System and method of manufacturing paint-free vehicle body panels

Abstract

Systems and methods that facilitate the production of paint-free vehicle body panels with improved manufacturing productivity, part surface quality, end-user functionality, and long-term performance over incumbent material and process technology. The painting step is eliminated from the production workflow, reducing manufacturing complexity and production cycle time in comparison to existing techniques.

Description

SYSTEM AND METHOD OF MANUFACTURING PAINT-FREEVEHICLE BODY PANELSCLAIM OF PRIORITY

[0001] This patent application claims the benefit of priority to Pezeshkian et al, U.S. Provisional Patent Application Serial Number 63 / 618,472, entitled “SYSTEM AND METHOD OF MANUFACTURING PAINT-FREE VEHICLE BODY PANELS,” filed on January 8, 2024, which is hereby incorporated by reference herein in its entirety.BACKGROUND

[0002] Traditional vehicle body panels are commonly constructed of stamped metal alloys or injection- and / or compression-molded polymers that require subsequent paint application to impart premium appearance and maintain in-field durability. These coatings are typically applied by spray in a complex, multi-stage process and in elaborate, capital-intensive facilities. Reactioninjection molding (RIM) has been used in the past to form and / or finish small parts for use on vehicles. In RIM, a set of resins are combined during injection molding, upon which a polymerization reaction occurs and a durable material is formed.SUMMARY

[0003] The current disclosure is directed to systems and methods for manufacturing paint-free vehicle body panels. In particular, the present disclosure is directed towards the parallel operations of molding, surface treatment, finishing, and demolding of vehicle body panels that facilitates the production of paint-free vehicle body panels with improved manufacturing productivity, part surface quality, end-user functionality, and long-term performance over incumbent material and process technology. Significantly, the painting step is eliminated from the production workflow, reducing manufacturing complexity and production cycle time in comparison to existing techniques.

[0004] In one or more embodiments, the thickness of a coating layer is directly controlled by altering the spacing between core and cavity sides of themold. In one or more embodiments, novel surface effects can be achieved leveraging the mold finish with no change to the coating formulation or additional surface preparation. In certain embodiments, aesthetic and functional films, including in-mold electronics, can be incorporated between the substrate and the coating by insertion into the mold during the disclosed methods.

[0005] In some embodiments, a method of manufacturing a paint-free vehicle panel is provided. The method comprises: injecting resin into a first cavity of a mold for the panel to form a body panel substrate; and injecting a reactive resin into a second cavity of the mold, the reactive resin injected adjacent the body panel substrate. In one or more embodiments, the reactive resin bonds to the body panel substrate and produces a paint-free coating on the body panel substrate. In one or more embodiments, the reactive resin injected into the second cavity of the mold is the only finishing step. In certain embodiments, particular pigments may be incorporated into the reactive resin to achieve desired aesthetic effects.

[0006] In one or more embodiments, a method of manufacturing a paint-free vehicle panel is provided. The method comprises: injecting resin into a first cavity adjacent a first side of a multi-sided mold; turning the multi-sided mold; surface treating the resin on the first side of the multi-sided mold while injecting resin into the first cavity adjacent a second side of the multi-sided mold; injecting a reactive resin into a second cavity adjacent the first side of the multisided mold while surface treating the resin on the second side of the multi-sided mold, and injecting resin into the first cavity adjacent a third side of the multisided mold; and demolding the resin on the first side of the multi-sided mold while injecting a reactive resin into the second cavity adjacent the second side of the multi-sided mold, surface treating the resin on the third side of the multisided mold, and injecting resin into the first cavity adjacent a fourth side of the multi-sided mold.

[0007] In another embodiment a multi-sided mold is provided. The multisided mold comprises: four mold sides, each of the mold sides configured to define a cavity with two mold halves, and a surface treatment tool engaged with the multi-sided mold, the surface treatment tool configured to apply at least one of flame, plasma, corona and / or spray-applied primer to at least one of the molded sides.FIGURES

[0008] FIG. 1 depicts a flow diagram of a method of manufacturing a paint- free body panel, in accordance with an embodiment of the current disclosure.

[0009] FIG. 2 depicts a flow diagram of a method of using a multi-sided mold to manufacture a paint-free body panel, in accordance with an embodiment of the current disclosure.

[0010] FIG. 3 A depicts a multi-sided mold in a first position, in accordance with an embodiment of the current disclosure.

[0011] FIG. 3B depicts a multi-sided mold in a second position, in accordance with an embodiment of the current disclosure.

[0012] FIG. 3C depicts a multi-sided mold in a third position, in accordance with an embodiment of the current disclosure.

[0013] FIG. 3D depicts a multi-sided mold in a fourth position, in accordance with an embodiment of the current disclosure.

[0014] FIG. 4A depicts a multisided mold in a first position, in accordance with an embodiment of the current disclosure.

[0015] FIG. 4B depicts a multi-sided mold in a second position, in accordance with an embodiment of the current disclosure.

[0016] FIG. 4C depicts a multi-sided mold in a third position, in accordance with an embodiment of the current disclosure.

[0017] FIG. 4D depicts a multi-sided mold in a fourth position, in accordance with an embodiment of the current disclosure.

[0018] FIG. 5 depicts a mold in various steps of manufacturing a paint-free body panel, in accordance with an embodiment of the current disclosure.

[0019] FIG. 6 depicts an illustrative body panel with various options of finishes, in accordance with an embodiment of the current disclosure.

[0020] FIG. 7 depicts an illustrative gate design, in accordance with an embodiment of the current disclosure.

[0021] FIG. 8A depicts an illustrative vent design, in accordance with an embodiment of the current disclosure.

[0022] FIG. 8B depicts a traditional vent design known in the art.

[0023] FIG. 9A depicts a first illustrative seal design, in accordance with an embodiment of the current disclosure.

[0024] FIG. 9B depicts a second illustrative seal design, in accordance with an embodiment of the current disclosure.

[0025] FIG. 9C depicts a third illustrative seal design, in accordance with an embodiment of the current disclosure.

[0026] FIG. 9D depicts a fourth illustrative seal design, in accordance with an embodiment of the current disclosure.

[0027] FIG. 9E depicts a fifth illustrative seal design, in accordance with an embodiment of the current disclosure.

[0028] FIG. 10A depicts a first traditional approach to trimming.

[0029] FIG. 10B depicts a second traditional approach to trimming.DETAILED DESCRIPTION

[0030] The present disclosure is generally directed to systems and methods for manufacturing paint-free vehicle body panels using, for example, the parallel operations of molding, surface treatment, finishing, and demolding of vehicle body panels that facilitate the production of paint-free vehicle body panels with improved manufacturing productivity, part surface quality, end-user functionality, and long-term performance over incumbent material and process technology. Significantly, the painting step is eliminated from the production workflow, reducing manufacturing complexity and production cycle time in comparison to existing techniques. Until now, RIM has been used to form small parts for use on vehicles, but RIM has not been used for vehicle body panels, which are much larger and more complex to form using RIM.

[0031] The system comprises a multi-sided mold which may be turned such that each face of the multi-sided mold can be facing a different stage during manufacturing. In some embodiments, the multi-sided mold may be configured to engage with at least two mold halves. In some embodiments, four sides of the multi-sided mold are configured to define at least one cavity with at least one of the mold halves such that when the mold halves are closed, a resin may be injected into the cavity through a first injection gate. In some embodiments, when the resin is injected into the cavity formed by a first side of the multi-sided mold and a first mold half, a substrate for a vehicle body panel is formed. Once the resin solidifies adequately, the mold halves may be opened, and the multisided mold may be turned such that the first side of the multi-sided mold nowhas a body panel substrate attached and a second side of the multi-sided mold is facing the first injection gate. The mold halves may then be closed, and the resin may be injected into the cavity formed by the second side of the multi-sided mold and a second mold half to form a second body panel substrate.

[0032] In one or more embodiments, running in parallel with the forming of the second body panel substrate, surface treatment may be applied to the first body panel substrate attached to the first side of the multi-sided mold. The surface treatment prepares the substrate to bond to a reactive resin. In some embodiments, the surface treatment may be flame, plasma, corona, or spray- applied primer. The mold halves may be opened again to turn the multi-sided mold such that the first side is adjacent a second injection gate. The above processes may be repeated along with injecting a reactive resin adjacent to the first body panel substrate through the second injection gate such that the reactive resin bonds to the first body panel substrate to form a finished surface. The cavity on the side of the second injection gate is deeper than the cavity on the side of the first injection gate to allow the reactive resin to evenly coat the body panel substrate. When the reactive resin is cured, the mold halves may be opened, and the first body panel substrate may be demolded and used without needing a separate finishing step. The first side of the multi-sided mold is then free to be rotated to the first injection gate to repeat the process.

[0033] Referring now to FIG. 1, there is shown an illustrative method 100 of manufacturing a paint-free body panel using resin in accordance with certain embodiments. At step 110, a resin is injected into a first cavity of a mold for the panel to form a molded resin. The molded resin may also be referred to as a substrate. At step 120, a reactive resin is injected into a second cavity of the mold adjacent the substrate, such that the reactive resin bonds to the substrate and produces a paint-free coating on the substrate. The reactive resin bonding to the substrate is the only finishing step required. No painting or polishing steps are required. In some embodiments, the reactive resin is polyurethane-based. In some embodiments, the reactive resin is polyurea-based. In some embodiments, the method 100 may include surface treating the substrate prior to injecting the reactive resin to prepare the substrate to bond to the reactive resin.

[0034] Referring now to FIGS. 2 and 3A-D, there is shown an illustrative method 200 of using a multi-sided mold 300 to manufacture a body panel usingresin in accordance with certain embodiments. At step 210, a resin is injected into a first cavity 355 adjacent a first side 310 of the multi-sided mold 300 using a first injection system 350 through an injection gate 385. The injected resin solidifies to form a molded substrate, which may also be referred to as a first body panel substrate 330. In some embodiments, the resin is comprised of at least one of the group comprising: polypropylene-based resins, polycarbonate- based resins, polyester-based resins, polyamide-based resins, and styrenic copolymers. In some embodiments, the first mold half 380 may be textured such that the coating of the reactive resin becomes textured as well (as shown in FIG. 6). In order to achieve this, the first mold half 380 may be changed out at any time to change the coating pattern or depth. In some embodiments, the first mold half 380 may be polished to provide a glass-like finish to the body panel. In some embodiments, the first mold half 380 may be textured to provide a matte and / or satin finish on the body panel.

[0035] At step 220, the multi-sided mold 300 is turned on a turntable or rotating platen 307. In some embodiments, the turntable / rotating platen 307 must be able to hold more than 100 tons to allow for the manufacturing of large body panels. In some embodiments, in place of a rotary configuration, manufacturing may progress linearly through a series of molding stations with the part supported by a mold core engaging with an opposing set of mold halves on a sliding table or platen. The part progresses sequentially from station to station until the body panel is completely formed. In some embodiments, the sliding table / platen must be able to hold more than 100 tons.

[0036] At step 230, the first body panel substrate 330 attached to the first side 310 of the multi-sided mold 300 is surface-treated to prepare it for the finishing step. While the first body panel substrate 330 receives surface treatment 360, a second side 315 of the multi-sided mold 300 is adjacent the first cavity 355 into which the resin is injected through the injection gate 385, forming a second body panel substrate 335. In some embodiments, the resin is polypropylene-based, which should be surface treated to enable bonding to other materials. The surface treatment allows the reactive resin to bond sufficiently to the body panel substrate.

[0037] At step 240, the first side 310 of the multi-sided mold 300 is forming a second cavity 365 with the second mold half 375. A reactive resin may beinjected into the second cavity 365 to apply a coating 332 on the first body panel substrate 330 using a second injection system 370. In some embodiments, while the reactive resin is injected into the second cavity 365, the second body panel substrate 335 attached to the second side 315 of the multi-sided mold 300 may be surface treated 360, and the first cavity 355, now adjacent a third side 320 of the multi-sided mold 300, may be injected with resin through the injection gate 385, forming a third body panel substrate 340. In some embodiments, the reactive resin is polyurethane-based. In some embodiments, the reactive resin is polyurea-based.

[0038] Step 240 may also be referred to as the finishing step, as it does not require any finishing once it has been demolded. Traditionally, a body panel requires several finishing steps. However, in some embodiments, using this method, step 240, which may include coating the first body panel substrate 330, is the only finishing step, and the first body panel substrate 330 does not need any other finishing steps after it has been demolded with the coating 332 molded to it. In some embodiments, another material 334 may be inserted into the second cavity 365 prior to injecting the reactive resin. The other material 334 may be at least one of aesthetic and / or functional films, such as electronic films, heating elements, lighting elements, and / or sensors. This may provide aesthetic appeal by providing, for example, lights embedded in the body panels. This may also provide, for example, an effective deicer when heating is inserted into the body panels. There has been a problem with car handles and doors being frozen shut by freezing rain, for example; heating in the body panels would provide a way to melt the ice enough for the doors to be opened.

[0039] In some embodiments, the second mold half 375 may be textured such that the coating of the reactive resin becomes textured as well (as shown in FIG. 6). In order to achieve this, the second mold half 375 may be changed out at any time to change the coating pattern or depth. In some embodiments, the second mold half 375 may be polished to provide a glass-like finish to the body panel. In some embodiments, the second mold half 375 may be textured to provide a matte and / or satin finish on the body panel.

[0040] At step 250, the first body panel substrate 330 attached to the first side 310 of the multi-sided mold 300 may be demolded 390. A person of skill in the art would understand how to appropriately demold a body panel substrate.As the finishing step has already been completed, the first body panel substrate 330 is ready to be used right after it is demolded without any extra finishing steps. While the first body panel substrate 330 attached to the first side 310 of the multi-sided mold 300 is being demolded 390, the reactive resin may be injected into the second cavity 365 adjacent the second body panel substrate 335 attached to the second side 315 of the multi-sided mold 300, the third body panel substrate 340 attached to the third side 320 of the multi-sided mold 300 may receive surface treatment, and resin may be injected into the first cavity 355 adjacent a fourth side 325 of the multi-sided mold 300 through the injection gate 385 to form a fourth body panel substrate 345.

[0041] In one or more embodiments, the multi-sided mold 300 is made from a sufficiently strong and stiff material. In some embodiments, the material may be one of steel, aluminum, and / or a composite material. On four of the sides of the multi-sided mold 300, there may be a cavity formed in each side such that when paired with a certain mold half, the multi-sided mold 300 will form a certain body panel. In some embodiments, a given molding operation may enable the manufacture of multiple similar or dissimilar parts in a single injection step using a family or multi-cavity mold design. A person of skill in the art will understand that this multi-sided mold 300 design may be made for any vehicle body panel. The multi-sided mold 300 would be manufactured with the specific cavities needed to form the desired body panels.

[0042] A fifth side of the multi-sided mold 300 is configured to be engaged with a turntable / rotating platen 307 such that the multi-sided mold 300 may be turned at the completion of each step. Since the curing times of the different steps vary, a person of skill in the art will understand that the multi-sided mold 300 may not turn immediately after a step is completed, but it may have to wait for a different step to be completed before being turned. In addition, the temperatures required for solidifying or curing the different resins may vary as well and can be controlled independently.

[0043] Adjacent the second side 315 of the multi-sided mold 300, a surface treatment tool 360 is configured to provide surface treatment to the resin prior to injecting the reactive resin. In some embodiments, the surface treatment may be flame, plasma, corona, or spray-applied primer.

[0044] The turntable 307 may be engaged with a motor that is controlled by a controller 305 (shown in FIG. 3B). The controller 305 determines the rotation of the turntable 307 based on at least one of the curing times of the resin and the reactive resin, and the timing of the surface treatment. Each step must be fully completed before the controller engages the motor to turn the turntable 307. In some embodiments, the first mold half 380 and the second mold half 375 open prior to the multi-sided mold 300 turning in order to free the molded resin from the cavities 355, 365.

[0045] The first mold half 380 includes an injection gate 385 through which the first injection system 350 may inject resin into the first cavity 355.

[0046] In some embodiments of the present disclosure, the second mold half 375 may be substantially similar to the first mold half 380 to allow a thin coating of the reactive resin. In some embodiments, the second mold half 375 may define a deeper cavity than the first mold half 380 to allow a thicker coating of the reactive resin. The reactive resin may have a uniform or variable thickness. A person skilled in the art will understand the relationship between the difference of the depth of the cavities formed by the mold halves and the thickness of the reactive resin.

[0047] Referring now to FIGS. 4A-4B, there is shown an illustrative multisided mold 400 in various positions, in accordance with certain embodiments. Referring now to FIG. 4 A, in a first position 401 of the multi-sided mold 400, a first side 410 of the multi-sided mold 400 may be facing a first mold half 480. Together, the first side 410 and the first mold half 480 may define a first cavity 455. In some embodiments, the first mold half 480 may be engaged with a first injection system 450. The first injection system 450 may be configured to fill the first cavity 455 with a resin which is configured to solidify to form a body panel substrate. The body panel substrate may be referred to as a first body panel substrate 430.

[0048] Referring now to FIG. 4B, in a second position 402 of the multi-sided mold 400, a second side 415 of the multi-sided mold 400 may be facing the first mold half 480. Together, the second side 415 and the first mold half 480 define the first cavity 455. In some embodiments, the first mold half 480 may be engaged with a first injection system 450. The first injection system 450 may be configured to fill the first cavity 455 with a resin which is configured to solidifyto form a body panel substrate. The body panel substrate may be referred to as a second body panel substrate 435. While the multi-sided mold 400 is in the second position 402, the first side 410 of the multi-sided mold 400 may be adjacent to a second injection system 460. The second injection system 460 may be configured to inject a reactive resin onto the first body panel substrate 430. The injected reactive resin may form a first intermediate layer 434. In some embodiments, there may be a second mold half configured to engage with the second side 415 to define a second cavity. In some embodiments, the second injection system 460 may be configured to fill the second cavity with a reactive resin to form the first intermediate layer 434 on the first body panel substrate 430.

[0049] Referring now to FIG. 4C, in a third position 403 of the multi-sided mold 400, a third side 420 of the multi-sided mold 400 may be facing the first mold half 480. Together, the third side 420 and the first mold half 480 may define the first cavity 455. In some embodiments, the first mold half 480 may be engaged with a first injection system 450. The first injection system 450 may be configured to fill the first cavity 455 with a resin which is configured to solidify to form a body panel substrate. The body panel substrate may be referred to as a third body panel substrate 440. While the multi-sided mold 400 is in the third position 403, the second side 415 of the multi-sided mold 400 may be adjacent to the second injection system 460. The second injection system 460 may be configured to inject a reactive resin onto the second body panel substrate 435. The injected reactive resin may form a second intermediate layer 439. While the multi-sided mold 400 is in the third position 403, the first side 410 of the multisided mold 400 may be facing a third mold half 475. Together, the first intermediate layer 434 on the first body panel substrate 430 and the third mold half 475 may define a third cavity 465. In some embodiments, the third mold half 475 may be engaged with a third injection system 470. The third injection system 470 may be configured to fill the third cavity 465 with a reactive resin which is configured to solidify to form a first coating layer 432 adjacent to the first intermediate layer 434.

[0050] Referring now to FIG. 4D, in a fourth position 404 of the multi-sided mold 400, a fourth side 425 of the multi-sided mold 400 may be facing the first mold half 480. Together, the fourth side 425 and the first mold half 480 maydefine the first cavity 455. In some embodiments, the first mold half 480 may be engaged with a first injection system 450. The first injection system 450 may be configured to fill the first cavity 455 with a resin which is configured to solidify to form a body panel substrate. The body panel substrate may be referred to as a fourth body panel substrate 445. While the multi-sided mold 400 is in the fourth position 404, the third side 420 of the multi-sided mold 400 may be adjacent to the second injection system 460. The second injection system 460 may be configured to inject a reactive resin onto the third body panel substrate 440. The injected reactive resin may form a third intermediate layer 444. While the multisided mold 400 is in the fourth position 404, the second side 415 of the multisided mold 400 may be facing the third mold half 475. Together, the second intermediate layer 439 on the second body panel substrate 435 and the third mold half 475 may define the third cavity 465. In some embodiments, the third mold half 475 may be engaged with the third injection system 470. The third injection system 470 may be configured to fill the third cavity 465 with a reactive resin which is configured to solidify to form a second coating layer 437 adjacent the second intermediate layer 439. While the multi-sided mold 400 is in the fourth position 404, the first side 410 of the multi-sided mold 400 may be adjacent a demolding tool 490. The demolding tool 490 may be configured to demold the first body panel substrate 430 from the first side 410 of the multisided mold 400. In some embodiments, the two mold halves 475, 480 may have already been opened to allow the multi-sided mold 400 to move towards the demolding tool 490 such that the demolding tool 490 may demold the first body panel substrate 430 during the operation of the other steps outlined above. Once the first body panel substrate 430 has been demolded from the first side 410 of the multi-sided mold 400, the first side 410 may be moved towards the first mold half 480 to start the process over again. A person of skill in the art will understand that this process may be lengthened by adding sides to the multisided mold, such as to add more layers of coatings and / or surface treatments.

[0051] Referring now to FIG. 5, there is shown an example mold in various steps of manufacturing a paint-free body panel. At step 501, a first mold half 510 is adjacent a second mold half 580. A first injection system 550 may inject resin into a cavity defined by the first mold half 510 and the second mold half 580 to form a body panel substrate 530. At step 502, the body panel substrate 530 maybe surface-treated 560. At step 503, a second injection system 570 may inject a reactive resin into a cavity defined by the first mold half 510 and a third mold half 575 to form a coating 532 over the body panel substrate 530. At step 504, the body panel substrate 530 may be demolded 590 without needing any subsequent finishing steps, as the coating 532 provides a finishing surface for the body panel substrate 530. In some embodiments, the first side 510 may be moved between the steps on a sliding platen 508. In some embodiments, the sliding platen 508 must be able to hold more than 100 tons.

[0052] Generally, throughout this disclosure, resin may refer to at least one of the group comprising: polypropylene-based resins, polycarbonate-based resins, polyester-based resins, polyamide-based resins, and styrenic copolymers. Generally, throughout this disclosure, reactive resin may refer to at least one of the group comprising: polyurethane-based resins and polyurea-based resins. In some embodiments, at least one film may be inserted into at least one of the first cavity 355, 455, the second cavity, and / or the third cavity 365, 465 prior to injecting the resin and / or reactive resin, such that the film is embedded in the molded part. In some embodiments, the film may be an aesthetic film and / or a functional film. In some embodiments, the film may be at least one of the group comprising: electronic films, heating films, lighting films, adhesion promoting films, and other functional films. In some embodiments, the resin and / or the reactive resin may be formulated to achieve a clear, opaque, special effect, and / or tinted finish.

[0053] In some embodiments, at least one of a substrate, an intermediate layer, and / or a coating layer may be decorated and / or modified by at least one of the group comprising: printing, laser marking, and etching. In some embodiments, at least one of the mold halves may be at least one of textured and / or polished such that the resulting molded resin may be textured, polished, or some combination of the two. In some embodiments, the polished mold half may result in a molded resin which is high gloss. In some embodiments, the textured mold half may result in a molded resin which is matte, satin, and / or other texture.

[0054] Referring now to FIG. 6, there is shown an illustrative configuration 600 of a step in the panel manufacturing process. In this illustrative configuration, a first mold surface 610 is adjacent a substrate 620, which isadjacent a coating 645, which is adjacent a second mold surface 650. The coating 645 may be referred to as an outer finish layer 640 or may consist of additional layers. In some embodiments, at least one intermediate finish layers 630 may be adjacent the substrate 620 and the outer finish layer 640. In some embodiments, the side of the second mold surface 655 adjacent the outer finish layer 640 may be textured 660 to produce a matte finish 675, satin finish 685, or other textured finish on the outer finish layer 640. In some embodiments, the side of the second mold surface 655 adjacent the outer finish layer 640 may be polished 670 to produce a mirror or high gloss finish 665 on the outer finish layer 640. In some embodiments, the second mold surface 650 may be at least one of smooth 670 and / or textured 660, producing a substrate 620 that has a smooth finish and / or a textured finish. In some embodiments, the outer finish layer 640, the at least one intermediate finish layer 630, and / or the substrate 620 may be molded using a resin formulated to achieve a clear finish 690, opaque finish 693, special effect finish 695, and / or tinted finish 697. In some embodiments, the special effect finish 695 may achieve a metallic appearance. In some embodiments, an intermediate finish layer 630 may be an aesthetic or functional film. In some embodiments, at least one of heating, lighting, adhesion-promoting films, and / or other functional films may be inserted into the cavity prior to injecting resin. In some embodiments, the first mold surface 610 is the first side 310 of the multi-sided mold 300. In some embodiments, the substrate 620 is the first body panel substrate 330. In some embodiments, the outer finish layer is the coating 332. In some embodiments, the second mold surface 650 is the second mold half 375.

[0055] Referring now to FIG. 7, there is shown an illustrative gate design 700 in accordance with the disclosed principles. In some embodiments, the injection gate 385 (FIGS. 3A-3D) may comprise the design 700 according to FIG. 7. The illustrative gate design 700 may include a hot or cold runner 730 having a plurality of gates 710, 720. In some embodiments, there may be one center gate 710 and at least two outer gates 720. The number of gates 710, 720 may be determined by the substrate volume that needs to be filled. In some embodiments, at least one gate may be employed directly onto the substrate surface 750. In some embodiments, injection may occur simultaneously from all gates or in an appropriate sequence of gates. In some embodiments, theappropriate sequence of gates may be determined based on the desired distribution along the flow length 740.

[0056] Referring now to FIG. 8 A, there is shown an illustrative vent design 800 in accordance with the disclosed principles. Surrounding the perimeter of the coating 830, there may be an overflow vent 810. The overflow vent 810 provides an escape for air while the coating 830 is being injected into the mold. Referring to FIG. 8B, there is shown a traditional vent design 850 known in the art. In the traditional vent design 850, there is only one venting area 860 located at the last area to fill. As the injected material pressurizes, the air is forced out into the venting area 860. However, since there is only one venting area 860, there is a possibility of air bubbles remaining in the injected material, which will cause the final product to be defective. With an overflow vent 810 surrounding the perimeter of the coating 830 in accordance with the disclosed principles, as shown in FIG. 8A, trapped air has an additional outlet. In some embodiments, the coating 830 may be the coating 332 (FIG. 3C).

[0057] Referring now to FIG. 9 A, there is shown a first illustrative seal design 900 in accordance with the disclosed principles. The first illustrative seal design 900 may also be referred to as a three-shot design. A temporary seal 910 may be injected onto a side 917 of the tool 915. The temporary seal 910 may be incompatible with the resin forming the substrate 920 and the reactive resin forming the coating 925 such that the temporary seal 910 does not bond to either the substrate 920 or the coating 925 and can be removed without an additional operation, such as trimming. In some embodiments, the temporary seal 910 may be placed such that it provides a protective barrier for the tool 915 to avoid fluid, such as reactive resin, leaking into any crevices of the tool 915. In some embodiments, the temporary seal 910 may be a recyclable material that can be continuously reused. In some embodiments, the tool 915 may be the multi-sided mold 300 (FIGS. 3A-3D), and the side 917 of the tool 915 may be at least one of the first side 310, the second side 315, the third side 320, and / or the fourth side 325 of the multi-sided mold 300.

[0058] Referring now to FIG. 9B, there is shown a second illustrative seal design 930 in accordance with the disclosed principles. The tool 915 may include an overflow 935 around the perimeter of the substrate 920, such that when the resin is injected onto the tool 915, some resin may flow into theoverflow 935. The coating 925 may then be injected over the substrate 920 and may fill the remaining volume of the overflow 935. The overflow 935 may be trimmed by the application of mechanical load inside the tool or in a subsequent trimming operation at approximately the trim line 940 after substrate 920 is removed from the tool 915. In some embodiments, the trimming operation may consist of laser cutting, waterjet cutting, milling, or shearing. In some embodiments, the tool 915 may be the multi-sided mold 300 (FIGS. 3A-3D), and the side 917 of the tool 915 may be at least one of the first side 310, the second side 315, the third side 320, and / or the fourth side 325 of the multi-sided mold 300.

[0059] Referring now to FIG. 9C, there is shown a third illustrative seal design 950 in accordance with the disclosed principles. The tool 915 may include a seal 955 set at a short distance from the substrate 920 and coating 925. In some embodiments, the seal 955 may be a polymeric seal. The tool 915 may further include a space for a vestige 960 such that when the substrate 920 and coating 925 are injected, some reactive resin may at least partially fill the space for a vestige 960. The seal 955 may be adjacent the vestige 960 such that the reactive resin is prevented from leaking into the tool 915. When the substrate 920 is removed from the tool 915, the vestige 960 may be removed without cutting or trimming by the application of mechanical load inside the tool, or the vestige 960 may be trimmed at approximately the trim line 965. In some embodiments, the trimming operation may consist of laser cutting, waterjet cutting, milling, or shearing. In some embodiments, the tool 915 may be the multi-sided mold 300 (FIGS. 3A-3D, and the side 917 of the tool 915 may be at least one of the first side 310, the second side 315, the third side 320, and / or the fourth side 325 of the multi-sided mold 300.

[0060] Referring now to FIG. 9D, there is shown a fourth illustrative seal design 970 in accordance with the disclosed principles. The tool 915 may include at least one seal 975 adjacent the substrate 920 and the coating 925 such that the reactive resin is prevented from leaking into the tool 915. In some embodiments, the seal 975 may be included in both mold halves. In some embodiments, the seal 975 may be a polymeric seal. When the substrate 920 is removed from the tool 915, the seal 975 may be removed without cutting or trimming. In some embodiments, the tool 915 may be the multi-sided mold 300(FIGS. 3A-3D), and the side 917 of the tool 915 may be at least one of the first side 310, the second side 315, the third side 320, and / or the fourth side 325 of the multi-sided mold 300.

[0061] Referring now to FIG. 9E, there is shown a fifth illustrative seal design 990 in accordance with the disclosed principles. The tool 915 may include at least one slider or side action 995 that may act as a sealing surface adjacent the substrate 920 and the coating 925 such that reactive resin is prevented from leaking into the tool 915. To form an effective seal, the slider or side action 995 may consist of a different metal than the principal tool sides. The slider or side action 995 may incorporate design features to enable effective sealing. In some embodiments, the tool 915 may be the multi-sided mold 300 (FIGS. 3A-3D), and the side 917 of the tool 915 may be at least one of the first side 310, the second side 315, the third side 320, and / or the fourth side 325 of the multi-sided mold 300.

[0062] Referring now to FIGS. 10A-10B, there is shown a first traditional approach 1000 to trimming and a second traditional approach 1050 to trimming. In the first traditional approach 1000, the substrate 1020 is injected into the mold 1010. The coating 1030 is then injected onto the substrate 1020 with some portion of the substrate 1020 not covered where it interfaces with the mold surface 1010 to form a seal. In order to have a clean edge, the portion of the substrate 1020 not covered by the coating 1030 is cut off along a first cut line 1040. Then a portion of the substrate 1020 that is covered by the coating 1030 is cut off along a second cut line 1045 to provide a clean edge of both the substrate 1020 and the coating 1030. This approach results in additional material waste and a longer production process.

[0063] In the second traditional approach 1050, the substrate 1070 is injected onto the tool 1060 such that the substrate 1070 defines a cavity. The coating 1080 is then injected into the cavity defined by the substrate 1070 such that the coating does not contact the tool 1060. This second traditional approach 1050 does not require cutting or trimming, but the coating 1080 does not cover the whole substrate 1070. This approach visually exposes the substrate to the end user while increasing risk of environmental degradation, which may be undesirable for aesthetic or functional reasons.

[0064] It should further be noted that, although the functions and / or steps of the processes are depicted in a particular order or arrangement, the depicted order and / or arrangement of steps and / or functions is simply provided for illustrative purposes. Unless explicitly described herein to the contrary, the various steps and / or functions of the processes can be performed in different orders, in parallel with each other, in an interleaved manner, and so on.EXAMPLES

[0065] Some examples of this disclosure include the following:

[0066] Example 1 includes a method of manufacturing a paint-free vehicle body panel, the method comprising: injecting resin into a first cavity of a mold for the resin to form a body panel substrate; and injecting a reactive resin into a second cavity of the mold, the reactive resin injected adjacent the body panel substrate; wherein the reactive resin bonds to the body panel substrate and produces a paint-free coating on the body panel substrate.

[0067] Example 2 includes the method of example 1, wherein the reactive resin is a first reactive resin, the method further comprising: injecting a second reactive resin into a third cavity of the mold, the second reactive resin injected adjacent the first reactive resin; and wherein the first reactive resin forms a first intermediate finishing layer.

[0068] Example 3 includes the method of example 1 or example 2, wherein the reactive resin is configured to achieve at least one of a clear finish, a tinted finish, an opaque finish, and / or a special effect finish.

[0069] Example 4 includes the method of any one of examples 1-3, wherein at least one surface defining at least one of the first cavity and / or the second cavity of the mold is at least one of textured and / or polished.

[0070] Example 5 includes the method of any one of examples 1-4, further comprising: surface treating the body panel substrate prior to injecting the reactive resin.

[0071] Example 6 includes the method of any one of examples 1-5, further comprising: inserting at least one of aesthetic or functional films into the second cavity of the mold prior to injecting the reactive resin.

[0072] Example 7 includes a method of manufacturing a paint-free vehicle panel, the method comprising: injecting resin into a first cavity adjacent a first side of a multi-sided mold; turning the multi-sided mold; surface treating theresin on the first side of the multi-sided mold while injecting resin into the first cavity adjacent a second side of the multi-sided mold; injecting a reactive resin into a second cavity adjacent the first side of the multi-sided mold while surface treating the resin on the second side of the multi-sided mold, and injecting resin into the first cavity adjacent a third side of the multi-sided mold; and demolding the resin on the first side of the multi-sided mold while injecting a reactive resin into the second cavity adjacent the second side of the multi-sided mold, surface treating the resin on the third side of the multi-sided mold, and injecting resin into the first cavity adjacent a fourth side of the multi-sided mold.

[0073] Example 8 includes the method of example 7, wherein the resin is comprised of at least one of the group comprising: polypropylene-based resins, polycarbonate-based resins, polyester-based resins, polyimide-based resins, and styrenic copolymers.

[0074] Example 9 includes the method of example 7 or example 8, wherein the reactive resin is comprised of at least one of the group comprising: polyurethane-based resins and polyurea-based resins.

[0075] Example 10 includes the method of any one of examples 7-9, further comprising: inserting at least one of aesthetic or functional films into the second cavity of the mold prior to injecting the reactive resin.

[0076] Example 11 includes the method of any one of examples 7-10, wherein at least one surface defining at least one of the first cavity and / or the second cavity of the mold is at least one of textured and / or polished.

[0077] Example 12 includes a multi-sided mold, comprising: at least four mold sides, each of the mold sides configured to define a cavity with a mold half; and a surface treatment tool engaged with the multi-sided mold, the surface treatment tool configured to apply surface treatment to at least one of the mold sides.

[0078] Example 13 includes the multi-sided mold of example 12, wherein the cavity is a first cavity, and wherein the mold half is a first mold half, the multi-sided mold further comprising: a second mold half defining a second cavity configured to engage with the mold sides.

[0079] Example 14 includes the multi-sided mold of example 13 or example 14, wherein at least one of the first mold half and / or the second mold half is textured.

[0080] Example 15 includes the multi-sided mold of any one of examples 13-14, wherein at least one of the first mold half and / or the second mold half is polished.

[0081] Example 16 includes the multi-sided mold of any one of examples 13-15, wherein at least one of the first mold half and / or the second mold half is partially polished and partially textured.

[0082] Example 17 includes the multi-sided mold of any one of examples 12-16, further comprising: an injection system configured to engage with the cavity defined by at least one of the mold sides and the mold half.

[0083] Example 18 includes the multi-sided mold of example 17, further comprising: an injection gate adjacent the mold half, the injection gate configured to receive injections from the injection system.

[0084] Example 19 includes the multi-sided mold of any one of examples 12-18, further comprising: a sealing system adjacent the cavity, the sealing system configured to prevent fluid leaks.

[0085] Example 20 includes the multi-sided mold of any one of examples 12-19, wherein the mold half is removable.

[0086] This disclosure is not limited to the particular systems, devices and methods described, as these may vary. The terminology used in the description is for the purpose of describing the particular versions or embodiments only and is not intended to limit the scope of the disclosure.

[0087] The following terms shall have, for the purposes of this application, the respective meanings set forth below. Unless otherwise defined, all technical and scientific terms used herein have the same meanings as commonly understood by one of ordinary skill in the art. Nothing in this disclosure is to be construed as an admission that the embodiments described in this disclosure are not entitled to antedate such disclosure by virtue of prior invention.

[0088] As used herein, the singular forms “a,” “an,” and “the” include plural references, unless the context clearly dictates otherwise. Thus, for example, reference to a “vent” is a reference to one or more vents and equivalents thereof known to those skilled in the art, and so forth.

[0089] As used herein, the term “about” means plus or minus 10% of the numerical value of the number with which it is being used. Therefore, about 50 mm means in the range of 45 mm to 55 mm.

[0090] As used herein, the term “consists of’ or “consisting of’ means that the device or method includes only the elements, steps, or ingredients specifically recited in the particular claimed embodiment or claim.

[0091] In embodiments or claims where the term “comprising” is used as the transition phrase, such embodiments can also be envisioned with replacement of the term “comprising” with the terms “consisting of’ or “consisting essentially of”

[0092] While the present disclosure has been illustrated by the description of exemplary embodiments thereof, and while the embodiments have been described in certain detail, it is not the intention of the Applicants to restrict or in any way limit the scope of the appended claims to such detail. Additional advantages and modifications will readily appear to those skilled in the art. Therefore, the disclosure in its broader aspects is not limited to any of the specific details, representative devices and methods, and / or illustrative examples shown and described. Accordingly, departures may be made from such details without departing from the spirit or scope of the Applicant's general inventive concept.

[0093] With respect to the use of substantially any plural and / or singular terms herein, those having skill in the art can translate from the plural to the singular and / or from the singular to the plural as is appropriate to the context and / or application. The various singular / plural permutations may be expressly set forth herein for sake of clarity.

[0094] In addition, even if a specific number is explicitly recited, those skilled in the art will recognize that such recitation should be interpreted to mean at least the recited number (for example, the bare recitation of "two recitations," without other modifiers, means at least two recitations, or two or more recitations). Furthermore, in those instances where a convention analogous to “at least one of A, B, and C, et cetera” is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (for example, “a system having at least one of A, B, and C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, et cetera). In those instances where a convention analogous to “at least one of A, B, or C, et cetera” is used, in general such a construction is intended in the sense one havingskill in the art would understand the convention (for example, “a system having at least one of A, B, or C” would include but not be limited to systems that have A alone, B alone, C alone, A and B together, A and C together, B and C together, and / or A, B, and C together, et cetera). It will be further understood by those within the art that virtually any disjunctive word and / or phrase presenting two or more alternative terms, whether in the description, sample embodiments, or drawings, should be understood to contemplate the possibilities of including one of the terms, either of the terms, or both terms. For example, the phrase “A or B” will be understood to include the possibilities of “A” or “B” or “A and B.”

[0095] In addition, where features of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.

[0096] Various of the above-disclosed and other features and functions, or alternatives thereof, may be combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, each of which is also intended to be encompassed by the disclosed embodiments.

Claims

CLAIMS1. A method of manufacturing a paint-free vehicle body panel, the method comprising: injecting resin into a first cavity of a mold for the resin to form a body panel substrate; and injecting a reactive resin into a second cavity of the mold, the reactive resin injected adjacent the body panel substrate; wherein the reactive resin bonds to the body panel substrate and produces a paint-free coating on the body panel substrate.

2. The method of claim 1, wherein the reactive resin is a first reactive resin, the method further comprising: injecting a second reactive resin into a third cavity of the mold, the second reactive resin injected adjacent the first reactive resin; and wherein the first reactive resin forms a first intermediate finishing layer.

3. The method of claim 1, wherein the reactive resin is configured to achieve at least one of a clear finish, a tinted finish, an opaque finish, and / or a special effect finish.

4. The method of claim 1, wherein at least one surface defining at least one of the first cavity and / or the second cavity of the mold is at least one of textured and / or polished.

5. The method of claim 1, further comprising: surface treating the body panel substrate prior to injecting the reactive resin.

6. The method of claim 1, further comprising: inserting at least one of aesthetic or functional films into the second cavity of the mold prior to injecting the reactive resin.

7. A method of manufacturing a paint-free vehicle panel, the method comprising:injecting resin into a first cavity adjacent a first side of a multi-sided mold; turning the multi-sided mold; surface treating the resin on the first side of the multi-sided mold while injecting resin into the first cavity adjacent a second side of the multi-sided mold; injecting a reactive resin into a second cavity adjacent the first side of the multi-sided mold while surface treating the resin on the second side of the multisided mold, and injecting resin into the first cavity adjacent a third side of the multi-sided mold; and demolding the resin on the first side of the multi-sided mold while injecting a reactive resin into the second cavity adjacent the second side of the multi-sided mold, surface treating the resin on the third side of the multi-sided mold, and injecting resin into the first cavity adjacent a fourth side of the multisided mold.

8. The method of claim 7, wherein the resin is comprised of at least one of the group comprising: polypropylene-based resins, polycarbonate-based resins, polyester-based resins, polyimide-based resins, and styrenic copolymers.

9. The method of claim 7, wherein the reactive resin is comprised of at least one of the group comprising: polyurethane-based resins and polyurea-based resins.

10. The method of claim 7, further comprising: inserting at least one of aesthetic or functional films into the second cavity of the mold prior to injecting the reactive resin.

11. The method of claim 7, wherein at least one surface defining at least one of the first cavity and / or the second cavity of the mold is at least one of textured and / or polished.

12. A multi-sided mold, comprising:at least four mold sides, each of the mold sides configured to define a cavity with a mold half; and a surface treatment tool engaged with the multi-sided mold, the surface treatment tool configured to apply surface treatment to at least one of the mold sides.

13. The multi-sided mold of claim 12, wherein the cavity is a first cavity, and wherein the mold half is a first mold half, the multi-sided mold further comprising: a second mold half defining a second cavity configured to engage with the mold sides.

14. The multi-sided mold of claim 13, wherein at least one of the first mold half and / or the second mold half is textured.

15. The multi-sided mold of claim 13, wherein at least one of the first mold half and / or the second mold half is polished.

16. The multi-sided mold of claim 13, wherein at least one of the first mold half and / or the second mold half is partially polished and partially textured.

17. The multi-sided mold of claim 12, further comprising: an injection system configured to engage with the cavity defined by at least one of the mold sides and the mold half.

18. The multi-sided mold of claim 17, further comprising: an injection gate adjacent the mold half, the injection gate configured to receive injections from the injection system.

19. The multi-sided mold of claim 12, further comprising: a sealing system adjacent the cavity, the sealing system configured to prevent fluid leaks.

20. The multi-sided mold of claim 12, wherein the mold half is removable.

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