Molding system and molded-in-color panel

Abstract

In one embodiment, a molding system for creating a molded-in-color panel has a first mold member with a first forming surface for forming a portion of a panel with an exposed surface. The molding system has a second mold member having a second forming surface for forming a concealed portion of the panel. One of the first and second mold members is translatable relative to the other to collectively receive a heated molded-in-color resin to form the panel. The molding system has an injector for injecting molded-in-color resin into the mold. The second forming surface is sufficiently smooth so that the exposed surface of the panel is free of visible flow lines.

1 . A molding system for creating a molded-in-color panel, the molding system comprising:
 a first mold member having a first forming surface for forming a portion of a panel with an exposed surface;   a second mold member having a second forming surface for forming a concealed portion of the panel, one of the first and the second mold members being translatable relative to the other to collectively receive a heated resin with a molded-in-color to form the panel, the second forming surface being sufficiently smooth so that the exposed surface of the panel is free of visible flow lines; and   an injector for injecting molded-in-color resin into the first and second mold members.   
   
   
       2 . The molding system of  claim 1  wherein second forming surface has a tolerance for a height change on a flow surface in the mold of fifteen percent of a thickness of the vehicle panel or less. 
   
   
       3 . The molding system of  claim 1  wherein the molded-in-color resin is a metallic molded-in-color resin. 
   
   
       4 . The molding system of  claim 1  wherein the injector further comprises:
 a sprue portion to receive heated molded-in-color resin from the injector;   a runner to transmit the heated molded-in-color resin therethrough;   a gate portion in fluid communication with the runner to one of the first mold member and the second mold member; and   a cold slug well portion in fluid connection with the runner to inhibit impurities in the heated molded-in-color resin from entering the one of the first mold member and the second mold member;   wherein the cold slug well portion has a length that is approximately one and a half times greater than a diameter of the runner.   
   
   
       5 . The molding system of  claim 4  wherein the runner is further defined as a first runner portion in fluid communication with the sprue, a second runner portion in fluid communication with the first runner portion, and a third runner portion in fluid communication with the gate, the cold slug well portion and the second runner portion such that the first runner portion is in fluid communication with the second runner portion with an angle approximately equal to ninety degrees and the second runner portion is in fluid communication with the third runner portion with an angle approximately equal to ninety degrees. 
   
   
       6 . The molding system of  claim 4  wherein the gate redirects the heated molded-in-color resin from the runner approximately ninety degrees. 
   
   
       7 . The molding system of  claim 4  wherein the runner is further defined as a first runner portion in fluid communication with the sprue, a second runner portion in fluid communication with the first runner portion, and a third runner portion in fluid communication with the gate, the cold slug well portion and the second runner portion such that the first runner portion and the third runner portion are generally parallel. 
   
   
       8 . The molding system of  claim 7  wherein the first runner portion is generally perpendicular to the second runner portion. 
   
   
       9 . The molding system of  claim 7  wherein the second runner portion is generally perpendicular to the third runner portion. 
   
   
       10 . The molding system of  claim 7  wherein the second runner portion is generally perpendicular to the first runner portion and the third runner portion. 
   
   
       11 . The molding system of  claim 4  further comprising at least one punch provided within one of the first or second mold members, the at least one punch being actuatable to extend through the forming surface of one of the first or second mold members and being actuatable to form an aperture through a partially cooled panel;
 wherein an intersection of the punch and the forming surface of the first or second mold members is sufficiently smooth so that the exposed surface of the panel is free of visible flow lines.   
   
   
       12 . The molding system of  claim 11  further comprising a nest provided in the other of the one of the first or second mold members such that the at least one punch extends through the nest to nest therein;
 wherein an intersection of the nest and the other of the one of the first or second mold members is sufficiently smooth so that the exposed surface of the panel is free of visible flow lines.   
   
   
       13 . A method for creating a molded-in-color panel in a mold, the method comprising:
 providing a mold having a first mold member with a first forming surface to produce an exposed portion of a molded-in-color panel and a second mold member with a second forming surface to produce a concealed portion of a molded-in-color panel, the second forming surface having a sufficiently smooth surface to prevent visible flow lines;   injecting molded-in-color resin in the mold; and   cooling the molded-in-color resin to form a molded-in-color panel such that the exposed portion of the panel formed by the other of the forming surface of the first or second mold members is generally free of flow lines.   
   
   
       14 . The method of  claim 13  further comprising fabricating the concealed portion of the second forming surface to a tolerance for a height change on a flow surface in the mold of fifteen percent of a thickness of the vehicle panel or less. 
   
   
       15 . The method of  claim 13  further comprising injecting molded-in-color resin through a sprue portion, a runner and a gate portion to the mold such that a cold slug well portion in fluid communication with the runner inhibits impurities from entering the mold wherein the cold slug well portion has a length that is approximately one and a half times greater than a diameter of the runner portion. 
   
   
       16 . The method of  claim 13  further comprising:
 providing at least one punch within one of the first or second mold members, the at least one punch being actuatable to extend through the forming surface of the one of the first or second mold members such that an intersection of the at least one punch and the forming surface of the one of the first or second mold members is sufficiently smooth so that the exposed surface of the panel is free of visible flow lines;   partially cooling the molded-in-color resin; and   punching at least one aperture through the partially cooled molded-in-color resin in the mold while the mold is closed.   
   
   
       17 . The method of  claim 13  further comprising injecting the molded-in-color resin through a generally U-shaped runner. 
   
   
       18 . The method of  claim 13  wherein injecting molded-in-color resin further comprises injecting molded-in-color metallic resin. 
   
   
       19 . A molded-in-color panel formed in the steps comprising:
 providing a mold having a first mold member with a first forming surface to produce an exposed portion of a molded-in-color panel and a second mold member with a second forming surface to produce a concealed portion of a molded-in-color panel, the second forming surface having a sufficiently smooth surface to prevent visible flow lines;   injecting molded-in-color resin in the mold; and   cooling the molded-in-color resin to form a molded-in-color panel such that the exposed portion of the panel formed by the other of the forming surface of the first or second mold members is generally free of flow lines.   
   
   
       20 . The molded-in-color panel formed in the steps of  claim 19  further comprising fabricating the concealed portion of the second forming surface to a tolerance for a height change on a flow surface in the mold of fifteen percent of a thickness of the vehicle panel or less.