US4937030A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of fabricating a slush mold and skin made therefrom
Assignee: Mitsuboshi Belting Ltd
•
Filing: 1989-08-02
•
Granted: 1990-06-26
•
Expires: 2009-08-02
Abstract
Abstract A method of forming a slush mold and a synthetic resin skin utilizing the slush mold. The method includes the steps of roughing a foamed synthetic resin surface to define a prototype having a plurality of irregularly spaced and irregularly sized recesses, forming a metal mold to have a molding surface accurately complementary to the prototype surface and molding a skin of synthetic resin against the molding surface of the metal mold. The recesses preferably have a cross section dimension in the range of approximately 170 to 500 microns and a depth in the range of approximately 8 to 133 microns. Narrower preferred ranges are disclosed. The surface preferably has a regular unbiased variance of less than approximately 300 microns and preferably less than 200 microns.
Inventors
- 👤 Takashi Nishiyama
- 👤 Shuichi Yokota
- 👤 Masaru Takino
- 👤 Hiroaki Asakura
- 👤 Junichiro Iseki
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 14:30
CPC Classifications
B; B29; B29C; B29C33/00; B29C33/38; B29C33/3842; B29C33/42; B29C33/424; B29C41/00; B29C41/02; B29C41/18
Claims Analysis
Total Claims: 36
Claim 1
Independent Claim
63 words
The method of forming a synthetic skin comprising the steps of; providing a skin; forming a mold to have a molding surface having irregularly spaced, irregularly sized recesses; and producing a surface with recesses therein arranged such that the unbiased variance for the spacing between the recesses on the skin is less than 300 microns by molding the skin against said molding surface.
Claim 2
Independent Claim
63 words
The method of forming a synthetic skin comprising the steps of; providing a skin; forming a mold to have a molding surface having irregularly spaced, irregularly sized recesses; and producing a surface with recesses therein arranged such that the unbiased variance for the spacing between the recesses on the skin is less than 300 microns by molding the skin against said molding surface.
Claim 3
Dependent Claim
46 words
The method of forming a synthetic resin skin of claim 1 wherein said prototype surface defines a plurality of distributed recesses having a cross section in the range of approximately 170 to 500 microns and a depth in the range of approximately 8 to 133 microns.
Claim 4
Dependent Claim
44 words
The method of forming a synthetic resin skin of claim 1 wherein said prototype surface defines a plurality of distributed recesses having a regular unbiased variance in the lateral distances between the centerlines of said recesses, said variance being less than approximately 200 microns.
Claim 5
Dependent Claim
28 words
The method of forming a synthetic resin skin of claim 1 wherein said step of molding said skin against said molding surface comprises a step of slush molding.
Claim 6
Independent Claim
158 words
The method of forming a synthetic resin skin comprising the steps of: forming a prototype having a first surface with a plurality of distributed recesses therein; forming a reverse mold having a complementary second surface by setting a first moldable material against said first surface; forming a mandrel having a complementary third surface by setting a second moldable material against said second surface; forming a metal plate on said third surface; separating said metal plate from said third surface, the surface of said metal plate formed against said third surface comprising a fourth surface complementary to said first surface; molding a synthetic resin skin against said fourth surface and producing a fifth surface on said skin with recesses therein arranged such that the unbiased variance of the spacing for the recesses on the fifth surface is less than 300 microns; and removing said skin from said fourth surface, the surface of said skin formed against said fourth surface.
Claim 7
Independent Claim
158 words
The method of forming a synthetic resin skin comprising the steps of: forming a prototype having a first surface with a plurality of distributed recesses therein; forming a reverse mold having a complementary second surface by setting a first moldable material against said first surface; forming a mandrel having a complementary third surface by setting a second moldable material against said second surface; forming a metal plate on said third surface; separating said metal plate from said third surface, the surface of said metal plate formed against said third surface comprising a fourth surface complementary to said first surface; molding a synthetic resin skin against said fourth surface and producing a fifth surface on said skin with recesses therein arranged such that the unbiased variance of the spacing for the recesses on the fifth surface is less than 300 microns; and removing said skin from said fourth surface, the surface of said skin formed against said fourth surface.
Claim 8
Dependent Claim
25 words
The method of forming a synthetic resin skin of claim 5 wherein said prototype comprises a layer of foamed synthetic resin defining said first surface;
Claim 9
Dependent Claim
35 words
The method of forming a synthetic resin skin of claim 5 wherein said prototype comprises a layer of foamed synthetic resin defining said first surface, said first surface being formed by roughing said first surface.
Claim 10
Dependent Claim
40 words
The method of forming a synthetic resin skin of claim 5 wherein said prototype comprises a layer of foamed synthetic resin defining said first surface, said first surface being formed by roughing said first surface with a leather watermarking means.
Claim 11
Dependent Claim
34 words
The method of forming a synthetic resin skin of claim 5 wherein said first surface defines a plurality of distributed recesses having a cross section in the range of approximately 170 to 500 microns.
Claim 12
Dependent Claim
33 words
The method of forming a synthetic resin skin of claim 5 wherein said first surface defines a plurality of distributed recesses having a depth in the range of approximately 8 to 133 microns.
Claim 13
Dependent Claim
34 words
The method of forming a synthetic resin skin of claim 5 wherein said first surface defines a plurality of distributed recesses having a cross section in the range of approximately 300 to 400 microns.
Claim 14
Dependent Claim
33 words
The method of forming a synthetic resin skin of claim 5 wherein said first surface defines a plurality of distributed recesses having a depth in the range of approximately 50 to 100 microns.
Claim 15
Dependent Claim
34 words
The method of forming a synthetic resin skin of claim 5 wherein said first surface defines a plurality of distributed recesses having a cross section in the range of approximately 320 to 370 microns.
Claim 16
Dependent Claim
33 words
The method of forming a synthetic resin skin of claim 5 wherein said first surface defines a plurality of distributed recesses having a depth in the range of approximately 60 to 80 microns.
Claim 17
Dependent Claim
44 words
The method of forming a synthetic resin skin of claim 5 wherein said first surface defines a plurality of distributed recesses having a regular unbiased variance in the lateral distances between the centerlines of said recesses, said variance being less than approximately 200 microns.
Claim 18
Dependent Claim
18 words
The method of forming a synthetic resin skin of claim 5 wherein said prototype comprises an automobile dashboard
Claim 19
Dependent Claim
20 words
The method of forming a synthetic resin skin of claim 5 wherein said first moldable material comprises a synthetic resin.
Claim 20
Dependent Claim
20 words
The method of forming a synthetic resin skin of claim 5 wherein said second moldable material comprises a synthetic resin.
Claim 21
Dependent Claim
33 words
The method of forming a synthetic resin skin of claim 5 wherein said step of forming a metal plate on said third surface comprises a step of electroplating metal on said third surface.
Claim 22
Dependent Claim
33 words
The method of forming a synthetic resin skin of claim 5 wherein said step of forming a metal plate on said third surface comprises a step of electroplating nickel on said third surface.
Claim 23
Dependent Claim
28 words
The method of forming a synthetic resin skin of claim 5 wherein said step of molding said skin against said fourth surface comprises a step of slush molding.
Claim 24
Independent Claim
120 words
The method of forming a slush mold, comprising the steps of: forming a prototype having a rough first surface with a plurality of distributed recesses having an unbiased variance of the spacing between the centerlines of the recesses of no more than 300 microns. forming a reverse mold having a complementary second rough surface by setting a first moldable material against said first surface; forming a mandrel having a complementary rough third surface by setting a second moldable material against said second surface; forming a metal plate on said third surface; and separating said metal plate from said third surface, the surface of said metal plate formed against said third surface comprising as fourth surface complementary to said first surface.
Claim 25
Independent Claim
120 words
The method of forming a slush mold, comprising the steps of: forming a prototype having a rough first surface with a plurality of distributed recesses having an unbiased variance of the spacing between the centerlines of the recesses of no more than 300 microns. forming a reverse mold having a complementary second rough surface by setting a first moldable material against said first surface; forming a mandrel having a complementary rough third surface by setting a second moldable material against said second surface; forming a metal plate on said third surface; and separating said metal plate from said third surface, the surface of said metal plate formed against said third surface comprising as fourth surface complementary to said first surface.
Claim 26
Dependent Claim
24 words
The method of forming a slush mold of claim 22 wherein said prototype comprises a layer of foamed synthetic resin defining said first surface.
Claim 27
Dependent Claim
34 words
The method of forming a slush mold of claim 22 wherein said prototype comprises a layer of foamed synthetic resin defining said first surface, said first surface being formed by roughening said first surface.
Claim 28
Dependent Claim
39 words
The method of forming a slush mold of claim 22 wherein said prototype comprises a layer of foamed synthetic resin defining said first surface, said first surface being formed by roughening said first surface with a leather watermarking means.
Claim 29
Dependent Claim
33 words
The method of forming a slush mold of claim 22 wherein said first surface defines a plurality of distributed recesses having a cross section in the range of approximately 170 to 500 microns.
Claim 30
Dependent Claim
32 words
The method of forming a slush mold of claim 22 wherein said first surface defines a plurality of distributed recesses having a depth in the range of approximately 8 to 133 microns.
Claim 31
Dependent Claim
33 words
The method of forming a slush mold of claim 22 wherein said first surface defines a plurality of distributed recesses having a cross section in the range of approximately 300 to 400 microns.
Claim 32
Dependent Claim
32 words
The method of forming a slush mold of claim 22 wherein said first surface defines a plurality of distributed recesses having a depth in the range of approximately 50 to 100 microns.
Claim 33
Dependent Claim
33 words
The method of forming a slush mold of claim 22 wherein said first surface defines a plurality of distributed recesses having a cross section in the range of approximately 320 to 370 microns.
Claim 34
Dependent Claim
31 words
The method of forming a slush mold of claim 22 said first surface defines a plurality of distributed recesses having a depth in the range of approximately 60 to 80 microns.
Claim 35
Dependent Claim
43 words
The method of forming a slush mold of claim 22 wherein said first surface defines a plurality of distributed recesses having a regular unbiased variance in the lateral distances between the centerlines of said recesses, said variance being less than approximately 200 microns.
Claim 36
Dependent Claim
17 words
The method of forming a slush mold of claim 22 wherein said prototype comprises an automobile dashboard.
References Cited (Backward Citations)
US2435643A
Cited
US2895206A
Cited
US3428725A
Cited
US3565978A
Cited
US3562049A
Cited
US3979487A
Cited
US4217325A
Cited
US4466936A
Cited
US4500373A
Cited
US4714424A
Cited
US4716003A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1993-06-25 | 1993-12-25 | 1994-06-26 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1997-06-25 | 1997-12-25 | 1998-06-26 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2001-06-25 | 2001-12-25 | 2002-06-26 | $7700.00 | Window Closed / Lapsed |