A method for producing a component assembly for a motor vehicle, wherein the component assembly has a base body for an instrument panel of the motor vehicle and at least one functional component, wherein the at least one functional component is injection-molded to the base body during the production of the component assembly and the component assembly is produced using a gas external pressure process. A component assembly for a motor vehicle is also provided, having a base body for an instrument panel of the motor vehicle and at least one functional component, wherein the base body is produced as an integral injection-molded part together with the at least one functional component using an external gas pressure process. Also, a motor vehicle having a component assembly is provided.

[Problem] The present invention relates to a manufacturing method for obtaining a molded article having an expanded layer in the molded article, wherein an expanding agent and device used to manufacture a resin having expansion properties, and a means for increasing expansion ratio are provided. [Solution] In the present invention, an expanding agent placed in a heating cylinder of a molding machine is configured as a liquid, the volume of the expanding agent is controlled, and the expanding agent is injected into a molten resin in the heating cylinder of the molding machine. The volume of the injected expanding agent can thereby be accurately measured each time. When a low-boiling liquid such as water, an alcohol, or an ether is used as the injected expanding agent, all of the liquid is vaporized by the temperature of the heating cylinder of the molding machine, and no residue thereof is therefore left in the molded article. When sodium bicarbonate water is used as the injected expanding agent, solvent water vaporizes and water vapor also becomes expandable gas, which is less expensive than using sodium bicarbonate as the expanding agent for a master batch using the resin that is to be molded.

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.

A controller for an injection molding system is in communication with a melt flow control unit, a gas assist control unit, and a gas counter pressure control unit. The controller can effect real-time adjustments to gas assist pressure and/or gas counter pressure as a function of melt pressure or flow front position.

An improved injection mold for forming an injection molded component. The injection mold includes a main cavity block and a main core block that are moveable with respect to one another. The main cavity block has a cavity block mating face that includes a first mold surface and the main core block has a core block mating face that includes a second mold surface. A plurality of induction heating coils extend within the main cavity block and a plurality of gas inlet channels extend through the main core block. The second mold surface includes a plurality ridges that cooperatively form a continuous gas flow path that is disposed in fluid communication with the plurality of as inlet channels. The continuous gas flow path follows a serpentine shape to provide even and uninterrupted gas flow across the second mold surface.

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.

A thermoplastics injection molding process coats a field joint of a pipeline by positioning a mold tool around the field joint to define a mold cavity. Thermoplastics material injected into the mold cavity forms a field joint coating that will set in the mold cavity. As the thermoplastics material shrinks in the mold cavity while the field joint coating sets, compacting pressure is applied radially inwardly within the mold cavity against a radially outer side of the field joint coating. A compacting fluid introduced into the mold cavity between the mold tool and the field joint coating may be used to apply pressure against the field joint coating. This accelerates and controls cooling of the field joint coating while maximizing quality.

A method for producing a component assembly for a motor vehicle, wherein the component assembly has a base body for an instrument panel of the motor vehicle and at least one functional component, wherein the at least one functional component is injection-molded to the base body during the production of the component assembly and the component assembly is produced using a gas external pressure process. A component assembly for a motor vehicle is also provided, having a base body for an instrument panel of the motor vehicle and at least one functional component, wherein the base body is produced as an integral injection-molded part together with the at least one functional component using an external gas pressure process. Also, a motor vehicle having a component assembly is provided.

The present disclosure relates to a resin injector and oil compactor used to manufacture composite components by RTM and FIP processes. A resin injector comprising an automated resin degassing and charging/discharging station and an in-line heat exchanger. An oil compactor capable of applying a dynamic compaction at a desired frequency, nominal pressure and temperature to an FIP mold. A multi-injection equipment for manufacturing composite parts by RTM and FIP is provided. The multi-injection equipment includes 1 or more cylinder injectors for delivery liquid resin into an RTM or FIP mold cavity. An oil compactor equipment to work with FIP is provided. The oil compactor contains an oil container and a heat exchanger to maintain the oil at a desired temperature. The pre-heated oil is injected into the FIP under pressure after the resin injection to fulfill the impregnation of the fibrous strengthener and consolidate the composite part.

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.