Side sill trim part and method of molding same

Abstract

Improved side sill or rocker panel trim part and methods of molding same are provided. In the methods, a substantially “C” like cross-sectional shaped mold cavity ( 53 ) is provided having a pair of terminal cavity portions ( 56, 58 ) therein. A living hinge-forming cavity space ( 54 ) is provided between a midpoint of the cavity and one of the terminal end portions. The part comprises a longitudinal axis extending therealong and a pair of leg portions and an intermediate section interconnecting the leg portions. The part includes a substantially “C” shaped cross-section transverse to the longitudinal axis with the intermediate section including a show surface side with the legs extending away from the show surface side. A hinge joint is provided adjacent one of the legs so that the part is bendable at the hinge to form a substantially closed “C” position.

1 . Method of making a side sill or rocker panel part of the type having a substantially “C” like cross-sectional shape oriented transverse to a longitudinal axis of the part, comprising, providing a mold cavity defining a space congruent with said cross-sectional shape and having a opposing terminal portions of said space with each terminal portion being disposed adjacent a mold part line, determining an approximate midpoint of the space located between said terminal portions, and providing a living hinge forming cavity space between said midpoint and one of said terminal portions, injecting a mass of molten resin into said cavity over said hinge forming cavity space and into said terminal portions, allowing said molten resin to harden, ejecting said resin from said mold cavity thereby forming a substantially “C” cross-sectional part with a hinged attachment leg formed adjacent one terminal portion of said part.  
   
   
       2 . Method as recited in  claim 1  further comprising co-molding a paint film over said part.  
   
   
       3 . Method as recited in  claim 2  wherein said paint film is inserted into said cavity prior to injection of said mass of molten resin into said cavity.  
   
   
       4 . Method as recited in  claim 1  further comprising positioning said part adjacent an automotive frame member, pivotally moving said attachment leg toward said frame member and securing said attachment leg member to said frame member.  
   
   
       5 . Method of making a side sill or rocker panel automotive part having a longitudinal axis extending therealong, said part including a “C” configuration when viewed in a cross-sectional plane taken transverse to said longitudinal axis and having spaced top and bottom legs and an intermediate portion connecting said top and bottom legs and having an inside surface and a show side surface with both of said legs extending away from said inside surface, said method comprising providing a mold cavity defining a space congruent with said configuration and having opposing terminal portions of said space, said terminal portions of said space being disposed relative to each other at an angle of less than 180°, providing a living hinge-forming space in said space proximate to one of said opposing terminal portions, injecting a mass of molten resin into said cavity substantially filling said space and flowing over said hinge-forming space, allowing said molten resin to harden, ejecting said resin from said cavity thereby forming a side sill or rocker panel with one of said legs defining a hinged attachment leg formed along one end of said part and adapted for pivotal movement so that said legs can be disposed relative to each other in a substantially closed “C” position.  
   
   
       6 . Method as recited in  claim 5  wherein said legs can be disposed relative to each other at an angle of between about 180°-270°.  
   
   
       7 . Method as recited in  claim 6  wherein said end portions of said legs can be disposed relative to each other at an angle of between about 225° and 270°.  
   
   
       8 . Side sill or rocker panel automotive part having a longitudinal axis extending therealong, said part comprising a pair of leg portions and an intermediate section interconnecting said leg portions, said part having a substantial “C” shaped cross section transverse to said longitudinal axis, said intermediate section including a show surface side with said legs extending away from said show surface side, a hinged joint provided adjacent one of said legs, said part being bendable at said hinge to form a substantially closed “C” position.  
   
   
       9 . Automotive part as recited in  claim 8  wherein said legs are disposed relative to each other at an angle of between about 180° and 270°.  
   
   
       10 . Automotive part as recited in  claim 9  wherein said legs are disposed relative to each other at an angle of between about 225° to about 270°.  
   
   
       11 . Side sill automotive part as recited in  claim 8  further including a paint film laminate covering said show surface.