System with interchangeable inserts for molding customized mud flaps
AssigneeTrailer Aerodynamics LLC
InventorJustin K. Morgan
Life of this patent
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Abstract
A system for forming a mud flap includes a first section, a second section, and an interchangeable insert. The first section is for molding a front of the mud flap and defines a first surface and a first cavity. The second section is for molding a first portion of a rear of the mud flap and defines a second surface that is to abut the first surface, a receiver portion that is recessed relative to the second surface, and a second cavity. The interchangeable insert is to fit within the receiver portion and is for molding a first type of a second portion of the rear of the mud flap and defines a third surface that is to abut the first surface, and a third cavity that is to fluidly communicate with the first cavity and the second cavity and to form first indicia.
Claims20
A method of forming a perforated mud flap, the method comprising:
- providing a first mold section for molding a front face of the perforated mud flap, the first mold section defining a first parting surface and a first mold cavity;
- providing a second mold section for molding a first portion of a rear face of the perforated mud flap, the second mold section defining a second parting surface and a second mold cavity, and including a receiver portion that is recessed with respect to the second parting surface;
- providing a mold insert configured to fit within the receiver portion, the mold insert defining a third parting surface and a third mold cavity for forming a second portion of the rear face of the perforated mud flap;
- inserting the mold insert into the receiver portion;
- matingly engaging the first parting surface with the second parting surface and the third parting surface, thereby establishing fluid communication among the first mold cavity, the second mold cavity, and the third mold cavity;
- injecting polymer into the first mold cavity, the second mold cavity, and the third mold cavity;
- disengaging the first parting surface from the second parting surface and the third parting surface;
- and,
- removing the perforated mud flap, wherein the perforated mud flap includes a plurality of perforations cooperatively formed by the first mold section and at least the mold insert and extending between the front face and the rear face, and wherein the rear face includes indicia that is formed by the mold insert.
A perforated mud flap formed by injection of a polymer into a first mold cavity of a first mold section, a second mold cavity of a second mold section, and a third mold cavity of a mold insert that is seated within a receiver portion of the second mold section, the perforated mud flap comprising:
- a front face;
- a rear face including:
- indicia formed by solidification of the polymer in an indicia-forming portion of the third mold cavity, and
- a witness line at least partially surrounding the indicia and formed by solidification of the polymer in a gap between an outer edge of the mold insert and a perimeter of the receiver portion;
- and
- a plurality of perforations extending between the front face and the rear face, wherein a first subset of the plurality of perforations partially defines an outline of the indicia and does not interrupt a continuity of the indicia.
A system for forming a mud flap having a plurality of perforations, the system comprising:
- a first mold section for molding a front face of the mud flap, the first mold section defining:
- a first parting surface, and
- a first mold cavity;
- a second mold section for molding a first portion of a rear face of the mud flap, the second mold section defining:
- a second parting surface that is configured to abut the first parting surface,
- a receiver portion that is recessed with respect to the second parting surface, and
- a second mold cavity;
- a first mold insert configured to fit within the receiver portion and for molding a first type of a second portion of the rear face of the mud flap, the first mold insert defining:
- a third parting surface that is configured to abut the first parting surface, and
- a third mold cavity that is configured to fluidly communicate with the first mold cavity and the second mold cavity and to form first indicia that has a first outline that is partially defined by a first subset of the plurality of perforations;
- and,
- a second, alternative mold insert configured to fit within the receiver portion and for molding a second type of the second portion of the rear face of the mud flap, the second, alternative mold insert defining:
- a fourth parting surface that is configured to abut the first parting surface, and
- a fourth mold cavity that is configured to fluidly communicate with the first mold cavity and the second mold cavity and to form second indicia that is different than the first indicia, the second indicia having a second outline that is partially defined by a second subset of the plurality of perforations.
Dependencies are inferred from the claim text.