Liner apparatus and method for making the same

Abstract

A liner apparatus ( 200 ) and a method ( 600 ) for making the same. The apparatus ( 200 ) can include one or more inserts ( 400 ) and one or more frames ( 300 ). The apparatus ( 200 ) can be implemented for use in a wide variety of different operating environments ( 120 ) utilizing a wide variety of different materials. The apparatus ( 200 ) can be made using a variety of different tools ( 500 ) and processes. Frames ( 300 ) comprised of plastic ( 310 ) or even a foam-like plastic ( 312 ) formed using a super critical fluid (SCF) ( 320 ) can overmolded the inserts ( 400 ). Inserts ( 400 ) can be comprised of non-woven material ( 412 ) and include a hinge area ( 440 ).

1 . A method ( 600 ) for making a liner apparatus ( 200 ), said method ( 600 ) comprising:
 forming ( 700 ) an insert ( 400 ), wherein said insert ( 400 ) is not substantially flat ( 434 ); and   overmolding ( 800 ) a frame ( 300 ) onto said insert ( 400 ).   
     
     
         2 . The method ( 600 ) of  claim 1 , wherein said frame ( 300 ) is comprised of a foam-like plastic ( 312 ), and wherein said insert ( 400 ) is comprised of a non-woven material ( 412 ). 
     
     
         3 . The method ( 600 ) of  claim 2 , wherein said foam-like plastic ( 310 ) is made using a super critical fluid ( 320 ). 
     
     
         4 . The method ( 600 ) of  claim 3 , wherein said super critical fluid ( 320 ) is comprised between about 0.001% to about 1.0% of at least one of: (a) N 2  gas ( 324 ); and (b) CO 2  gas ( 326 ). 
     
     
         5 . The method ( 600 ) of  claim 3 , wherein said overmolding ( 800 ) said frame ( 300 ) onto said insert ( 400 ) comprises:
 injecting ( 844 ) the super critical fluid ( 320 ) into a cavity ( 550 ); and   ceasing ( 848 ) the application of pressure to said super critical fluid ( 320 ) while it solidifies into said foam-like plastic ( 312 ).   
     
     
         6 . The method ( 600 ) of  claim 1 , wherein said frame ( 300 ) is comprised of a foam-like plastic ( 310 ) that is comprised of a solidified super critical fluid ( 320 ) that includes a gas ( 322 ) and a melted plastic ( 332 ). 
     
     
         7 . The method ( 600 ) of  claim 1 , wherein said overmolding ( 700 ) a frame ( 300 ) onto said insert ( 400 ) includes:
 gripping ( 810 ) the insert ( 400 );   removing ( 820 ) the insert ( 400 ) from an insert mold ( 510 );   positioning ( 830 ) the insert ( 400 ) into an overmolding tool ( 540 );   molding ( 840 ) the frame ( 300 ) around the insert ( 400 ) to make a liner ( 200 ) that includes a frame ( 300 ) and an insert ( 400 ); and   removing ( 850 ) the liner apparatus ( 200 ) from the overmolding tool ( 540 ).   
     
     
         8 . The method ( 600 ) of  claim 1 , wherein the liner apparatus ( 200 ) is comprised of more than one insert ( 400 ) connected by a hinge area ( 440 ). 
     
     
         9 . The method ( 600 ) of  claim 1 , wherein an overmolding tool ( 540 ) is used to overmold ( 800 ) the frame ( 300 ) onto the insert ( 400 ). 
     
     
         10 . The method ( 600 ) of  claim 9 , wherein said overmolding tool ( 540 ) includes a cavity ( 550 ) for molding ( 740 ) the frame ( 300 ) and a needle ( 560 ) for securing ( 731 ) the position of the insert ( 400 ). 
     
     
         11 . The method ( 600 ) of  claim 9 , wherein said overmolding tool ( 540 ) further includes a tie draw ( 570 ) and a threaded insert ( 580 ) for overmolding ( 800 ) the frame ( 300 ) onto the insert ( 400 ). 
     
     
         12 . The method ( 600 ) of  claim 1 , wherein said forming ( 700 ) of the insert ( 400 ) comprises:
 cutting ( 710 ) rolls of non-woven material ( 412 ); and   heating ( 720 ) the rolls of non-woven material ( 412 ).   
     
     
         13 . The method ( 600 ) of  claim 12 , wherein said forming ( 700 ) of the insert ( 400 ) further comprises:
 inserting ( 730 ) the heated non-woven material ( 412 ) into an insert mold ( 510 );   forming ( 740 ) the insert ( 400 ) within the insert mold ( 510 ); and   trimming ( 750 ) the formed sheet ( 414 ) into the desired contour of the insert ( 400 ); and   positioning ( 760 ) the insert ( 400 ) for overmolding ( 800 ) by an overmolding tool ( 540 ).   
     
     
         14 . The method ( 600 ) of  claim 1 , wherein overmolding ( 800 ) a frame ( 300 ) onto said insert ( 400 ) includes combining ( 842 ) a gas ( 322 ) with a melted plastic ( 332 ) to form a super critical fluid ( 320 ). 
     
     
         15 . The method ( 600 ) of  claim 14 , wherein overmolding ( 800 ) a frame onto said insert ( 400 ) further includes:
 injecting ( 844 ) the super critical fluid ( 320 ) into a cavity ( 550 ); and   allowing ( 846 ) the super critical fluid ( 320 ) to cool and solidify into said foam-like plastic ( 310 ).   
     
     
         16 . The method ( 600 ) of  claim 15 , wherein no pressure is applied to the cavity ( 550 ) while the super critical fluid ( 320 ) is allowed to cool and solidify into said foam-like plastic ( 310 ). 
     
     
         17 . A method ( 600 ) for making a liner apparatus ( 200 ) comprised of an insert ( 400 ) and a frame ( 300 ), said method ( 600 ) comprising:
 forming ( 700 ) the insert ( 400 ), wherein the insert ( 400 ) includes a non-woven material ( 412 ) that is not substantially flat ( 434 ); and   overmolding ( 800 ) the frame ( 300 ) onto the insert ( 400 ) using an overmolding tool ( 540 );   wherein forming ( 700 ) the insert ( 410 ) includes:
 cutting ( 710 ) rolls of non-woven material ( 412 ); 
 heating ( 720 ) the rolls of non-woven material ( 412 ); 
 inserting ( 730 ) the heated non-woven material ( 412 ) into an insert mold ( 510 ); and 
 forming ( 740 ) the insert ( 400 ) within the insert mold ( 510 ); 
 wherein overmolding ( 800 ) the frame ( 300 ) onto the insert ( 400 ) using the overmolding tool ( 540 ) includes: 
 removing ( 820 ) the insert ( 400 ) from an insert mold ( 510 ); 
 positioning ( 830 ) the insert ( 400 ) into an overmolding tool ( 540 ); 
 molding ( 840 ) the frame ( 300 ) around the insert ( 400 ) to make a liner ( 200 ) that includes a frame ( 300 ) and an insert ( 400 ); and 
 removing ( 850 ) the liner ( 200 ) from the overmolding tool ( 540 ). 
   
     
     
         18 . The method ( 600 ) of  claim 17 , wherein molding ( 840 ) the frame ( 300 ) around the insert ( 400 ) to make a liner apparatus ( 200 ) that includes a frame ( 300 ) and an insert ( 400 ) includes:
 combining ( 842 ) a gas ( 322 ) and a melted plastic ( 332 ) to form a super critical fluid ( 320 );   injecting ( 844 ) the super critical fluid ( 320 ) into a cavity ( 550 ); and   allowing ( 846 ) the super critical fluid ( 320 ) to cool and solidify into said foam-like plastic ( 310 );   wherein said liner apparatus ( 200 ) includes a plurality of inserts ( 400 ) that include a hinge area ( 440 ).   
     
     
         19 . A liner apparatus ( 200 ), said liner apparatus ( 200 ) comprising:
 a plurality of inserts ( 400 ), wherein said plurality of inserts ( 400 ) include a non-woven material ( 412 ) and at least one said insert ( 400 ) is not substantially flat ( 434 ), wherein at least one said insert ( 400 ) includes a hinge area ( 440 );   a frame ( 300 ), wherein said frame ( 300 ) includes a foam-like plastic material ( 312 );   wherein said foam-like plastic frame ( 310 ) is comprised of a super critical fluid ( 320 ) comprised of a melted plastic ( 332 ) and a gas ( 322 ) that has been allowed to cool into said foam-like plastic material ( 312 ).   
     
     
         20 . The liner apparatus ( 200 ) of  claim 19 , wherein said foam-like plastic material ( 312 ) in said frame ( 300 ) possesses a plurality of enhanced attributes ( 340 ) relative to said plastic ( 310 ), wherein said plurality of enhanced attributes ( 340 ) include: (a) a reduced mass ( 341 ); (b) a reduced warp ( 342 ); (c) a reduced cycle time ( 343 ); (d) a reduced clamping requirement ( 344 ); and (e) an improved sound insulation ( 345 ).