Two-shot injection compression molding technique for panel with edge molded second shot having weight reduction features

Abstract

A molding process for forming a part, with steps of injection molding, via a first shot, a base member, the base member defines a top face, a bottom face, and a perimeter edge; injection molding, via a second shot, an edge member around at least a portion of the perimeter edge of the base member, so that the edge member is formed to wrap around a portion of the top face and the bottom face of the base member, whereby the edge member defines: a top portion that is disposed against the top face of the base member; a bottom portion that is disposed against the bottom face of the base member; and an outer edge portion that extends outwardly from the perimeter edge of the base member, one of the top portion, the bottom portion and the outer edge portion of the edge member defines a weight-saving feature.

Description

23POLY0083 -WO-ORD 1TWO-SHOT INJECTION COMPRESSION MOLDING TECHNIQUE FOR PANEL WITH EDGE MOLDED SECOND SHOT HAIVNG WEIGHT REDUCTION FEATURES BACKGROUND

[0001] The embodiments herein relate to molding techniques and more specifically to a two-shot injection compression molding technique for a panel with an edge molded second shot having wight reduction features.

[0002] Large transparent panels for the automotive industry are typically made utilizing molding techniques. The molding process is typically a two-shot injection compression molding (2K-ICM) which provides for design freedom and part integration of a lightweight part. The part can be produced by this process with relatively low pressure, tonnage and residual stress, and have reasonable optical clarity. As two materials are utilized in this process, however, asymmetric cooling may cause warpage, which may affect the quality, aesthetics and ability of the panel to meet form, fit and function specifications.BRIEF SUMMARY

[0003] This disclosure provides a molding process for forming a part, the molding process including: injection molding, via a first shot, a base member, wherein the base member defines a top face, a bottom face, and a perimeter edge; injection molding, via a second shot, an edge member around at least a portion of the perimeter edge of the base member, so that the edge member is formed to wrap around a portion of the top face and the bottom face of the base member, whereby the edge member defines: a top portion that is disposed against the top face of the base member; a bottom portion that is disposed against the bottom face of the base member; and an outer edge23POLY0083 -WO-ORD 2portion that extends outwardly from the perimeter edge of the base member, wherein one of the top portion, the bottom portion and the outer edge portion of the edge member defines a weight-saving feature.BRIEF DESCRIPTION OF THE DRAWINGS

[0004] The following is a brief description of the drawings wherein like elements are numbered alike and which is presented for the purposes of illustrating the exemplary embodiments disclosed herein and not for the purposes of limiting the same.

[0005] FIG. 1 shows a top view of a base member of a panel manufactured according to an embodiment, with an edge member shown in hidden lines;

[0006] FIG. 2 shows a bottom view of a base member manufactured according to an embodiment, with the edge member shown in hidden lines;

[0007] FIG. 3 shows a top view of the base member with an edge member manufactured according to an embodiment, to define the panel;

[0008] FIG. 4 shows a bottom view of the panel according to an embodiment;

[0009] FIG. 5 is a sectional view of a portion of the panel, showing the edge member and base member according to an embodiment;

[0010] FIG. 6 is a sectional view of a portion of the panel, showing the edge member and base member according to another embodiment;23POLY0083 -WO-ORD 3

[0011] FIG. 7 is a sectional view of a portion of the panel, showing the edge member and base member, where the edge member has a weight saving feature in the form of a chamfer on inner facing ends, according to an embodiment;

[0012] FIG. 8 is a sectional view of a portion of the panel, showing the edge member and base member, where the edge member has a weight saving feature in the form of a chamfer on an outer facing end, according to an embodiment;

[0013] FIG. 9 is a sectional view of a portion of the panel, showing the edge member and base member, where the edge member has a weight saving feature in the form of a chamfer on another outer facing end, according to an embodiment;

[0014] FIG. 10 is a sectional view of a portion of the panel, showing the edge member and base member, where the edge member has a weight saving feature in the form of a groove on an outer facing surface, according to an embodiment;

[0015] FIG. 11 is a sectional view of a portion of the panel, showing the edge member and base member, where the edge member has a weight saving feature in the form of a groove on another outer facing surface, according to an embodiment;

[0016] FIG. 12 shows the panel having a plurality of discrete edge members, according to an embodiment;

[0017] FIG. 13 is a sectional view of a portion of the panel, showing the edge member and base member, where the edge member has a cavity configured for gas injection, according to an embodiment;

[0018] FIG.14 shows the panel utilized in an automobile, according to an embodiment;23POLY0083 -WO-ORD 4

[0019] FIG.15 shows the panel utilized as a display, according to an embodiment;

[0020] FIG. 16 shows the panel utilized for a personal computer case, according to an embodiment; and

[0021] FIG. 17 is a flowchart showing a method of manufacturing the panel, according to an embodiment.DETAILED DESCRIPTION

[0022] A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.

[0023] Turning to FIGS. 1 and 2, a base member 110 of a panel (or part) 100 is shown. The base member 110 can be formed by a first shot (IK) of an injection compression molding (ICM) process using a first nozzle 115.

[0024] The base member 110 is shown as being planar with a top surface 120A and a bottom surface 120B. The base member 110 extends along a longitudinal axis 130A between first and second ends 140A, 140B and along a transverse axis 130B, that is normal to the longitudinal axis 130A, between third and fourth ends 140C, 140D. The opposite ends, generally 140, form a perimeter edge 150. The base member 110 is shown as being planar but it may have other shapes, depending on the design requirements. It is to be appreciated that the utilization of top and bottom as labels is not intended to require any particular orientation of the panel 100.

[0025] Shown in dashed lines in FIGS. 1 and 2, and shown as a solid structure in FIGS. 3 and 4, is an edge member 160 that extends over the top surface 120A and the bottom surface 120B23POLY0083 -WO-ORD 5of the base member 110 of the panel 100. The edge member 160 can be formed by a second shot (2K) of the injection compression molding (ICM) process using nozzles 116, such as four nozzles, 116A-116D positioned along each end 140A-140D of the base member 110. The edge member 160 may be injection molded or gas injection molded or injection compression molding over the base member 110.

[0026] On the top surface 120A, the edge member 160 has a top portion 160A1 that extends along the perimeter edge 150, and between the perimeter edge 150 and an inner end 160B1 of the edge member 160 that is at a first distance DI (FIG. 1) from the perimeter edge 150. On the bottom surface 120B, the edge member 160 has a bottom portion 160A2 that is defined along the perimeter edge 150, between the perimeter edge 150 and an inner end 160B2 of the edge member 160 that is at a second distance D2 (FIG. 2) from the perimeter edge 150.

[0027] In one embodiment the first and second distances DI, D2 are the same as each other, though they may be different from each other. In one embodiment, the distances DI and D2 each may be one inch, or such other distance as determined to prevent warping of the panel 100 during manufacturing of the panel 100.

[0028] Turning to FIG. 5, the top portion 160A1 of the edge member 160 has a first thickness T1 between a bottom face 162A of the top portion 160A1 that faces the top surface 120A of the base member 110 and a top face 164A of the top portion 160A1 that faces away from the base member 110. The bottom portion 160A2 of the edge member 160 has a second thickness T2 between a top face 162B of the bottom portion 160A2 that faces the bottom surface 120B of the base member 110 and a bottom face 164B of the bottom portion 160A2 that faces away from the base member 110. In one embodiment, the first and second thicknesses Tl, T2 are the same as each other, though they may be different from each other.23POLY0083 -WO-ORD 6

[0029] The edge member 160 has an outer edge portion 160A3 that extends from the perimeter edge 150 away from the base member 110 from an inner edge 161Athat faces the perimeter edge 150 of the base member 110 to an outer edge 16 IB that faces away from the perimeter edge 150 of the base member 110 to define a third thickness T3. In the embodiment of FIG. 5, the third thickness T3 is greater than the first and second thicknesses Tl, T2.

[0030] The outer edge portion 160A3 has a top face 164C that is continuous with the top face 164A of the top portion 160A1 of the edge member 160 and a bottom face 164D that is continuous with the bottom face 164B of the bottom portion 160A2 of the edge member 160. With this configuration, the edge member 160 wraps around the perimeter edge 150 of the base member 110 to cover a top perimeter area 170A (FIG. 1) of the top surface 120A of the base member 110 and a bottom perimeter area 170B (FIG. 2) of the bottom surface 120B of the base member 110. A thickness T4 of the outer edge portion 160A3 between the top and bottom faces 164C and 164D of the outer edge portion 160A3, as shown in FIG. 5, is the sum of the thickness (a fifth thickness) T5 of the base member 110, and the first and second thicknesses Tl, T2 of the top and bottom portions 160A1, 160A2 of the edge member 160.

[0031] The top faces 164A, 164C of the top and edge portions 160A1, 160A3 of the edge member 160 may be collectively referred to as the top face 165 A of the edge member 160. The bottom faces 164B, 164D of the bottom and edge portions 160A2, 160A3 of the edge member 160 may be collectively referred to as the bottom face 165B of the edge member 160. The inner ends 160B1, 160B2 of the top and bottom portions 160A1, 160A2 may be generally referred to as the inner end 166A of the edge member 160. The outer edge 16 IB of the edge portion 160A3 shall alternatively be referred to as the outer end 166B of the edge member 160.23POLY0083 -WO-ORD 7

[0032] As shown in FIG. 6, in one embodiment, the first, second and third thickness T1-T3 of the edge member 160, formed around the base member 110, are the same as each other.

[0033] As shown in FIG. 7 the top portion 160A1 and the bottom portion 160A2 of the edge member 160 define first and second weight saving features 180 A, 180B (generally a weight saving feature 180). The first weight saving feature 180A is a first chamfer 190A (or top-inner edge feature) at the intersection of the top face 164A and the inner end 160B1 of the top portion 160A1. The first chamfer 190A narrows toward the base member 110. The second weight saving feature 180B is a second chamfer 190B (or bottom -inner edge feature) at the intersection of the bottom face 164B and the inner end 160B2 of the bottom portion 160A2. The second chamfer 190B narrows toward the base member 110, such that the first and second chamfers 190 A, 190B may have a same size and shape as each other. That is, in FIG.7, the weight saving features 180A, 180B are located along the top and bottom faces 165 A, 165B of the edge member 160, near the inner end 166 A of the edge member 160.

[0034] As shown in FIG. 8, another embodiment of the weight saving feature 180C can be another chamfer 190C (or a top-outer edge feature) defined along the intersection of the top face 164C (shown in a dashed line) and the outer edge 16 IB (shown partially in a dashed line) of the edge portion 160A3 of the edge member 160. That is, the edge portion 160A3 narrows toward the outer edge 16 IB, and the bottom faces 164B, 164D are coplanar. The taper may extend between a location 200A on the top face 164Athat is aligned with the inner edge 161 A of the edge portion 160A3, and a location 200B on the outer edge 161B that is aligned with the top face 162B of the bottom portion 160A2 of the edge member 160. That is, in FIG.8, the weight saving feature 180C is located along the top face 165 A of the edge member 160, at the outer end 166B of the edge member23POLY0083 -WO-ORD 8

[0035] As shown in FIG. 9, another embodiment of the weight saving feature 180D can be another chamfer 190D (or a bottom-outer edge feature) defined along the intersection of the bottom face 164d (shown in a dashed line) and the outer edge 16 IB (shown partially in a dashed line) of the edge portion 160A3 of the edge member 160, or they can be different from each other. The weight saving feature of FIG. 9 can be the same size and shape as the weight saving feature of FIG. 8. That is, in FIG.9, the weight saving feature 180D is located along the bottom face 165B of the edge member 160, at the outer end 166B of the edge member 160.

[0036] As shown in FIG. 10, another embodiment of the weight saving feature 180E may be an outwardly facing groove 190E or impression (or top groove feature). The groove 190E may define a semi-circular shape. As shown in FIG. 10, the groove 190E can be defined along the bottom face 164D of the edge portion 160 A3 of the edge member 160, between the inner and outer edges 161A, 161B of the edge portion 160A3. The groove 190E can extend between 50 and 80 percent of the thickness of the edge portion 160A3 of the edge member 160. That is, in FIG.10, the weight saving feature 180E is located along the bottom face 165B of the edge member 160, near the outer end 166B of the edge member 160.

[0037] As shown in FIG. 11, another embodiment of the weight saving feature 180F may be another outwardly facing groove 190F or impression (or bottom groove feature). As shown in FIG.11, the groove 190F can be defined along the top face 164C of the edge portion 160 A3 of the edge member 160, between the inner and outer edges 161A, 161B of the edge portion 160A3. The weight saving feature of FIG. 11 can be the same size and shape as the weight saving feature of FIG. 10, and is illustrated this way, though they may be different from each other. That is, in FIG.11, the weight saving feature 180F is located along the top face 165 A of the edge member 160, near the outer end 166B of the edge member 160.23POLY0083 -WO-ORD 9

[0038] As shown in FIG. 12, in one embodiment, the edge member 160 is discontinuous around the perimeter edge 150 of the base member 110. That is, the edge member 160 defines a plurality of discrete edge members, including first through fourth discrete corner members 160A- 160D and first through fourth discrete intermediate members 160E-160H. One of the discrete intermediate members 160E-160H is between each of the discrete corner members 160A-160D.

[0039] As shown in FIG. 13, in one embodiment, a passage 200 is defined in the edge portion 160A3 of the edge member 160, between the inner and outer edges 161A, 161B of the edge portion 160A3. The passage 200 is defined around at least a portion of the perimeter edge 150. The passage 200 is utilized for gas injection. That is, in FIG.13, the passage 200 is located near the outer end 166B of the edge member 160.

[0040] As shown in FIG. 14, the panel 100 may be one or more of a sunroof 100 A, windshield 100B, a rear quarter window 100C, or a tailgate 100D of an automobile 300 A. As shown in FIG. 15, the panel 100 may be utilized as a display 300B for a computing system. As shown in FIG. 16, a plurality of the panels 100 are configured as walls of a unitary enclosure 300C for a personal computer.

[0041] Turning to FIG. 17, a flowchart shows a method of manufacturing a panel 100 including block 1710 of injection compression molding or injection molding, via a first shot, the base member 110, where the base member 110 defines a top surface 120 A, a bottom surface 120B, and a perimeter edge 150.

[0042] As shown in block 1720, the method includes injection compression molding or injection molding, via a second shot, an edge member 160 around at least a portion of the perimeter edge 150 of the base member 110, so that the edge member 160 wraps around a portion of the top surface 120A and the bottom surface 120B of the base member 110 and defines a weight saving23POLY0083 -WO-ORD 10feature 180 along one or more of a top face 165 A, a bottom face 165B, and at or near one or more of an inner end 166A or an outer end 166B of the edge member 160.

[0043] In one embodiment, one or both of the base member and the edge member are polymers. In one embodiment, the base member is one of transparent, semitransparent or opaque. The edge member may be another one of transparent, semitransparent or opaque.

[0044] The polymeric material is chosen based upon the desired properties, such as thermal stability. Examples of polymeric materials include, but are not limited to, polyesters, polycarbonates, polystyrenes (e.g., copolymers of polycarbonate and styrene, polyphenylene ether-polystyrene blends), polyimides (e.g., polyetherimides), acrylonitrile-styrene-butadiene (ABS), polyarylates, polyalkylmethacrylates (e.g., polymethylmethacrylates (PMMA)), polyolefins (e.g., polypropylenes (PP) and polyethylenes, high density polyethylenes (HDPE), low density polyethylenes (LDPE), linear low density polyethylenes (LLDPE)), polyamides (e.g., polyamideimides), polyarylates, polysulfones (e.g., poly aryl sulfones, polysulfonamides), polyphenylene sulfides, polytetrafluoroethylenes, poly ethers (e.g., poly ether ketones (PEK), poly ether etherketones (PEEK), polyethersulfones (PES)), polyacrylics, polyacetals, polybenzoxazoles (e.g., polybenzothiazinophenothiazines, polybenzothiazoles), polyoxadiazoles, polypyrazinoquinoxalines, polypyromellitimides, polyquinoxalines, polybenzimidazoles, polyoxindoles, poly oxoisoindolines (e.g., polydioxoisoindolines), polytriazines, polypyridazines, polypiperazines, polypyridines, polypiperidines, polytriazoles, polypyrazoles, polypyrrolidones, polycarboranes, polyoxabicyclononanes, polydibenzofurans, polyphthalamide, polyacetals, polyanhydrides, polyvinyls (e.g., polyvinyl ethers, polyvinyl thioethers, polyvinyl alcohols, polyvinyl ketones, polyvinyl halides, polyvinyl nitriles, polyvinyl esters, polyvinylchlorides), polysulfonates, poly sulfides, polyureas, polyphosphazenes, poly silazanes, poly siloxanes, fluoropolymers (e.g.,23POLY0083 -WO-ORD 11polyvinyl fluoride (PVF), polyvinylidene fluoride (PVDF), polyvinyl fluoride (PVF), fluorinated ethyl ene-propylene (FEP), polyethylene tetrafluoroethylene (ETFE)), polycarbonate-siloxane block copolymer (such as LEXAN™ EXL Resin), terephthalate ester of resorcinol (ITR) (such as LEXAN™ SLX Resin), N-phenylphenol phthaleinylbisphenol (PPP -BP) (such as LEXAN™ XHT Resin), or a combination comprising at least one of the foregoing.

[0045] The part can comprise a polyester. Polyesters include those derived from an aliphatic, cycloaliphatic, or aromatic diol, or mixtures thereof, containing from 2 to about 10 carbon atoms and an aliphatic, cycloaliphatic, or aromatic dicarboxylic acid, and have repeating units of the following general formula:O O1 I' 2

[0046] — o— R — ()— C— R2— C H —

[0047] wherein n is an integer of from 2 to 6, and R1and R2are each independently a divalent C1-C20 aliphatic radical, a C2-C12 cycloaliphatic alkyl radical, or a C6-C24 aromatic radical. The polyesters can be formed from terephthalic acid and a combination of ethylene glycol and cyclohexadimethanol, for example, formed from terephthalic acid and a combination of ethylene glycol, di ethylene glycol and cyclohexadimethanol. Examples of polyesters include at least one of polyethylene terephthalate), spiroglycol modified polyethylene terephthalate, polycycl ohexylenedimethylene terephthalate glycol, poly(l,4-cyclohexylenedimethylene 1,4-cyclohexanedicarboxylate), and polyethyelene naphthalate, poly-cyclohexylenedimethylene-terephthalate-glycol, polycyclohexylenedimethylene terephthalate, or polyethylene terephthalate with diethylene glycol. The polyester can comprises poly(ethylene terephthalate) ("PET"), e.g., unmodified PET. The polyester can comprise spiroglycol modified amorphous PET.

[0048] The system disclosed herein include(s) at least one of the following aspects:23POLY0083 -WO-ORD 12

[0049] According to a first aspect of the disclosure, disclosed is a molding process for forming a part, the molding process including: injection compression molding, via a first shot, a base member, wherein the base member defines a top face, a bottom face, and a perimeter edge; injection molding, via a second shot, an edge member around at least a portion of the perimeter edge of the base member, so that the edge member is formed to wrap around a portion of the top face and the bottom face of the base member, whereby the edge member defines: a top portion that is disposed against the top face of the base member; a bottom portion that is disposed against the bottom face of the base member; and an outer edge portion that extends outwardly from the perimeter edge of the base member, wherein one of the top portion, the bottom portion and the outer edge portion of the edge member defines a weight-saving feature.

[0050] According to a second aspect of the disclosure related to the process, the process is an injection compression molding process.

[0051] According to a third aspect of the disclosure related to the process, the process is a gas assisted injection molding process.

[0052] According to a fourth aspect of the disclosure related to the process, a passage is defined in the outer edge portion of the edge member, and gas is injected into the passage.

[0053] According to a fifth aspect of the disclosure related to the process, one or both of the base member and the edge member are polymers.

[0054] According to a sixth aspect of the disclosure related to the process, the part is molded so that: the base member is one of transparent, semitransparent or opaque.

[0055] According to a seventh aspect of the disclosure related to the process, the part is molded so that: the edge member is another of is one of transparent, semitransparent or opaque.23POLY0083 -WO-ORD 13

[0056] According to an eighth aspect of the disclosure related to the process, the part is molded so that the top portion the edge member defines: an inner edge that extends over the top face of the base member; a bottom face that faces the top face of the base member; and a top face that faces away from the top face of the base member; the bottom portion of the edge member defines: an inner edge that extends over the bottom face of the base member; a top face that faces the bottom face of the base member; and a bottom face that faces away from the bottom face of the base member; and the outer edge portion defines: an inner edge that is against the perimeter edge of the base member; an outer edge that is spaced apart from the perimeter edge of the base member; a top face that is aligned with the top face of the top portion of the edge member; and a bottom face that is aligned with the bottom face of the bottom portion of the edge member.

[0057] According to a ninth aspect of the disclosure related to the process, the part is molded so that the weight-saving feature is defined along one or more of: a top-inner edge feature at the inner edge the top portion of the edge member; a bottom-inner edge feature at the inner edge the bottom portion of the edge member; a top-outer edge feature at the outer edge portion of the edge member; or a bottom-outer edge feature at the outer edge portion of the edge member.

[0058] According to a tenth aspect of the disclosure related to the process, the part is molded so that: the weight-saving feature is a chamfer defined along one or more of the inner edge of the top portion of the edge member, the inner edge of the bottom portion of the edge member, and top face at the outer edge portion of the edge member, and the bottom face at the outer edge portion of the edge member.

[0059] According to an eleventh aspect of the disclosure related to the process, the part is molded so that: the weight-saving feature is a groove formed along one or both of the top face and the bottom face of the outer edge portion of the edge member.23POLY0083 -WO-ORD 14

[0060] According to a twelfth aspect of the disclosure related to the process, the part is molded so that: the top portion of the edge member defines a first thickness between the top and bottom faces of the top portion of the edge member; the bottom portion of the edge member defines a second thickness between the top and bottom faces of the bottom portion of the edge member; and the outer edge portion of the edge member defines a third thickness between the inner edge and the outer edge of the outer edge portion of the edge member, wherein the first and second thicknesses are the same as each other.

[0061] According to a thirteenth aspect of the disclosure related to the process, the part is molded so that: the third thickness is the same as the first and second thicknesses.

[0062] According to a fourteenth aspect of the disclosure related to the process, the part is molded so that: the third thickness is longer than the first and second thicknesses.

[0063] According to a fifteenth aspect of the disclosure related to the process, the part is molded so that: the edge member is discontinuous around the perimeter edge of the base member.

[0064] According to a sixteenth aspect of the disclosure related to the process, the part is molded so that: the edge member defines a plurality of discrete edge members spaced apart from each other around the perimeter edge of the base member, including comer edge members and intermediate edge members between the comer edge members.

[0065] According to a seventeenth aspect of the disclosure, a panel is formed by a process having one or more of the above aspects.

[0066] According to an eighteenth aspect of the disclosure, an automobile is disclosed having one or more of a sunroof, window, and a tailgate, wherein the one or more of the sunroof, the window, and the tailgate comprises the disclosed panel.23POLY0083 -WO-ORD 15

[0067] According to a nineteenth aspect of the disclosure, an enclosure is disclosed including a plurality of walls, each including the disclosed panel, wherein the enclosure is an electronics enclosure or an appliance enclosure.

[0068] According to a twentieth aspect of the disclosure, a display is disclosed for a computing system, including the disclosed panel.

[0069] In general, the invention may alternately comprise, consist of, or consist essentially of, any appropriate components herein disclosed. The invention may additionally, or alternatively, be formulated so as to be devoid, or substantially free, of any components, materials, ingredients, adjuvants or species used in the prior art compositions or that are otherwise not necessary to the achievement of the function and / or objectives of the present invention. The endpoints of all ranges directed to the same component or property are inclusive and independently combinable (e.g., ranges of “less than or equal to 25 wt%, or 5 wt% to 20 wt%,” is inclusive of the endpoints and all intermediate values of the ranges of “5 wt% to 25 wt%,” etc.). Disclosure of a narrower range or more specific group in addition to a broader range is not a disclaimer of the broader range or larger group. “Combination” is inclusive of blends, mixtures, alloys, reaction products, and the like. Furthermore, the terms “first,” “second,” and the like, herein do not denote any order, quantity, or importance, but rather are used to denote one element from another. The terms “a” and “an” and “the” herein do not denote a limitation of quantity, and are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. “Or” means “and / or.” The suffix “(s)” as used herein is intended to include both the singular and the plural of the term that it modifies, thereby including one or more of that term (e.g., the film(s) includes one or more films). Reference throughout the specification to “one embodiment”, “another embodiment”, “an embodiment”, and so forth, means that a particular element (e.g., feature, structure, and / or characteristic) described in23POLY0083 -WO-ORD 16connection with the embodiment is included in at least one embodiment described herein, and may or may not be present in other embodiments. In addition, it is to be understood that the described elements may be combined in any suitable manner in the various embodiments.

[0070] The modifier “about” used in connection with a quantity is inclusive of the stated value and has the meaning dictated by the context (e.g., includes the degree of error associated with measurement of the particular quantity). The notation “+ 10%” means that the indicated measurement can be from an amount that is minus 10% to an amount that is plus 10% of the stated value. The terms “front”, “back”, “bottom”, and / or “top” are used herein, unless otherwise noted, merely for convenience of description, and are not limited to any one position or spatial orientation. “Optional” or “optionally” means that the subsequently described event or circumstance can or cannot occur, and that the description includes instances where the event occurs and instances where it does not. Unless defined otherwise, technical and scientific terms used herein have the same meaning as is commonly understood by one of skill in the art to which this invention belongs. A “combination” is inclusive of blends, mixtures, alloys, reaction products, and the like.

[0071] All cited patents, patent applications, and other references are incorporated herein by reference in their entirety. However, if a term in the present application contradicts or conflicts with a term in the incorporated reference, the term from the present application takes precedence over the conflicting term from the incorporated reference.

[0072] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or may be presently unforeseen may arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they may be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.

Claims

23POLY0083 -WO-ORD 17CLAIMS1) A molding process for forming a part, the molding process comprising:injection molding, via a first shot, a base member, wherein the base member defines a top face, a bottom face, and a perimeter edge;injection molding, via a second shot, an edge member around at least a portion of the perimeter edge of the base member, so that the edge member is formed to wrap around a portion of the top face and the bottom face of the base member,whereby the edge member defines:a top portion that is disposed against the top face of the base member;a bottom portion that is disposed against the bottom face of the base member; andan outer edge portion that extends outwardly from the perimeter edge of the base member,wherein one of the top portion, the bottom portion and the outer edge portion of the edge member defines a weight-saving feature.2) The process of claim 1, wherein the process is one of:an injection compression molding process; ora gas assisted injection molding process.3) The process of claim 1 or 2, wherein a passage is defined in the outer edge portion of the edge member, and gas is injected into the passage.23POLY0083 -WO-ORD 184) The process of any of claims 1-3, wherein one or both of the base member and the edge member are polymers.5) The process of any of claims 1-4, wherein the part is molded so that one or more of:the base member is one of transparent, semitransparent or opaque; orthe edge member is another of is one of transparent, semitransparent or opaque.6) The process of any of claims 1-5, wherein the part is molded so:that the top portion the edge member defines:an inner edge that extends over the top face of the base member;a bottom face that faces the top face of the base member; anda top face that faces away from the top face of the base member;the bottom portion of the edge member defines:an inner edge that extends over the bottom face of the base member;a top face that faces the bottom face of the base member; anda bottom face that faces away from the bottom face of the base member; andthe outer edge portion defines:an inner edge that is against the perimeter edge of the base member;an outer edge that is spaced apart from the perimeter edge of the base member;23POLY0083 -WO-ORD 19a top face that is aligned with the top face of the top portion of the edge member; anda bottom face that is aligned with the bottom face of the bottom portion of the edge member.7) The process of any of claims 1-6, wherein the part is molded so that the weight-saving feature is defined along one or more of:a top-inner edge feature at the inner edge the top portion of the edge member;a bottom-inner edge feature at the inner edge the bottom portion of the edge member;a top-outer edge feature at the outer edge portion of the edge member; ora bottom-outer edge feature at the outer edge portion of the edge member.8) The process of any of claims 1-7, wherein the part is molded so that the weightsaving feature is a chamfer defined along one or more of: the inner edge of the top portion of the edge member; the inner edge of the bottom portion of the edge member; top face at the outer edge portion of the edge member; or the bottom face at the outer edge portion of the edge member.9) The process of any of claims 1-8, wherein the part is molded so that the weight-saving feature is a groove formed along one or both of the top face or the bottom face of the outer edge portion of the edge member.10) The process of any of claims 1-9, wherein the part is molded so that:the top portion of the edge member defines a first thickness between the top and bottom faces of the top portion of the edge member;23POLY0083 -WO-ORD 20the bottom portion of the edge member defines a second thickness between the top and bottom faces of the bottom portion of the edge member; andthe outer edge portion of the edge member defines a third thickness between the inner edge and the outer edge of the outer edge portion of the edge member,wherein the first and second thicknesses are the same as each other.11) The process of any of claims 1-10, wherein the part is molded so that:the third thickness is the same as the first and second thicknesses; orthe third thickness is longer than the first and second thicknesses; orthe edge member defines a plurality of discrete edge members spaced apart from each other around the perimeter edge of the base member, including comer edge members and intermediate edge members between the comer edge members.12) A panel formed by the process of any one of claims 1-11.13) An automobile comprising:one or more of a sunroof, window, and a tailgate,wherein the one or more of the sunroof, the window, and the tailgate comprises the panel of claim 12.14) An enclosure comprising a plurality of walls, each comprising the panel of claim 12, wherein the enclosure is an electronics enclosure or an appliance enclosure.15) A display for a computing system, comprising the panel of claim 12.

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