Automated Manufacturing Method and System and In-Mold Coated Plastic Article Produced Thereby

Abstract

An automated manufacturing method and system and in-mold coated plastic article produced thereby are provided. The system includes a combination compression and injection mold and a plurality of program-controlled manipulators. An automatic sprayer supported on a first manipulator sprays at least a portion of a mold surface with an in-mold coating composition. An end effector supported on a second manipulator picks up a heated blank of moldable plastic sheet material from an oven and places the heated blank in the mold. An inner portion of the heated blank is forced into an article-defining cavity of the mold and into contact with at least a portion of the composition. The composition and the inner portion cure and bond to one another and a plastic compatible with the plastic of the sheet is injected into the mold so as to form the coated plastic article.

Claims

1. An automated method of manufacturing a coated plastic article, the method comprising the steps of: providing a mold for making the article, the mold having upper and lower mold halves wherein one of the mold halves has a mold surface which at least partially defines an article-defining cavity; coating at least a portion of the mold surface with an in-mold coating composition; placing a heated blank of moldable plastic sheet material between the upper and lower mold halves, the blank having inner and outer surfaces wherein the plastic sheet material comprises a plastic resin; forcing an inner portion of the heated blank into the article-defining cavity so that the outer surface of the blank is in contact with at least a portion of the in-mold coating composition; causing the in-mold coating composition to cure to form a coating and causing plastic resin of the inner portion of the blank to form an adhesive layer which chemically bonds the blank to the coating; and molding a plastic compatible with the plastic resin of the sheet to form at least one component on the inner surface of the sheet and so as to form the coated plastic article and wherein the article is a laminated article molded as a unitary structure.

2. The method as claimed in claim 1, wherein the plastic sheet material is a composite plastic sheet material.

3. The method as claimed in claim 1, wherein the coating has a textured, class “A” surface.

4. The method as claimed in claim 1, wherein the step of forcing is performed in a single stamping stage.

5. The method as claimed in claim 2, wherein the composite plastic sheet material comprises a plurality of fibers dispersed within a thermoplastic resin.

6. The method as claimed in claim 5, wherein the thermoplastic resin is selected from polyolefins, thermoplastic polyolefin blends, polyvinyl polymers, diene polymers, polyamides, polyesters, polycarbonates, polyestercarbonates, styrene-containing polymers, acrylic polymers, polyimides, polylphenylene either, polyphenylene oxide, polyphenylenesulphide, polyethers, polyetherketones, polyacetals, polyurethanes, polybenzimidazole, and copolymers or mixtures thereof.

7. The method as claimed in claim 5, wherein the fibers are selected from glass fibers, carbon fibers, synthetic organic fibers, natural fibers, mineral fibers, metal and/or metalized or coated fibers, or mixtures thereof.

8. The method as claimed in claim 1, wherein the article is a decorative automotive interior trim article.

9. The method as claimed in claim 5, wherein the fiber content is from about 20% to about 80% by weight of the thermoplastic resin.

10. The method as claimed in claim 1, wherein the article has a thickness in a range of 1 mm to 10 mm.

11. An automated system for manufacturing a coated plastic article, the system comprising: a combination compression and injection mold having open and closed positions for making the article, the mold having upper and lower mold halves wherein one of the mold halves has a mold surface which at least partially defines an article-defining cavity; a program-controlled first manipulator and an automatic sprayer supported on the first manipulator for movement relative to at least two control axes for spraying at least a portion of the mold surface with an in-mold coating composition; a program-controlled second manipulator and an end effector supported on the second manipulator for movement relative to at least two control axes for picking a heated blank of moldable plastic sheet material from an oven and placing the heated blank between the upper and lower mold halves, the blank having inner and outer surfaces, the other one of the mold halves forcing an inner portion of the heated blank into the article-defining cavity so that the outer surface of the blank is in contact with at least a portion of the in-mold coating composition, wherein the mold halves cause the in-mold coating composition and the inner portion of the mold blank to cure and bond to one another in the closed position of the mold and wherein a plastic compatible with the plastic of the sheet is injected into the article-defining cavity to form at least one component on the inner surface of the sheet and so as to form the coated plastic article in the closed position of the mold.

12. The system as claimed in claim 11, wherein the plastic sheet material is a composite plastic sheet material.

13. The system as claimed in claim 11, wherein the coating has a textured, class “A” surface.

14. The system as claimed in claim 11, wherein each of the manipulators is a robot.

15. The system as claimed in claim 12, wherein the composite plastic sheet material comprises a plurality of fibers dispersed within a thermoplastic resin.

16. The system as claimed in claim 15, wherein the thermoplastic resin is selected from polyolefins, thermoplastic polyolefin blends, polyvinyl polymers, diene polymers, polyamides, polyesters, polycarbonates, polyestercarbonates, styrene-containing polymers, acrylic polymers, polyimides, polylphenylene either, polyphenylene oxide, polyphenylene-sulphide, polyethers, polyetherketones, polyacetals, polyurethanes, polybenzimidazole, and copolymers or mixtures thereof.

17. The system as claimed in claim 15, wherein the fibers are selected from glass fibers, carbon fibers, synthetic organic fibers, natural fibers, mineral fibers, metal and/or metalized or coated fibers, or mixtures thereof.

18. The system as claimed in claim 15, wherein the article is a decorative, automotive, interior trim article.

19. The system as claimed in claim 15, wherein the fiber content is from about 20% to about 80% by weight of the thermoplastic resin.

20. The system as claimed in claim 11, wherein the article has a thickness in a range of 1 mm to 10 mm.

21. An in-mold coated plastic article comprising: a rigid, molded substrate of compression-moldable, plastic sheet material, the substrate having inner and outer surfaces; a coating adhered to the outer surface of the substrate wherein the coating is formed in-mold with the substrate; and at least one component adhered to the inner surface of the substrate wherein the at least one component is formed in-mold with the substrate.

22. The article as claimed in claim 21, wherein the plastic sheet material is a composite plastic sheet material.

23. The article as claimed in claim 21, wherein the coating has a textured, class “A” surface.

24. The article as claimed in claim 22, wherein the composite plastic sheet material comprises a plurality of fibers dispersed within a thermoplastic resin.

25. The article as claimed in claim 24, wherein the thermoplastic resin is selected from polyolefins, thermoplastic polyolefin blends, polyvinyl polymers, diene polymers, polyamides, polyesters, polycarbonates, polyestercarbonates, styrene-containing polymers, acrylic polymers, polyimides, polylphenylene either, polyphenylene oxide, polyphenylene-sulphide, polyethers, polyetherketones, polyacetals, polyurethanes, polybenzimidazole, and copolymers or mixtures thereof.

26. The article as claimed in claim 24, wherein the fibers are selected from glass fibers, carbon fibers, synthetic organic fibers, natural fibers, mineral fibers, metal and/or metalized or coated fibers, or mixtures thereof.

27. The article as claimed in claim 21, wherein the article is a decorative, automotive, interior trim article.

28. The article as claimed in claim 24, wherein the fiber content is from about 20% to about 80% by weight of the thermoplastic resin.

29. The article as claimed in claim 21, wherein the article has a thickness in a range of 1 mm to 10 mm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0071] FIG. 1 is a view, partially broken away, of an automotive interior wherein possible locations of a decorative interior trim part constructed in accordance with at least one embodiment of the present invention are indicated by arrows;

[0072] FIG. 2 is a front perspective view of a decorative, automotive interior trim part or article constructed in accordance with at least one embodiment of the present invention;

[0073] FIG. 3A is a sectional view of the part of FIG. 2 taken along lines 3-3 of FIG. 2;

[0074] FIG. 3B is an enlarged view of a portion of the part of FIG. 3A taken within a dashed box labeled 3B;

[0075] FIG. 3C is a rear perspective view, partially broken away, of the part of FIG. 2 after injection molding;

[0076] FIG. 4 is a side schematic view illustrating an automated manufacturing method and system of at least one embodiment of the present invention for making parts such as the part of FIGS. 1-3C; and

[0077] FIG. 5 is a view, similar to the view of FIG. 4, but illustrating a different embodiment of the method and system.

DETAILED DESCRIPTION

[0078] As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention that may be embodied in various and alternative forms. The figures are not necessarily to scale; some features may be exaggerated or minimized to show details of particular components. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a representative basis for teaching one skilled in the art to variously employ the present invention.

[0079] In general, at least one embodiment of the present invention deals with the development of an automated method of and system for compression molding plastic sheet material with an in-mold coating 8 to form an in-mold coated plastic article, generally indicated at 10. The sheet material may be porous, fiber-reinforced thermoplastic sheet material. The method of the at least one embodiment allows one to compression mold heated blanks 9 (FIGS. 4 and 5) of moldable, plastic sheet material with a cost and cycle time that can be used for automotive and other high volume applications. The method of the present invention requires only a single stamping step or stage.

[0080] The composite thermoplastic sheet material preferably comprises a plurality of discontinuous or continuous fibers dispersed within a thermoplastic resin. The thermoplastic resin is preferably selected from polyolefins, thermoplastic polyolefin blends, polyvinyl polymers, diene polymers, polyamides, polyesters, polycarbonates, polyestercarbonates, styrene-containing polymers, acrylic polymers, polyimides, polylphenylene ether, polyphenylene oxide, polyphenylene sulphide, polyethers, polyetherketones, polyacetals, polyurethanes, polybenzimidazole, and copolymers or mixtures thereof.

[0081] The fibers are preferably selected from glass fibers, carbon fibers, synthetic organic fibers, natural fibers, mineral fibers, metal and/or metalized or coated fibers, or mixtures thereof. The fibers may be selected from polyaramid fibers, polyester fibers, nylon fibers, hemp fibers, sisal fibers, basalt fibers, steel fibers, aluminum fibers, copper fibers, zinc fibers, or mixtures thereof.

[0082] The composite sheet material preferably has a porosity between about 5% to about 95% by volume and an areal density of from about 400 g/m.sup.2 to about 4000 g/m.sup.2. The fiber content is preferably from about 20% to about 80% by weight of the thermoplastic resin.

[0083] At least one embodiment of the present invention provides a method of and system for making a laminated trim component, such as vehicle, interior trim component, generally indicated at 10 in FIG. 2. Exemplary locations for such articles are indicated in FIG. 1 by arrows. The article 10 has an outer “A” surface 12 (FIGS. 2 and 3B) and an inner “B” surface 14 (FIG. 3A). The “A” surface 12 may be textured as indicated in FIG. 2 to look like a grained, injection molded part. Examples of such textures include a “wood grain” texture 11, a leather grain texture 13, a carbon fiber texture 15, a natural fiber texture 19 and a texture 21 which provides a “logo” or other desired decorative design. As is well known in the art, the texture of the in-mold, coating 8 is typically provided by the surfaces of the article-defining cavity (62, 62′) of a female die (60, 60′) of a molding machine.

[0084] Referring specifically to FIGS. 3A and 3B, during the above-noted compression molding process, the thermoplastic which serves as a matrix to the fibers forms an adhesive layer 7 to chemically bond the substrate 6 (i.e. the blank 9) to the coating 8 formed from the in-mold coating composition. The heat and pressure in the article-defining cavity (62, 62′) causes the thermoplastic to migrate through the fibers so that the concentration of the thermoplastic is greater at the interface between the coating 8 and the substrate 6 than the concentration of the thermoplastic at other locations in the substrate 6 as indicated by the relative “darkness” of the adhesive layer 7 compared to the “darkness” of the rest of the substrate 6.

[0085] Referring now to FIG. 3C, the article 10 may also include a plurality of components which are made from plastic resin which initially flows from injection molding “drops” 30 to form stiffening ribs 32, receptacles 34 and posts 36 to provide attachment locations for various automotive components including wiring harnesses, etc. on the “B” surface 14 of the article 10.

[0086] A system constructed in accordance with two embodiments of the present invention is generally indicated at 20 and 20′ in FIGS. 4 and 5, respectively. The parts or components of the system 20′ which are the same or similar to the parts or components of the system 20 in either structure or function have a single prime designation.

[0087] The system 10 includes a plurality of program-controlled manipulators or robots 22, 24, 26 and 28. The robots 22 and 24 have the ability to pick up unheated and heated blanks 9 within a specified range of allowable blanks using multiple, end-of-arm, tooling or grippers 41. The robots 22 and 24 pick up and orient the unheated and heated blanks, respectively, at load, heating and molding stations 43, 45 and 47, respectively.

[0088] The robot 26 has an automatic sprayer 42 for spraying an in-mold coating composition, for example, one provided by Red Spot Paint and Varnish Co. Inc. of Evansville, Ind. The robot 28 has an end-of-arm tooling or end effector 49 to pick up a finished article 10 at the molding station 47 and place the finished article 10 on a conveyor 51.

[0089] The robots 20, 24, 26 and 28 are preferably multi-axis robots and are preferably vision-guided by cameras (not shown) located on or adjacent the robots. The robot 22 may be vision-guided to identify, pick, orient, and present the blanks 9 “bottom down” so that they are supported on a belt 53 within an oil-heated oven 55 at the heating station 45. The grippers 41 and 49 accommodate multiple blank and part families, respectively.

[0090] Benefits of Vision-based Robot Automation include but are not limited to the following:

[0091] Smooth motion in high speed applications;

[0092] Handles multiple blanks and parts;

[0093] Slim designs to operate in narrow spaces;

[0094] Integrated vision; and

[0095] Dual end-of-arm tooling or grippers 41 and 49 designed to handle multiple blank and part families.

[0096] A master control station or system controller (not shown) determines locations and orientations of the blanks 9 of moldable plastic sheet materials, heated blanks, and finished articles 10, using any suitable machine vision system having at least one camera. Any one or more of various arrangements of vision systems may be used for providing visual information from image processors to the master controller. The vision system may include three-dimensional stationary cameras or robot-mounted cameras that provide light over fields of vision or view, creating a stripe of light (or other pattern) across the blanks or finished articles as they pass under the cameras. In various embodiments, the light may be a laser beam. The cameras, their image processors and the master controller may be configured to locate various features such as holes. Alternatively, or in addition, the master controller may register the contours of the finished article 10 based on the various depths of the light on the surfaces of the article 10.

[0097] In some embodiments, multiple cameras can be situated at fixed locations on a frame structure (not shown) at the stations 43, 45 and 47 or may be mounted on the arms of the robots 22, 24, 26 and 28. Cameras may be spaced apart from one another on the frame structure. The cameras are typically operatively connected to the master controller via their respective image processors. The master controller also controls the robots 22, 24, 26 and 28 of the system 10 through their respective robot controllers (not shown). Based on the information received from the cameras, the master controller then provides control signals to the robot controllers that actuate robotic arm(s) of the robots 22, 24, 26 and 28 used in the system 10.

[0098] The master controller at the master control station can include a processor and a memory on which is recorded instructions or code for communicating with the robot controllers, the vision systems, the robotic system sensor(s), etc. The master controller is configured to execute the instructions from its memory, via its processor. For example, the master controller can be a host machine or distributed system, e.g., a computer such as a digital computer or microcomputer, acting as a control module having a processor and, as the memory, tangible, non-transitory computer-readable memory such as read-only memory (ROM) or flash memory. The master controller can also have random access memory (RAM), electrically-erasable, programmable, read only memory (EEPROM), a high-speed clock, analog-to-digital (A/D) and/or digital-to-analog (D/A) circuitry, and any required input/output circuitry and associated devices, as well as any required signal conditioning and/or signal buffering circuitry. Therefore, the master controller can include all software, hardware, memory, algorithms, connections, sensors, etc., necessary to monitor and control the vision subsystem, the robotic subsystem, etc. As such, a control method can be embodied as software or firmware associated with the master controller. It is to be appreciated that the master controller can also include any device capable of analyzing data from various sensors, comparing data, making the necessary decisions required to control and monitor the vision subsystem, the robotic subsystem, sensors. etc.

[0099] An end effector on each robot arm of the robots 22, 24 and 28 may include a series of grippers supported to pick up the heated and un-heated blanks as well as the finished articles. The robotic arm is then actuated by its controller to pick up the heated or un-heated blank or the finished article with the particular gripper. The robot arm of the robot 28 puts the finished parts 10 on the conveyor 51 after positioning its gripper 49 relative to the article 10 using the determined location from the visual position data of the particular vision subsystem including its camera and image processor.

[0100] The composite blank or sheet 9 is heated in the oven 55 while on the belt 57 to a first softening temperature. The composite sheet 9 is stretchable when heated to the first softening temperature.

[0101] As shown in FIG. 4, the system 10 also includes a female die, generally indicated at 60, having an article-defining cavity 62 defined by inner surfaces of the female die 60. The female die 60 is typically positioned on a lower base member of a press (not shown). The system 10 also includes a male die, generally indicated at 64, typically mounted on a movable member of the press for forcing an inner portion of a heated blank 9 of thermoplastic material into the female die 60 in a direction along a substantially vertical axis and against the previously sprayed in-mold material. The stamping press including the upper moveable member forces the male die 64 including protrusions 66, into the female die 60 which is supported on the lower base member of the stamping press.

[0102] In the embodiment of FIG. 5, the positions and movements of the male die 64′ and the female die 62′ are reversed for the reasons noted below.

[0103] In one embodiment of the present invention, the method includes placing or positioning a previously heated (in a range of approximately 320° F. to approximately 570° F.) blank 9 of moldable, composite plastic sheet material over the cavity 62 of the female die 60. If the plastic is polypropylene, the temperature may be approximately 400° F. The blank 9 has a predefined position and orientation over the cavity 62. Outer peripheral portions of the blank 9 may be perforated at holes (not shown) to enable the blank 9 to be held at posts (not shown) which extend upwardly through the holes from the outer surface of the female die 60. The posts are removably positioned on the upper surface of the female die 60 to form different patterns or clusters of posts depending on the size and shape of the desired article. In this way, the holding forces at the outer peripheral portions of the heated blank 9 can be varied so that the heated blank 9 stretches but does not wrinkle, tear or rip during a deep-drawn compression molding process. Also, spring-loaded angled clamps (not shown) extend upwardly from the upper surface of the female die 60 to controllably hold outer peripheral portions of the blank 9. The posts and the clamps may be removable or retractable to vary the positions and/or locations at which the outer peripheral portions of the blank 9 are held based on the size and shape of the formed article 10.

[0104] The inner portion of the heated blank 9 is forced into the cavity 62 of the female die 60 along the substantially vertical axis and against the now dry, in-mold coating composition or material which had previously been sprayed on the inner surfaces of the female die 60 by the robot 26. The outer portions of the heated blank 9 adjacent the cavity 62 are held by the posts and clamps to resist movement of the outer portions towards the article-defining cavity 62 during the step of forcing so that the deep-drawn material controllably stretches but does not wrinkle, rip or tear during the step of forcing.

[0105] Then the male die 60 is retracted in the opposite direction along the vertical axis, and the deep-drawn article is removed from the female die 60 by the robot 28 and any excess material (which typically includes the holes) from the periphery of the deep-drawn article 10 is also removed.

[0106] As shown in FIG. 5, the lower mold half 64′ may include passages 80′ for molding a plastic injected by a nozzle 82′ into the lower mold half 64′. The plastic is compatible with the plastic of the composite blank or sheet 9 to bond the plastics together and to form the at least one component such as the components 32, 34 and 36 at the inner surface 14 of the composite sheet 9 (FIG. 3C) at the molding station 47′. Alternatively, as shown in FIG. 4, the upper mold half 64 may have the passages 80 for molding a plastic injected by a nozzle 82.

[0107] Also, a robot such as the robot 28 is not shown in FIG. 5 for the sake of simplicity. Rather, only its end effector 49′ is shown.

[0108] While exemplary embodiments are described above, it is not intended that these embodiments describe all possible forms of the invention. Rather, the words used in the specification are words of description rather than limitation, and it is understood that various changes may be made without departing from the spirit and scope of the invention. Additionally, the features of various implementing embodiments may be combined to form further embodiments of the invention.