An injection molding die of the invention, includes: a cavity die having a molding recess formed thereon, the molding recess molding a molded-product main body on which a design surface of a resin molded product is formed; and a core die that exists to be openable and closable with respect to the cavity die and forms a cavity having the molding recess between the cavity die and the core die, when the core die is closed and coupled to the cavity die, and the injection molding die is used in a resin molding method of causing a design surface of the resin molded product during molding to be brought into close contact with the cavity die by setting temperatures of the cavity die and the core die to be higher than or equal to a deformation temperature of a resin to be molded.

A method of forming a thin-walled skin includes coating at least one side of a mold cavity of a molding tool, evacuating air from the mold cavity, and filling the mold cavity with a molten polymeric resin. Among other optional variations of the disclosed method, an inert gas is injected into the molten polymeric resin simultaneously with the step of filling the mold cavity with a molten polymeric resin. As a result, high quality, large, thin-walled skins are produced by the teachings of the present disclosure.

Aspects hereof provide methods for molding a single-phase solution comprised of a polymer composition and a gas. The polymer composition and the gas are maintained under pressure during the molding operation to prevent a cellular structure from being formed by the dissolved gas in the polymer composition coming out of solution. The mold cavity in which the single-phase solution is introduced for molding purposes is pressurized to a mold pressure that is sufficient to maintain the single-phase solution as a single-phase solution as the mold cavity is filled. Subsequent to filling the mold cavity with the single-phase solution under pressure, the resulting article may be exposed to a reduction in pressure causing the entrapped gas to form a cellular structure.

Aspects hereof provide methods for molding a single-phase solution comprised of a polymer composition and a gas. The polymer composition and the gas are maintained under pressure during the molding operation to prevent a cellular structure from being formed by the dissolved gas in the polymer composition coming out of solution. The mold cavity in which the single-phase solution is introduced for molding purposes is pressurized to a mold pressure that is sufficient to maintain the single-phase solution as a single-phase solution as the mold cavity is filled. Subsequent to filling the mold cavity with the single-phase solution under pressure, the resulting article may solidify entrapping the compressed gas, or the article may be exposed to a reduction in pressure causing the entrapped gas to form a cellular structure.

The invention relates to a component (1) comprising a planar decorative element (4) with a front side (5) and a rear side (6). A cover layer (9, 10) is arranged on each of at least two regions of the front side (5) of the planar decorative element (4), these at least two cover layers (9, 10) being spaced completely apart from one another, and said at least two cover layers (9, 10) and at least one region (12, 14) of the front side (5) of the planar decorative element (4) together forming a visible side (2) of the component (1).

A method is provided to fabricate an injection molded piece with a weakened portion in an injection molding system having a cavity defined by a fixed mold part and a moveable mold part. The method comprises injecting raw material in a liquid state into the cavity to form the injection molded piece; moving a weakening insert into the injection molded piece from a first surface of the injection molded piece; injecting a gas to the first surface of the injection molded piece with a controlled pressure, wherein moving the weakening insert into the injection molded piece and injecting the gas are performed while the injection molded piece is in the liquid state.

An injection molding apparatus including an injection device, a mold, a gas supply device, and a temperature control device is provided. The mold has a mold cavity, wherein the injection device is adapted to inject a material into the mold cavity. The gas supply device is adapted to supply a gas to the mold cavity such that the pressure in the mold cavity is increased. The temperature control device is adapted to control the temperature in the mold cavity. In addition, an injection molding method is also provided.

An injection molding apparatus including a mold and an injection device is provided. The mold includes a fixed portion and a movable portion. A molding concavity is formed between the fixed portion and the movable portion, and the movable portion is adapted to move relative to the fixed portion to change a volume of the molding cavity, so that a pressure inside the molding concavity is adjusted between a pressurized state and a non-pressurized state. The injection device is adapted to inject a material into the molding concavity. The material includes a supercritical fluid, the supercritical fluid is prevented from being gasified in the pressurized state, and the supercritical fluid is gasified in the non-pressurized state. In addition, an injection molding method is also provided.

An injection molding apparatus including a mold, a gas supply device, and an injection device is provided. The mold has a molding cavity. The gas supply device is adapted to supply a gas into the molding cavity to adjust a pressure in the molding cavity from a non-pressurized state to a pressurized state by the gas. The injection device is adapted to inject a material into the molding concavity. The material includes a foaming material, the foaming material is prevented from being gasified in the pressurized state, and the foaming material is gasified in the non-pressurized state. In addition, an injection molding method is also provided.

A method for producing a three-dimensionally shaped trim part of a motor vehicle, which has a visible side and a mounting side. A flowable material is injuected with pressure into a chamber of an injection molding tool, which has at least two mold shells, which, when assembled, form the chamber with a negative mold of the trim part, wherein at least one first of the mold shells forms the visible side and at least one second of the mold shells forms the mounting side of the trim part. The material is hardened in the chamber. A gas pressure is generated that acts in a planar manner between the second mold shell and the material during the hardening. The hardened material is removed as a trim part from the chamber of the injection molding tool.