in an overmold cavity and a seal in a third mold cavity;

[0030] [Fig.25], [Fig.26] and [Fig.27] are cross-sectional views similar to [Fig.24] and showing modified joints;

[0031] Figures [Fig. 28], [Fig. 29], [Fig. 30] and [Fig. 31] are cross-sectional views of part of a mold system showing the formation of a substrate in a first cavity of mold, an overmolded layer in an overmold cavity and a seal in a third mold cavity;

[0032] Fig. 32, Fig. 33 and Fig. 34 are cross-sectional views of part of a mold system showing the formation of a substrate in a first mold cavity, an overmolded layer in an overmold cavity and a seal in a third mold cavity;

[0033] Figures [Fig. 35], [Fig. 36], [Fig. 37] and [Fig. 38] are cross-sectional views showing a substrate, overmolded layers and / or alternative joints that can be formed by corresponding mold tools in a mold system; and

[0034] Figures 39, 40, and 41 are cross-sectional views showing components formed in an assembly adjacent to a surface of a different component. DETAILED DESCRIPTION

[0035] With further reference to the drawings, Figures 1 and 2 show a mold system 10 in which a vehicle component 12 is molded. As shown in [Fig. 2], the vehicle component 12 includes a substrate 14 formed of a first material and an overmolded layer 16 molded onto the substrate 14 and formed of a second material. The vehicle component 12 can have various end uses, and the overmolded layer 16 can be provided on all or part of the substrate 14, as required. In at least some embodiments, the overmolded layer 16 is formed from a low-viscosity material, such as polyurethane, and is molded onto the substrate 14 in a multi-injection molding process.

[0036] As shown in [Fig. 1], the mold system includes a first mold piece 18 and a second mold piece 20 arranged to define a first mold cavity 22 located between the mold pieces 18 and 20. To form the substrate 14, substrate material is placed in the mold cavity 22 and allowed to harden at least partially. Then, the second mold piece 20 is moved away from the first mold piece 18, and a third mold piece 24 ([Fig. 2]) is arranged relative to the first mold piece 18 to define, with a portion of the substrate 14, an overmold cavity 26. Material for the overmolded layer 16 is injected into the overmold cavity 26 so that the overmolded layer is formed directly on the substrate 14.The third mold part 24 may be entirely different from the second mold part 20, or the second mold part 18 may include a movable or removable portion which, when removed or moved from the position used to define the mold cavity 22, allows the transformed mold part to define the overmold cavity 26. In this respect, the new, moved, or changed mold part may be called the modified second mold part in some implementations and examples. In some implementations, . The overmold cavity 26 can be defined by simply moving the second mold piece 20 away from the first mold piece 18 to define an open area between the formed substrate 14 and at least part of a mold surface of the second mold piece 20. Alternatively, or instead, the first mold piece 18 can have movable or removable sections that can define all or part of the overmold cavity 26.

[0037] To limit or prevent overflow of material for the overmolded layer 16 when this material is injected into the mold cavity 26, the mold system 10 is configured with a seal, sometimes referred to here as an overflow seal 28, on one or more of the mold parts used to form the substrate 14 and the overmolded layer 16. The overflow seal 28 can be implemented in various ways, as shown in the drawings and described below.

[0038] In the embodiment shown in Figures 1 and 2, an example of an overflow seal 28 is embedded in or fixed to the first mold piece 18. The overflow seal 28 is positioned so that it defines a portion of at least the overmold cavity 26 and is overlapped by a portion of the third mold piece during the molding of the overmolded layer 16 (or the second mold piece in embodiments where the same mold piece is moved and used to define a portion of the overmold cavity). To reduce or eliminate the flow of material from the overmolded layer 16 between the substrate 14 and the first mold piece 18, the overflow seal 28 may also define a portion of the first mold cavity 22 and may be overlapped by and abutted against the substrate 14.The overflow joint 28, in at least some implementations, can be molded onto the first mold piece 18, for example within an overflow joint cavity 30 defined in the first mold piece 18.

[0039] The overflow seal 28 is a continuous, one-piece body and may be formed of or include a compressible material that does not bond to the substrate material 14 or the overmolded layer 16 during the molding process and while the freshly molded vehicle component remains in the mold. In some embodiments, the overflow seal 28 may include an insert, such as a metal stiffener or other more rigid support element, to provide increased support and structural integrity to the overflow seal 28. At least the portion of the overflow seal 28 that defines a part of the overmold cavity 26 may be compressible to ensure improved sealing between the mold pieces used to define the overmold cavity 26, and also between the substrate 14 and the first mold piece 16.Since the overflow joint 28 is present during the molding of both the substrate 14 and the overmolded layer 16, the material of the overflow joint 28 is chosen to withstand the temperatures and pressures that exist. during the molding process. The overflow seal material 28 can also be chosen so as not to bond to the substrate 14 and the overmolded layer 16 and to demold cleanly after the molding process. In at least some implementations, the overflow seal 28 includes or is defined by a silicone material, or a PTFE seal, or a coated or similar seal, with or without release agents, can be used.

[0040] Figure 3 shows a similar molding system 32 for the vehicle component 12. In this system, a first mold cavity 34 in which the substrate 14 is formed is defined by a first mold piece 36 and a second mold piece 38. The first mold piece 36 has a core 40 and a movable part 42 that moves relative to the core 40 and is called a core slide. In the molding process using this mold system 32, the core slide 42 is in a first position in which the core slide 42 butts against both the core 40 and the second mold piece 38, and the material for the substrate 14 is supplied into the first mold cavity 34.

[0041] After this, to provide the overmolded layer 16 on the component 12, the second mold piece 38 is modified / moved or replaced by another mold piece 38' (for example, the second mold piece is moved relative to the substrate and the first mold piece 36 or a different mold piece is substituted for the second mold piece, or a movable portion of the second mold piece is moved) to define a part of the overmolding cavity 44 in which the overmolded layer 16 will be formed. In addition, the core slide 42 is moved away and a third mold piece 46 is inserted and occupies part of the space resulting from the movement of the core slide 42.

[0042] As shown in [Fig.4], the third mold piece 46 includes an overflow seal 48 attached to it (for example molded in a cavity of the third mold piece). The overflow joint 48 is arranged to define a portion of the overmold cavity 44 and to abut against portions of the substrate 14 and the second mold piece 38, which also define a portion of the overmold cavity 44. The overflow joint 48 can be formed and can function as described above with regard to the overflow joint 28, to limit overflow and the formation of flash during the molding of the material for the overmolded layer 16 onto the substrate 14. Figure 5 illustrates a component formed with the overmolded layer 16 extending around an additional surface of the substrate 14 (shown in the form of an end or edge), which is made possible by an appropriately shaped overflow joint and corresponding mold pieces.In this example, the core 40 also defines part of the overmold cavity 44 and the overflow seal 48 also butts against the core 40 to reduce or prevent. material overflow from the overmold cavity 44 and the formation of burrs at the interface between the overmolded layer 16 and the core 40.

[0043] In the example shown in Figures 6 and 7, a mold system 49 includes a first mold piece 50 which has or is adjacent to a movable portion 52 on which an overflow seal 54 is carried. The first mold cavity 56, shown in [Fig. 6], is defined between the first mold piece 50, the second mold piece 58, and the overflow seal 54. The overflow seal 54 engages with portions of the first and second mold pieces 50, 58 to enclose this area of ​​the first mold cavity 56 during the molding of the substrate 14. Subsequently, the second mold piece 58 can be modified (and is referenced as 58' in [Fig. 7]) to define a portion of the overmold cavity 60, which is also defined by the substrate 14 and the overflow seal 54.At this stage of the molding process, the overflow seal 54 comes into contact with the first mold piece 50, the second mold piece 58' and the substrate 14 to enclose this area of ​​the overmold cavity 60 during the molding of the overmolded layer 16 onto the substrate 14. If desired, and as shown in [Fig.7], the movable mold piece 52 can be moved away from the substrate 14 to allow material from the overmolded layer 16 to flow around the adjacent surface of the substrate 14, in which case a part of the overmold cavity 60 can also be defined by the first mold piece 50, and a suitable seal can be ensured between the overflow seal 54 and the first mold piece 50.

[0044] The mold system 62 shown in Figures 8 and 9 is similar to that shown in Figures 6 and 7. In this example, the movable mold piece 52 is oriented and movable at a non-zero angle relative to the direction of movement of the second mold piece 58 relative to the first mold piece 50. The overflow seal 54 is slidingly engaged with the first mold piece 50 and compressed against the second mold piece 58 to define a portion of the first mold cavity 56 for forming the substrate 14, and the overmold cavity 60 for molding the overmolded layer 16 onto the substrate 14.To define the overmold cavity 60, the second mold piece 58' is modified and the portion of the overflow joint 54 abutting the second mold piece 58' can be partially decompressed from its state when the substrate 14 is formed, but still maintains contact with the substrate 14 and the second mold piece 58' and provides a sealing force between them to inhibit or prevent flow of material for the overmolded layer 16 along these junctions or interfaces.

[0045] In the example shown in [Fig. 10], to form the overmold cavity 60', the second mold piece 58 is modified, and the movable mold piece 52 is moved away from the substrate 14 so that a portion of the overmold cavity 60' is defined between the overflow joint 54 and the adjacent portion of the substrate 14. During this movement, the overflow joint 54 partially decompresses but maintains contact with the second mold piece 58' and the first mold piece 50, and a sealing force between them, to inhibit or prevent an overflow of material for the overmolded layer 16'.

[0046] A similar example is shown in [Fig. 11], the movable mold piece 52 having been moved from a first position used in the formation of the substrate 14 to a second position used in the formation of the overmolded layer 16. In this example, the overflow joint 54' includes an elongated interface portion 64 around which part of the substrate 14 is formed. During the movement of the movable mold piece 52, the interface portion 64 slides along a surface of the substrate 14 but maintains a seal with it in the second position of the movable mold piece 52. Thus, the overmold cavity 66 is defined between the substrate 14, the overflow seal 54' and the first mold piece 50, and is sealed by interlocking a portion of the overflow seal 54' which butts against the first mold piece 50 and a second portion of the overflow seal 54' in the interface portion 64 which comes into contact with the substrate 14.

[0047] In the implementation of a mold system 70 shown in Figures 12 and 13, the first mold cavity 72, shown in [Fig. 12], is defined between a first mold piece 74 and a second mold piece 76. An overflow seal 78 is carried by the first mold piece 74 at a location spaced away from the portion of the first mold piece 74 that defines a part of the first mold cavity 72. To define the overmold cavity 80, as shown in [Fig. 13], a different or modified second mold piece 76' can be provided to provide a space between itself and a part of the substrate 14, and the first mold piece 74 is moved so that the overflow seal 78 rests against the second mold piece 76' and the substrate 14.In the example shown, the first mold part 74 has a concave surface, and a raised external portion 82 including the overflow joint 78 is received in a pocket or cavity 84 in the second mold part 76 which is used to define the first mold cavity 72, as shown in [Fig. 12]. Other shapes and orientations of mold parts can be used, which employ the concept of the overflow joint as shown in Figures 12 and 13.

[0048] With reference now to Figures 14 to 17, a mold system 90 is shown in which the first mold cavity 92 for the substrate 14, as shown in [Fig. 14], is defined by a first mold piece 94, a second mold piece 96, and a third mold piece 98 or slide. [Fig. 15] shows a top view in which it can be seen that multiple third mold pieces / slides 98 can surround the entire periphery of the substrate 14 being molded.of formation. Figure 16 shows the overmold cavity 100, which is defined by the second mold piece 96' or a modified second mold piece 96', the substrate 14, and an overflow seal 102 carried by a fourth mold piece 104, which may be a slide or a lifter. In this system, the third mold pieces 98 are away from the passage and are not part of the overmold cavity 100. The overflow seal 102 is carried by different mold pieces 104 that are not part of the first mold cavity 92.The third mold pieces 98 move laterally, perpendicular to the direction of travel of the second mold piece 96 relative to the first mold piece 94, and the fourth mold piece(s) 104 move vertically, in / parallel to the direction of travel of the second mold piece, but the reverse could be true or other angles / directions of movement could be used to achieve the desired positioning of these mold pieces. During the molding of the overmolded layer 16 onto the substrate 14, the overflow seal 102 butts against and seals the substrate 14 and the second mold piece 96 – in this example, the first mold piece 94 does not define part of the overmolding cavity 100. [Fig. 17] shows the molded component 12 with the substrate 14 and the overmolded layer 16.

[0049] The example mold system 110 shown in [Fig. 18] is similar to the mold system 90 of Figures 14 to 17, but in this system 110, the third mold piece 98' which defines a part of the first mold cavity 92' includes a void 112 in a portion which defines the first mold cavity 92'. This void 112 is filled with material from the substrate 14 and provides a projection 114 projecting or extending outwards (for example a rib or flange) on this portion of the substrate 14. The projection 114 can be arranged around the periphery of the substrate 14, spaced from an external surface 116 of the substrate 14, i.e. offset from a corner 118 of the substrate, so that the overmolded layer 16 is formed on the corner 118 and on part of a peripheral edge 119 of the substrate, and a boundary of the overmolding cavity 100' is defined by the projection 114.The projection 114 can also provide increased compression of the overflow joint 102 or improved contact over a relatively small area and an improved seal can be formed between them, to inhibit or prevent the flow of material from the overmolded layer 16 between the projection 114 and the overflow joint 102.

[0050] In the embodiments described above, the overflow seals were carried by a mold part and used to seal a portion of an overmold cavity in which an overmolded layer 16 was formed on a substrate 14. In the embodiments described below, the overflow seal is molded onto the substrate and, after that, the overmolded layer 16 is molded onto one or both of the substrate 16 and the overflow seal. Since the overflow seal can be Formed from materials different from the overmolded layer 16, and having different sizes, shapes, and locations, the combined parts can provide a range of functions and benefits to a finished component and the vehicle in which the component is installed. For example, the seal can be formed from silicone or one or more other elastomeric materials that are compressible to form a seal when using the substrate, and are also compressible and used to form a seal against overflow of the material used in forming the overmolded layer. The overmolded layer 16 can, as noted previously, be formed from a low-viscosity material, such as polyurethane, or another material used to define at least a portion of a presentation surface or a Class A exterior surface of the finished component.

[0051] In the example shown in [Fig. 19], the mold system 120 includes a first mold cavity 122 which is formed between a first mold piece 124, a second mold piece 126 and a third mold piece 128 in a first position in which the third mold piece 128 comes into contact with the first mold piece 124 at a boundary of the first mold cavity 122. After the substrate 14 is formed in the first mold cavity 122 during a first phase of the molding process, the third mold piece 128 is moved to a second position, as shown in [Fig. 20], where a space is defined between the third mold piece 128 and both the first mold piece 124 and the substrate 14.This space is referred to here as a joint mold cavity 130 or a third mold cavity, with the first mold cavity 122 used to form the substrate 14, and a second cavity or overmold cavity (described later) used to form the overmolded layer 16.

[0052] In the second position, the third mold piece 128 can engage with the second mold piece 126 at a location spaced away from the substrate 14, and the first mold piece 124 at an external boundary of the joint mold cavity 130. The joint mold cavity 130 is thus defined between the first mold piece 124, the second mold piece 126, the third mold piece 128, and the portion of the substrate 14 exposed by the movement of the third mold piece 128 to its second position. The material for the joint 132 is provided in the joint mold cavity 130 in a second phase of the molding process. In this example, the joint 132 is molded onto a peripheral edge 134 of the substrate 14 and extends outward from the peripheral edge 134 to define a "lame" edge or joint around all or part of the substrate 14.The outwardly extending limp joint can, for example, create a joint between the substrate 14 and one or more adjacent components (as also described later in relation to Figures 39-41).

[0053] In a third phase of the molding process, the second mold piece 126 is moved or modified to define an overmold cavity 136. In this example, as shown in [Fig. 21], the modification involves replacing the second mold piece 126, which was used to define the first and third mold cavities 122, 130, with a different mold piece 126'. The overmold cavity 136 is defined between the modified second mold piece 126', the seal 132, and the substrate 14, along a portion of a surface of the substrate 14 extending inward from the peripheral edge 134 to which the seal 132 is fixed. In this example, a portion of the second mold piece 126' engages with and can pinch and seal the seal 132 to define a boundary of the overmold cavity 136.The material for the overmolded layer 16 is supplied in the overmolding cavity 136 and the overmolded layer 16 is molded onto a portion of the substrate 14 and a portion of the joint 132.

[0054] In the example of Figures 19-21, the third movable mold piece 128 defines only the portion of the first mold cavity 122 that corresponds to the peripheral edge 134 of the substrate 14. An external surface 138 of the substrate 14 was defined by the second mold piece 126, and an internal surface 140 of the substrate 14 was defined by the first mold piece 124. In the example shown in [Fig. 22], the third mold piece 128' defines portions of the first mold cavity 122' that define both the peripheral edge 134 and a portion of the internal surface 140 of the substrate 14. The remainder of the internal surface 140 of the substrate 14 is defined by a first mold piece 124', and the external surface is defined by the second mold piece 126, which can be the same as in the mold system 120 of the Figures. 19-21.

[0055] According to this arrangement, when the third mold piece 128' is moved to its second position, a gasket mold cavity 130' is defined which overlaps both the peripheral edge 134 and the portion of the internal surface 140 of the substrate 14 that was defined by the third mold piece 128'. In this example, the gasket mold cavity 130' also extends outward away from the edge 134 of the substrate 14, as described above in relation to [Fig. 20]. Thus, as shown in [Fig. 23], the gasket 132' is molded over the edge 134 and a portion of the internal surface 140 of the substrate 14, and also extends outward beyond the edge 134 of the substrate 14 in the opposite direction.

[0056] Next, as shown in [Fig. 24], in the third phase of the molding process, the overmold cavity 136 is formed by modifying the second mold piece 126 in any desired manner. In this example, the overmold cavity 136 and the resulting overmolded layer 16 are the same as those described in [Fig. 21]. [Fig. 25] illustrates a mold system in which the seal 132"' extends outwards over a shorter distance than the seals 132 and 132' shown in Figures 21 and 24, where these seals 132, 132' have a shaped portion general U or V with two lips joined together and arranged towards the outside of the substrate 14. The joint 132" shown in [Fig.25] includes a single lip and covers a portion of the internal surface 140 of the substrate 14 as in the example of Figures 23 and 24.

[0057] Figure 26 illustrates mold parts that define a joint 142 that does not extend outwards only for a relatively short distance beyond the edge 134 of the substrate 14. The joint 142 in this example overlaps the edge 134 of the substrate 14 and a portion of the inner surface 140 of the substrate 14. The overmolded layer 16 is shown molded onto the outer surface 138 of the substrate 14, and overlapping the portion of the joint 142 that extends outwards beyond the edge of the substrate 134. The overmolded layer 16 and the joint 142 are shown flush outside the substrate 14, but this is not necessary.

[0058] Figure 27 illustrates mold parts which, like the seal 142 shown in the [Fig. 26] define a seal 144 that extends outwards only a relatively short distance beyond the edge 134 of the substrate 14, and that extends inwards (in the direction from the outer surface to the inner surface) beyond the portion of the seal 144 that overlaps and is molded towards the peripheral edge 134 of the substrate 14. This portion of the seal 144 can provide a lip 146 that engages with an adjacent surface when installed on the vehicle. The seal 144 in this example overlaps the edge 134 of the substrate 14 and a portion of the inner surface 140 of the substrate 14. The overmolded layer 16 is shown molded onto the outer surface 138 of the substrate, and overlapping the portion of the seal 144 that extends outwards beyond the edge of the substrate 134.

[0059] Figures 28-31 represent a mold system 150 and a process for forming a component comprising a substrate 14, an overmolded layer 16 and edge seals 152 (Figures 30 and 31) on opposite sides of a substrate 14. As shown in [Fig.28], the mold system 150 includes a first mold piece 154, a second mold piece 156 and a pair of movable third mold pieces 158 arranged in a first position and at opposite sides of the first and second mold pieces. The first mold cavity 160 is defined in part by each of the mold parts 154, 156, 158, and as shown in [Fig. 29], in a first phase of a molding process using the mold system 150, the substrate 14 is molded within the first mold cavity 160. In a second phase of the molding process using the mold system 150, as shown in [Fig.30], the pair of third mold pieces 158 is moved to a second position in which cavities 162 (for example one in each third mold piece) are aligned with opposite sides of the substrate 14. The cavities 162 define a part of the third mold cavities 164 in which . The edge seams 152 are molded onto the substrate 14. The third mold cavities 164 are also partially defined by the substrate 14 and may also be partially defined by one or both of the first and second mold pieces 154, 156. Finally, as shown in [Fig. 31], in a third phase of the molding process using the mold system 150, the second mold piece 156 is modified to define the overmold cavity 166 between the second mold piece 156', the external substrate surface 138, and the edge seams 152. To complete the molding process, the material for the overmolded layer 16 is injected into the overmold cavity 166.

[0060] Figures 32-34 show a mold system 170 in which the first mold cavity 172 ([Fig.32]) is defined by a first mold piece 174, a second mold piece 176 and a third movable mold piece 178. After the substrate 14 is formed, the third mold piece 178 is moved to define, together with the substrate 14 and the first mold piece 174, the third mold cavity 180 ([Fig.33]) for the seal 182 which is molded onto the substrate 14. Finally, in [Fig.34], the second mold piece 176' is modified to define the overmold cavity 184 and the overmolded layer 16 is formed on the substrate 14 and on a portion of the seal 182.

[0061] Figures 35-38 show components 190, 192, 194, 196 that can be formed with a mold system similar to that of Figures 32-34, including mold parts of different shapes to provide overmolded layers 16 of different shapes and seals 191, 193, 195, and 197, as required. With movable mold parts used to form the seal, the seal can extend beyond the edges of the substrate and provide one or more protruding lips. Figure 39 illustrates component 194 shown in Figure 37 installed next to an adjacent vehicle component 200, where seal 195 engages with component 200 and provides a barrier against contaminants entering a gap 202 between components 194 and 200. Figures 40 and 41 illustrate respectively a component 204 and component 196 shown in Figure 38, where seals 206 and 197 bridge gaps 208 and 210 between the components and another component 200.Eliminating or reducing a visible gap can give components an improved or cleaner appearance, and can also help limit the accumulation of contaminants in the gap between adjacent components.

[0062] In at least some embodiments, the various mold systems provide improved sealing of a cavity in which an overmolded layer is formed on a substrate. Some materials used for the overmolded layer have low viscosity and are pressure molded, so the material tends to flow along the parting lines and form burrs. The burrs are then trimmed, which consumes labor and time and can affect the surface finish and The durability of the overmolded layer is compromised because the cut area is more susceptible to environmental damage. In some implementations, the overmolded layer defines part of the overall exterior presentation surface or "Class A" exterior surface of a component, and thus the surface finish and integrity of the overmolded layer can be important to the final product.

[0063] In certain embodiments, improved sealing is achieved by an overflow seal that is carried by or attached to a mold part. The overflow seal is compressible against the mold parts and / or the substrate to create a seal against the overflow or spillage of the material forming the overmolded layer. In this way, the boundary of the overmolded layer can be better controlled so that no burrs form and no subsequent trimming operations are required. The overflow seal can be provided on a fixed or moving mold part and can be positioned and used selectively to create a seal when and where necessary. The seal material can have a suitable hardness to provide the desired compression of the seal while also maintaining the structural integrity of the seal so that it can provide a desired finished shape to the adjacent area of ​​the overmolded layer.Furthermore, the gasket material can be selected to be moldable into a desired shape and to provide the required sealing integrity, preventing adhesion or bonding of the molded materials to the gasket, with or without the use of release agents. The overflow gasket can be inexpensive and easy to maintain, clean, or replace within a mold part when worn or fouled. The gasket can be in a fixed position on a mold part or on a movable mold part, and can be attached to an adjustable pneumatic or hydraulic slide to allow adjustment of the contact pressure so that there is sufficient sealing force for the process without pushing the substrate / moldable article out of position within the mold cavity.

[0064] In certain embodiments, improved sealing is achieved by a gasket that is itself overmolded onto the substrate before the overmolding of the overmolded layer. A wide variety of gasket and overmolded layer configurations are possible, to achieve a broad range of functions for various molded components. The gasket not only serves to limit or prevent overflow of the overmolding material and the formation of burrs during product formation, but it can also serve as a seal or hole filler on the finished product.

[0065] In at least some embodiments, a component formation process includes molding a substrate in a first mold cavity, providing an overmold cavity that is partly defined by the substrate, and molding an overmolded layer in the overmold cavity and onto the substrate. The overmold cavity is partly defined by an overflow seal that is carried by (e.g., attached to) a mold part and seals that portion of the overmold cavity. The overflow seal butts against and seals another mold part and a portion of the substrate, creating a seal at a parting line between adjacent mold parts and the substrate. During the molding of the overmolded layer, the seal can be pinched between mold parts and also between a mold part and the substrate at spaced locations to provide multiple sealed areas to inhibit or prevent overflow of the overmold material.

[0066] In at least some embodiments, a component formation process includes molding a substrate in a first mold cavity, providing a mold cavity for a seal where the seal mold cavity is defined in part by the substrate and molding a seal onto the substrate, and defining an overmold cavity that is defined in part by the substrate and the seal, and molding an overmolded layer into the overmold cavity and onto the substrate and the seal. The seal molded onto the substrate butts against and seals multiple mold parts and a portion of the substrate, and creates a seal at a parting line between adjacent mold parts and the substrate.

[0067] In at least some embodiments, a substrate is molded into a first mold cavity. Without opening the mold tools, another mold cavity is formed for a seal, which is then molded onto the substrate. Next, the mold tool can optionally be opened so that another mold tool can be provided, which defines part of an overmold cavity. Then, the mold tool is closed, and the seal is pinched between the mold parts, including the other mold tool, creating one or more seals to prevent leakage of the overmolded layer material when it is molded onto the substrate. Finally, the tool is opened, and the formed component, including the substrate, the overmolded layer, and the seal, is removed from the mold.

[0068] The forms of the innovations disclosed herein represent currently preferred embodiments, and many other forms and embodiments are possible. It is not intended here to mention all possible forms or equivalent ramifications of the innovations. It is understood that the terms used herein are purely descriptive, rather than restrictive, and that various changes may be made without departing from the spirit or scope of this disclosure.

[0069] All terms used in the claims are deemed to have their broadest acceptable meaning and ordinary meanings as understood by a person skilled in the art, unless expressly stated otherwise herein. In particular, the use of singular articles such as "a", " "the", "the said", etc. should be read to cite one or more of the indicated elements, unless a claim specifies an explicit limitation to the contrary.

Claims

Demands

1. A method for forming an overmolded component, comprising: • an arrangement of a first mold piece (18, 36, 50, 74, 94, 124, 124', 154, 174) and a second piece (20, 38, 58, 58', 76, 76', 96, 96', 126, 126', 156, 176, 176') with at least a portion of a first mold cavity (22, 34, 56, 72, 92, 122, 160, 172) defined by the first mold piece (18, 36, 50, 74, 94, 124, 124', 154, 174) and the second mold piece (20, 38, 58, 58', 76, 76', 96, 96', 126, 126', 156, 176, 176'); • a supply of a material to form a substrate (14) in the first mold cavity (22, 34, 56, 72, 92, 122, 160, 172);• a supply of an overmold cavity (26, 44, 60, 60', 66, 80, 100, 100', 136, 166, 184) which is defined at least in part by the substrate (14), one or both of the first mold piece (18, 36, 50, 74, 94, 124, 124', 154, 174) and of the second mold piece (20, 38, 58, 58', 76, 76', 96, 96', 126, 126', 156, 176, 176'), and a seal (28, 48, 54, 54', 78, 102, 132, 132', 132", 142, 144, 152, 182, 191, 193, 195, 197, 206) which engages with the substrate and also engages with one or both of the first mold piece (18, 36, 50, 74, 94, 124, 124', 154, 174) and the second mold piece (20, 38, 58, 58', 76, 76', 96, 96', 126, 126', 156, 176, 176'); and • a supply of material for an overmolded layer (16, 100, 136, 166, 184, 191, 193, 195, 197, 206) in the overmold cavity (26, 44, 60, 60', 66, 80, 100, 100', 136, 166, 184).;

2. Method according to claim 1, wherein the seal (28) is carried by the first mold piece (18) and comes into contact with the second mold piece (20) and the substrate (14).

3. Method according to claim 2, wherein the overmold cavity (26) is defined by the substrate (14), the second mold piece (20) and the seal (28).

4. Method according to claim 2, wherein the first mold piece (18) includes a cavity (130) and the seal (28) is located in the cavity (130).

5. A method according to claim 1, which also includes supplying a third mold piece (24, 46, 52, 98, 128, 128', 158) to define a portion of the overmold cavity (44, 60, 100, 136, 166), and in which the seal (48, 54, 78, 102, 132, 132', 152) is fixed to the third mold piece (24, 46, 52, 98, 128, 128', 158).

6. Method according to claim 1, wherein the seal (28, 48, 54, 78, 102, 132, 132', 152) is compressed during the formation of the overmolded layer (16).

7. A method according to claim 5, wherein the seal (48, 54, 78, 102, 132, 132') is compressed during the formation of the overmolded layer (16) and the seal comes into contact with the second mold piece (38, 58, 76, 96, 126, 126') and the substrate (14).

8. Method according to claim 5, wherein the joint (102, 132, 132') engages with the first mold piece (94, 124, 124'), the second mold piece (96, 126, 126') and the substrate (14).

9. A method according to claim 1, which also includes supplying a third mold piece (128, 128', 158) and wherein the seal (132, 132', 152) is fixed to the third mold piece, and the seal defines a portion of the first mold cavity (122, 122').

10. A method according to claim 9, wherein the third mold piece (128, 128') can be moved from a first position in which the seal (132, 132') defines a part of the first mold cavity (122, 122') to a second position in which the seal defines a part of the overmold cavity (136, 136').

11. A method according to claim 1, which also includes supplying a third mold piece (98, 178) and a fourth mold piece (104), wherein the method includes positioning the third mold piece (98, 178) so that the third mold piece (98, 178) defines a portion of the first mold cavity (92), and after the material for the substrate (14) is supplied into the first mold cavity, a displacement of the third mold piece (98) and supplying a fourth mold piece (104) which includes the seal (102) to define a portion of the overmold cavity (100).

12. A method according to claim 5, wherein a portion of the third mold piece (128, 128') spaced from the joint (132, 132') defines a part of the first mold cavity (122, 122') such that the joint does not define a part of the first mold cavity, and the method includes a displacement of the third mold piece (128, 128') from a first position in which the third mold piece defines a part of the first mold cavity (122, 122') to a second position in which the joint (132, 132') defines a part of the overmold cavity (136, 136').

13. A method for forming an overmolded component, comprising: • an arrangement of a first mold piece (124, 124', 154), a second piece (126, 126', 156) and a third mold piece (128, 128', 158) to define at least a portion of a first mold cavity (122, 122', 160); • a supply of material to form a substrate (14) in the first mold cavity (122, 122', 160); • an arrangement of the first mold piece (124, 124'), the second mold piece (126, 126') and the third mold piece (128, 128') to define a joint mold cavity (130, 130', 164), where the joint cavity is defined in part by the substrate (14); • a supply of a material for a joint (132, 132', 132”, 152) in the joint mold cavity (130, 130', 164); • a supply of an overmold cavity (136, 136', 166) which is defined at least in part by the joint (132, 132', 152) and the substrate (14);and • a supply of a material for an overmolded layer (16) in the overmolding cavity (136, 136', 166).;

14. A method according to claim 13, wherein the overmold cavity (100, 136, 166) is partly defined by a fourth mold piece (104) which is different from the first mold piece (94, 124), the second mold piece (96, 126) and the third mold piece (98, 128).

15. A method according to claim 13, wherein the third mold piece (128, 128') can be moved relative to the first piece of mold (124, 124') and to the second mold piece (126, 126') from a first position in which the third mold piece (128, 128') defines a part of the first mold cavity (122, 122') to a second position in which the third mold piece defines a part of the joint mold cavity (130, 130').

16. Method according to claim 15, wherein the joint mold cavity (130, 130') is defined by the first mold piece (124, 124'), the second mold piece (126, 126'), the third mold piece (128, 128') and the substrate (14).

17. A method according to claim 15, wherein the first mold piece (124, 124') defines a portion of the first mold cavity (122, 122') which defines at least a part of an internal surface (140) of the substrate (14), the second mold piece (126, 126') defines a portion of the first mold cavity (122, 122') which defines at least a part of an external surface (138) of the substrate (14), and the third mold piece (128, 128') defines a part of the first mold cavity (122, 122') which defines at least a part of a peripheral edge (134) of the substrate (14) between the internal surface (140) and the external surface (138).

18. Method according to claim 17, wherein the joint mold cavity (130, 130') is defined in part by the peripheral edge (134) of the substrate (14).

19. Method according to claim 13, wherein the seal (132, 132', 152) is compressed by one or more of the first mold piece (124, 124'), the second mold piece (126, 126') and the third mold piece (128, 128') to close a portion of the overmold cavity (136, 136').

20. Method according to claim 14, wherein the seal (102) is compressed by the fourth mold piece (104) to close a part of the overmold cavity (100).

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