METHOD OF MAKING AND INSPECTING AN IN MOLD COATED ARTICLE
A method of making an article is disclosed in which an in-mold coating is applied to a mold over with a polyurethane forming mixture is applied. A fluorescent dye is mixed with a polyurethane forming mixture to form an ultraviolet enhanced mixture. After forming, the coated article is exposed to a source of ultraviolet light and inspected to identify areas not covered by the in-mold coating. An article of manufacture is disclosed that includes a polyurethane layer having fluorescent dye and an in-mold coating applied to the polyurethane layer. An interior trim part for a vehicle made according to the process is also disclosed.
1 . A method of making an article, comprising:
applying an in-mold coating to a mold;
mixing a florescent dye in a polymeric forming mixture to form an ultraviolet enhanced mixture;
spraying the ultraviolet enhanced mixture over the in-mold coating;
curing the ultraviolet enhanced mixture to form a coated article;
exposing the coated article to a source of ultraviolet light; and
inspecting the coated article to identify areas on the coated article that are not covered by the in-mold coating.
2 . The method of claim 1 wherein the step of applying the in-mold coating is performed by spraying the mold with the in-mold coating.
3 . The method of claim 1 wherein the polymeric mixture is a polyurethane mixture of polyol and isocyanate.
4 . The method of claim 3 wherein the polyurethane mixture further comprises a color pigment that colors the polyurethane mixture to match the in-mold coating color.
5 . The method of claim 1 wherein the article made by the method is a vehicle interior trim part.
6 . The method of claim 1 wherein the step of mixing the florescent dye is performed by injecting the dye into a spraying system with polyol, isocyanate, and a color pigment.
7 . The method of claim 6 wherein a spray gun is provided that has a mixing chamber for mixing the dye, polyol, isocyanate, and a color pigment.
8 . The method of claim 6 wherein the florescent dye is added to the polyol in the amount of 0.025 to 0.2% by weight of the polyol.
9 . An article of manufacture, comprising:
a polyurethane layer having a florescent dye mixed into the layer; and
an in-mold coating applied to the polyurethane layer, wherein the coverage of the in-mold coating may be inspected by exposing the article to a source of ultraviolet light.
10 . The article of manufacture of claim 9 wherein the polyurethane mixture is a mixture of polyol and isocyanate.
11 . The article of manufacture of claim 10 wherein the polyurethane mixture further comprises a color pigment that colors the polyurethane mixture to match the in-mold coating color.
12 . The article of manufacture of claim 9 wherein the article made by the method is a vehicle interior trim part.
13 . An interior trim part for a vehicle made according to a process comprising:
applying an in-mold coating to a mold;
mixing a florescent dye in a polyurethane forming mixture to form a ultraviolet enhanced mixture;
spraying the ultraviolet enhanced mixture over the in-mold coating;
curing the ultraviolet enhanced mixture to form a coated article;
exposing the coated article to a source of ultraviolet light; and
inspecting the coated article to identify areas on the coated article that are not covered by the in-mold coating.
14 . The product of claim 13 wherein the step of applying the in-mold coating is performed by spraying the mold with the in-mold coating.
15 . The product of claim 13 wherein the polyurethane mixture is a mixture of polyol and isocyanate.
16 . The product of claim 15 wherein the polyurethane mixture further comprises a color pigment that colors the polyurethane mixture to match the in-mold coating color.
17 . The product of claim 13 wherein the step of mixing the florescent dye is performed by injecting the dye into a spraying system with polyol, isocyanate, and a color pigment.
18 . The product of claim 13 wherein the florescent dye is added to the polyol in the amount of 0.025 to 0.2% by weight of the polyol.
19 . The product of claim 13 wherein the fluorescent dye is added to the polyol in the amount of 0.1% by weight of the polyol.
20 . The product of claim 13 wherein a spray gun is provided that has a mixing chamber for mixing the dye, polyol, isocyanate, and a color pigment.