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US 6,607,681 B1Granted
Molded product having a coating film and process for forming coating film
AssigneeToyoda Gosei Co., Ltd.
InventorsTakayuki Ito, Toshihiko Asaya
Life of this patent
Estimating the term…
Abstract
A process for forming a coating layer on the surface of a molded product by boiling a coating solution in a closed metal mold. The molding process includes depressurizing the cavity of the metal mold, boiling a coating solution in the cavity and injecting a urethane material into the cavity under reduced pressure.
Claims25
A process for manufacturing a molded product having a coating layer on the surface, comprising:
- preparing a coating solution containing a coating material and at least one solvent, wherein the at least one solvent evaporates under reduced pressure, and filling a cavity of a mold with the coating solution;
- then
- closing the mold;
- then
- reducing pressure in the cavity whereby a coating layer is formed on the wall surface of the cavity by evaporating the at least one solvent from the coating solution in the cavity while the mold is closed such that the coating material is distributed on the walls of the cavity by means of evaporation of the solvent;
- and then
- supplying a filler material in the cavity while the cavity is under reduced pressure.
4 more elements
A process for molding a steering wheel in a mold having a mold cavity, wherein the cavity is formed such that a grip portion of the steering wheel faces downward, comprising:
- preparing a coating solution containing a coating, material and at least one solvent, wherein the at least one solvent evaporates under reduced pressure, and filling a cavity of the mold with the coating solution;
- then
- closing the mold;
- then
- boiling the coating solution in the mold cavity to evaporate the solvent, during which boiling a coating layer is formed on the wall surface of the cavity by distribution of the coating material from the coating solution by means of evaporation of the solvent;
- and then
- supplying a predetermined filler material in the cavity.
4 more elements
A process for manufacturing an insert molded product, comprising:
- preparing a coating solution containing a coating material and at least one solvent, wherein the at least one solvent evaporates under reduced pressure, and filling a cavity of the mold with the coating solution;
- and
- setting an insert member in a mold;
- then
- closing the mold;
- then
- forming a coating layer on rile wall surface of the cavity in the mold by evaporating the at least one solvent from the coating solution in the cavity while the mold is closed such that the coating material is distributed on the walls of the cavity by means of evaporation of the solvent;
- and then
- supplying a filler material into the cavity while the cavity is under reduced pressure.
6 more elements
A method of forming a coating on the wall surface of a cavity in a mold comprising:
- preparing a coating solution containing a coating material and at least one solvent, wherein the at least one solvent evaporates from the coating solution under reduced pressure;
- then
- closing the mold;
- then
- filling a cavity of the mold with the coating solution;
- and then
- depressurizing the cavity whereby a coating layer is formed on the wall surface of the cavity by distribution of the coating material on the walls of the cavity by means of evaporating the at least one solvent from the coating solution.
4 more elements
A method of forming a coating on the wall surface of a cavity in a mold, comprising;
- preparing a coating solution containing a coating material and at least one solvent, wherein the at least one solvent evaporates under reduced pressure, and filling a cavity of the mold with the coating solution;
- then
- closing the mold, and then
- depressurizing the cavity such that the coating material is distributed on the walls of the cavity by means of evaporation of the solvent.
1 more element
A process for manufacturing a urethane resin molded product formed by foam molding using water, comprising:
- preparing a coating solution containing a coating material and at least one solvent, wherein the at least one solvent evaporates under reduced pressure, and filling a cavity of a mold with the coating solution;
- then
- closing the mold;
- then
- boiling the coating solution in the cavity in the mold while the mold is closed, during which time the solvent evaporates in the cavity and a coating film is formed on the wall surface of the cavity from the coating solution by distribution of the coating material on the walls of the cavity by means of evaporation of the solvent;
- and then
- supplying a urethane material into the cavity at atmospheric pressure.
4 more elements
A process for manufacturing a foamed urethane molded product having a surface skin layer, comprising:
- preparing a coating solution containing a coating material and at least one solvent, wherein the at least one solvent evaporates under reduced pressure, and filling a cavity of a mold with the coating solution;
- closing the mold;
- then
- depressurizing the cavity of the mold;
- then
- boiling the coating solution in the cavity to cause the solvent in the cavity to evaporate, whereby a coating layer is formed on the wall surface of the cavity during said boiling by means of the coating material being distributed on the walls of the cavity by means of said solvent evaporating;
- and then
- supplying a urethane material into the cavity under reduced pressure.
5 more elements
A process for manufacturing a resin molded product, wherein molding and coating are performed simultaneously, the process comprising:
- preparing a coating solution containing a coating material and at least one solvent, wherein the at least one solvent evaporates under reduced pressure, and applying the coating solution to the wall surface of a cavity in a mold;
- then
- closing the mold;
- then
- boiling the coating solution in the cavity under reduced pressure to evaporate the solvent and to form a coating layer on the wall surface of the cavity while the mold is closed such that the coating material is distributed on the walls of the cavity by means of evaporation of the solvent;
- then
- heating a resin material to reduce flow resistance;
- then
- supplying the heated resin material into the cavity;
- and then
- curing the resin material in the cavity.
8 more elements
A process for manufacturing a urethane molded product, comprising:
- preparing a coating solution containing a coating material and at least one solvent, wherein the at least one solvent evaporates under reduced pressure, and filling a cavity of a mold with the coating solution;
- then
- closing the mold;
- then
- forming a coating layer on the surface of the cavity of the closed mold by evaporating the solvent from the coating solution in the cavity while the mold is closed, such that the coating material is distributed on the walls of the cavity by means of evaporation of the solvent;
- then
- first injecting a first urethane material containing a pigment into the cavity at atmospheric pressure;
- and then
- second injecting a second urethane material that includes a larger amount of a pigment than the first urethane material.
6 more elements
A process for manufacturing a urethane molded product, comprising:
- closing a mold;
- then
- supplying a coating solution containing a coating material and at least one solvent in a cavity of the closed mold at atmospheric pressure;
- and then
- depressurizing the cavity to form a coating layer on the entire surface of the cavity by evaporating the solvent from the coating solution such that the solvent distributes the coating material over the entire surface of the cavity as it evaporates.
2 more elements
A process for manufacturing a urethane molded product comprising:
- closing a mold;
- then
- depressurizing a cavity of the mold;
- and then
- supplying a coating solution containing a coating material and at least one solvent in the cavity, whereby the solvent evaporates and a coating layer is formed on the entire surface of the cavity by means of said solvent distributing said coating material over the surface of the cavity as said solvent evaporates.
2 more elements
A method of forming a coating on the wall surface of a cavity in a mold, comprising:
- closing he mold;
- then
- depressurizing the cavity of the mold;
- and then
- supplying a coating solution containing a coating material and at least one solvent into the cavity, whereby the solvent evaporates and a coating layer is formed on the entire surface of the cavity by means of said solvent distributing said coating material over the surface of the cavity as said solvent evaporates.
2 more elements
Dependencies are inferred from the claim text.