Description:A METHOD OF MANUFACTURING AN AESTHETIC AUTOMOTIVE COMPONENT WITH METAL ROD INSERT AND PRODUCT THEREOF
FIELD OF THE INVENTION
The present invention relates to an aesthetic automotive component, more particularly manufactured by means of insert molding process to produce reinforced composite structure.
BACKGROUND OF THE INVENTION
An automotive industry accompanies variable techniques of manufacturing aesthetic products. In terms of metal-based components may turn the component bulky and high exposure of atmosphere may result in oxidation which turns the metal involve corrosion or rusting in nature.
Manufacturing of only plastic parts may result in instability or brittle nature which can cause deprivation in the product’s lifecycle. Conventional techniques rely on human intervention by manufacturing a metal inserted plastic molded component for holding the metal rod until the process is completed.
This results in making of a metal reinforced plastic components to a hectic process and also the metal rod inserted could bring the chances of mis-aligned with the surrounding the plastic body.
Some of the prior arts are:
US20020111131A1 discloses an air vent for vehicles has a grid structure that is made of electrically conductive plastic components and that provides an electromagnetic shielding effect. The air vent can have a frame that surrounds the grid structure and that can be installed in the opening of a car body
CN214501433U discloses an air conditioner indoor unit and belongs to the technical field of household appliances. The air conditioner indoor unit comprises a shell assembly, a heat exchanger assembly and a fan assembly, wherein the heat exchanger assembly and the fan assembly are arranged in the shell assembly; the shell assembly comprises an air inlet panel and an air outlet panel, wherein an air inlet grille is arranged on the air inlet panel; the panel seat is connected to the front side of the air inlet panel, and an air outlet is formed in the panel seat; the plastic panel is in butt joint with the front end of the air inlet panel and is fixed on the panel seat to form the side surface of the rear part of the indoor unit of the air conditioner, and a grating plate is arranged on the plastic panel; and the metal panel is roughly L-shaped, is in butt joint with the front end of the plastic panel and is fixed on the panel seat, so that the side surface and the front surface of the front part of the indoor unit of the air conditioner are formed. According to the air conditioner indoor unit, the appearance texture and the grade of an air conditioner are improved due to the metal panel, the air outlet structure and the connecting structure can be conveniently formed on the plastic panel in an injection molding mode, and the improved appearance texture and user experience are achieved.
US20220072934A1 discloses an antimicrobial, injection molded air register for use in an air distribution system to direct airflow from ductwork into a passenger cabin of a vehicle or into an enclosed space within a residential structure is provided. The air register includes a perforated cover configured to cover an outlet end of the ductwork and a plurality of injection molded components supported by the cover to direct air flow into the passenger cabin. Each of the components includes a surface layer in fluid communication with the airflow and is made of a molded material which absorbs airborne liquid droplets containing infectious, disease-causing pathogens moving with the airflow. The molded material includes antimicrobial agents disbursed throughout each of the surface layers to reduce the number of pathogens contained within droplets absorbed by the surface layers.
US20050030234A1 discloses an air vent to be mounted on a vehicle body, has a frame molded of a plastic material and an antenna with a metallic antenna body. The antenna body is incorporated in the frame by being embedded in the plastic material or by over-molding the frame and antenna body with plastic material.
US6071591A discloses a motor vehicle dashboard including a body made of injection-molded plastic form, and at least one air duct integrally molded with the dashboard body. The air duct is produced by means of an at least partially absorbable removable insert, particularly an inflatable balloon.

To overcome this problem of the existing prior art, the present invention provides a solution to provide perfect alignment of the metal insert in an insert molding machine to reduce miscoordination and provides perfect settlement of the metal rod to be encapsulated by the plastic mold, which eliminates the human intervention and yield an aesthetic insert molded aesthetic automotive component (300).

OBJECTS OF THE INVENTION
The main objective of the present invention is to provide a combination of metal rod encapsulated by a narrow aesthetic automotive component (300) over it using the insert molding process.
Another objective of the present invention is to bring integrity as a composite component, enhancing functionality and durability.
Another objective of the present invention is to enhance structural strength by reinforcing the plastic parts with metal inserts for improved mechanical properties.
Another objective of the present invention is to achieve dimensional stability and ensure tight tolerances for assembly with aesthetic automotive components.
Another objective of the present invention is to manufacture a cost-effective and durable component.
Another objective of the present invention is to enable versatile designs tailored for specific applications in automotive industries and the like.
It is yet another object of the present invention to provide a method wherein the aesthetic plastic part comes under head impact zone to prevent plastic deflection.
 
SUMMARY OF THE INVENTION
It is the principle aspect of the present invention to provide a method (200) of manufacturing an aesthetic automotive component (300) with metal rod insert (104), comprising steps:
a. dislodging at step (201), a mold cavity (101) on a mold core (102) of an insert molding machine;
b. placing at step (202), a metal rod insert (104) on a plurality of magnetic inserts (103) positioned in the mold core (102);
c. lodging at step (203), the mold cavity (101) on the mold core (102) of the insert molding machine;
d. initiating at step (204), a thermoplastic resin injection into the assembled portion of the mold cavity (101), configured to encapsulate the metal rod insert (104), and
e. wherein the metal rod insert (104) is placed on the plurality of magnetic inserts (103) positioned on a core insert (105) configured to act as support members, holding the metal rod insert (104) in place for plastic injection and
f. dislodging at step (205), the mold cavity (101), remove a composited structure of the metal rod insert (104) encapsulated thermoplastic model as an output.

BRIEF DESCRIPTION OF DRAWINGS
The accompanying drawings, which are incorporated in and constitute a part of this disclosure, illustrate exemplary embodiments and, together with the description, serve to explain the disclosed principles.
Figure 1 illustrates the process flowchart of the method of insert molding of an aesthetic automotive component (300), in accordance with an embodiment of the present disclosure.
Figure 2 illustrates a perceptional view of the aesthetic automotive component (300), in accordance with an embodiment of the present disclosure.
Figure 2A illustrates a cross-sectional view of the aesthetic automotive component (300) and metal rod insert (104), in accordance with an embodiment of the present disclosure.
Figure 3 illustrates a exploded view of the aesthetic automotive component (300) along with machine components (100), in accordance with an embodiment of the present disclosure.
Figure 4 illustrates a perceptional view of the aesthetic automotive component (300) assembled to an automotive part (400), in accordance with an embodiment of the present disclosure.
Figure 4A illustrates a cross-sectional view of the aesthetic automotive component (300) and metal rod insert (104) assembled to an automotive part (400), in accordance with an embodiment of the present disclosure.

REFERENCE NUMERALS
S.No. PART NAME Ref. Num.
1 Insert Molding assembly (100)
2 Mold cavity (101)
3 Mold core (102)
4 Magnetic mold inserts (103)
5 Metal rod insert (104)
6 Core insert (105)
7 Aesthetic automotive component (300)
8 Automotive part (400)

DETAILED DESCRIPTION OF THE INVENTION
The present invention as embodied by “a method (200) of manufacturing an aesthetic automotive component (300) with metal rod insert (104)” succinctly fulfills the above-mentioned need[s] in the art. The present invention has objective[s] arising as a result of the above-mentioned need[s], said objective[s] having been enumerated herein above.
The following description is directed to a constant mechanical governor for regulating the engine speed and method there of as much as the objective(s) of the present invention are enumerated, it will be obvious to a person skilled in the art that, the enumerated objective(s) are not exhaustive of the present invention in its entirety and are enclosed solely for the purpose of illustration.
Further, the present invention encloses within its scope and purview, any structural alternative(s) and/or any functional equivalent (s) even though, such structural alternative(s) and/or any functional equivalent (s) are not mentioned explicitly herein or elsewhere, in the present disclosure. The present invention therefore encompasses also, any improvisation[s]/modification[s] applied to the structural alternative[s]/functional alternative[s] within its scope and purview. The present invention may be embodied in other specific form[s] without departing from the essential attributes thereof.
Furthermore, the terms and phrases used herein are not intended to be limiting but rather are to provide an understandable description. Throughout this specification, the use of the word comprises and variations such as comprises and comprising may imply the inclusion of an element or elements not specifically recited.
Referring to Figure 1 illustrates the process flowchart of the method of insert molding of an aesthetic automotive component (300), in accordance with an embodiment of the present disclosure. In the principle embodiment of the present invention is provided the method (200) of manufacturing an aesthetic automotive component (300) with metal rod insert (104). The process is performed on an insert molding machine or apparatus. The insert molding apparatus comprises a mold cavity (101). The mold cavity is detached from the position above the mold core (102) of the insert molding machine. The metal rod insert (104) is placed onto plurality of magnetic inserts (103) encapsulated over the core insert (105) positioned in the mold core (102).
Then, securing the mold cavity (101) back onto the mold core (102) of the insert molding machine. Subsequently, initiating the injection of thermoplastic resin into the joint assembly formed by the mold cavity (101) and the mold core (102), which is configured to encapsulate the metal rod insert (104) by filling the thermoplastic resin to surround the boundaries and completing the insert molding process. At last, removing the mold cavity (101) to extract the composited structure consisting of the encapsulated aesthetic automotive component enclosing the metal rod insert (104) as a part used in an aesthetic automotive component (300).
Figure 2 illustrates a perceptional view of an aesthetic automotive component (300), in accordance with an embodiment of the present disclosure. In one embodiment of the present invention, the output of this molding process is an automotive component (300). The aesthetic automotive component (300) has an atleast two ends, which are slightly deflected in a prescribed angle in order to assemble with an aesthetic automotive component (300).
Figure 2A illustrates a cross-sectional view of the aesthetic automotive component (300) and metal rod insert (104), in accordance with an embodiment of the present disclosure. In one embodiment of the present invention, the cross-sectional view of the aesthetic automotive component (300) encapsulating the metal rod insert (104) maintains centricity from end to end.
Figure 3 illustrates a exploded view of the aesthetic automotive component (300) along with machine components, in accordance with an embodiment of the present disclosure. In one embodiment of the present invention, the mold core (102) receives the core insert (105) having pockets which encapsulates the plurality of magnetic mold inserts (103). A metal rod insert (104) is placed over the plurality of magnetic mold inserts (103), the metal is chosen from magnetic materials, specifically any metal or alloy that is magnetic.
The mold cavity (101) is placed over the mold core (102) by means of sandwiching to create an arrangement to receive the thermoplastic resin from the insert molding machine causing the metal rod insert (104) to be surrounded by the thermoplastic resin and forming an expected shape designed on the mold cavity (101).
Figure 4 illustrates a perceptional view of the aesthetic automotive component (300) assembled to an automotive part (400), in accordance with an embodiment of the present disclosure. In one embodiment of the present invention, the automotive part (400) receives the aesthetic automotive component (300) with metal rod insert (104) after the insert molding process is successfully executed. The aesthetic automotive component is finally assembled to the automotive part (400), which declines the structural imbalances of the automotive part (400).
Figure 4A illustrates a section view of the aesthetic automotive component (300) assembled to an automotive part (400), in accordance with an embodiment of the present disclosure. In one embodiment of the present invention, the aesthetic automotive component (300) is positioned firmly to the automotive part (400) with fastening means and ensuring proper alignment, ensuring to absorb impact and minimize damage during low-speed collisions. Also, the automotive part (400) is a component which is positioned at the areas of the automobile aesthetic parts such as but not limited to wheels covers, bumpers, headlights, hoods, air vents, side openings, mirrors, interior trim materials and the like.
In one another embodiment of the present invention, the metal rod insert (104) made of high magnetic properties considerably a pure form of metal or an alloy such that but not limited to Iron (Fe), Nickel (Ni), Cobalt (Co), Steel , Gadolinium (Gd), Samarium (Sm), Neodymium (Nd), Ferritic Stainless Steel, Iron-Silicon Alloy and the like.
In a preferred embodiment the metal with high magnetic properties chosen for the metal rod insert (104) is SKD61 grade stainless steel.
In one another embodiment of the present invention, the magnetic inserts (103) are high temperature resistive such that but not limited to Alnico Magnets, Samarium Cobalt (SmCo) Magnets and the like.
In one another embodiment of the present invention, by the time of manufacturing of the aesthetic automotive component (300), the orientation of the thermoplastic resin injection to the resin molding machine can be kept horizontal or vertical direction.

WORKING OF THE PRESENT INVENTION
In one working example, the method of manufacturing an aesthetic automotive component with metal rod insert is provided, wherein for exemplary purposes the aesthetic automotive component is an air vent with a metal insert. The method of manufacturing comprises steps of:
detaching the mold cavity (101) positioned above the mold core (102) of the insert molding machine. Next, placing the metal rod insert (104) onto the plurality of magnetic inserts (103) encapsulated over the core insert (105) positioned in the mold core (102). Then, securing the mold cavity (101) back onto the mold core (102) of the insert molding machine. Subsequently, initiating the injection of thermoplastic resin into the joint assembly formed by the mold cavity (101) and the mold core (102), which is configured to encapsulate the metal rod insert (104) by filling the thermoplastic resin to surround the boundaries and completing the insert molding process. Finally, removing the mold cavity (101) to extract the composited structure, herein an air vent with a metal rod insert (104), consisting of the encapsulated aesthetic automotive component (300) enclosing the metal rod insert (104) as a part used in an aesthetic automotive component (300).

ADVANTAGES OF THE PRESENT INVENTION
The present invention provides an enhancement in Structural Integrity allowing the plastic mold to endure higher loads and stress.
The present invention provides a combination of lightweight nature of plastic with the robustness of metal, creating durable yet lightweight components.
The present invention provides an improved corrosion resistance over environmental exposure by enhancing its resistance to corrosion.
The present invention provides a method wherein the aesthetic plastic part comes under head impact zone to prevent plastic deflection.
The present invention provides a precision and Stability which ensures better dimensional accuracy and stability in the final product.
It will be apparent to a person skilled in the art that the above description is for illustrative purposes only and should not be considered as limiting. Various modifications, additions, alterations, and improvements without deviating from the spirit and the scope of the invention may be made by a person skilled in the art.
It is intended that the disclosure and examples be considered as exemplary only, with a true scope and spirit of disclosed embodiments being indicated by the following claims. , Claims:WE CLAIM:
1. A method (200) of manufacturing an aesthetic automotive component with metal rod insert (104), comprising steps:
a. dislodging at step (201), a mold cavity (101) on a mold core (102) of an insert molding machine;
b. placing at step (202), a metal rod insert (104) on a plurality of magnetic inserts (103) positioned in the mold core (102);
c. lodging at step (203), the mold cavity (101) on the mold core (102) of the insert molding machine;
d. initiating at step (204), a thermoplastic resin injection into the assembled portion of the mold cavity (101), configured to encapsulate the metal rod insert (104), and
e. wherein the metal rod insert (104) is placed on the plurality of magnetic inserts (103) positioned on a core insert (105) configured to act as support members, holding the metal rod insert (104) in place for plastic injection, and
f. dislodging at step (205), the mold cavity (101), remove a composited structure of the metal rod insert (104) encapsulated thermoplastic model as an output.

2. The method (200) for insert molding of a metal molding in an aesthetic automotive component (300), as claimed in claim 1, wherein the thermoplastic resin is injected at higher temperature range of 275-300 degree centigrade.
3. The method (200) for insert molding of a metal molding in an aesthetic automotive component (300), as claimed in claim 1, wherein the magnets sustain a temperature of 400 degree centigrade.

4. The method (200) for insert molding of a metal molding in an aesthetic automotive component (300), as claimed in claim 1, wherein the metal rod insert (104) is made of magnetic materials that are metals or alloys.

5. The method (200) for insert molding of a metal molding in an aesthetic automotive component (300), as claimed in claim 1, wherein the plurality of magnetic inserts (103) are high thermal resistive magnet, positioned spatially in the pockets in the core inserts (105).

6. The method (200) for insert molding of a metal molding in an aesthetic automotive component (300), as claimed in claim 1, wherein the plurality of magnetic inserts (103), holds the metal rod insert (104) hermetically tight with the core insert (105).

7. The method (200) for insert molding of a metal molding in an aesthetic automotive component (300), as claimed in claim 1, wherein the article is a thermoplastic model of an aesthetic automotive component (300) with deflected ends at a prescribed angle.

8. The method (200) for insert molding of a metal molding in an aesthetic automotive component (300), as claimed in claim 1, wherein a gate, provided at the edge of the core, for injection of molten resin material into the cavity, and arranged for performing injection molding of thermoplastic resin material around the insert or the rod.

9. An aesthetic automotive component (300) prepared by the method as claimed in Claim 1.
Dated this 28th day of April 2025

Kalyanchand Jhabakh (IN/PA-830)
Agent for Applicant