Patent ID: 8840819
Filing Date: 2014-09-23
Classification: B29C,B29L,B32B,B60R

Abstract:
1. A method of manufacture of an energy management system, the method comprising the steps of: providing a mold comprising a first mold portion and a second mold portion; spacing the first mold portion and the second mold portion about a polymeric parison; closing the first and second mold portions to pinch the polymer parison; injecting air into the parison forming a wall and a cavity from the polymer parison; drilling an aperture in the wall through a port in the first mold portion; dispensing a first plurality of beads into the cavity through the aperture; injecting steam into the first plurality of beads causing expansion of the first plurality of beads to form a first in-situ foam core having a thermal bond to the wall forming a structural plastic beam; separating the first mold portion from the structural plastic beam to create a space between the first mold portion and the structural plastic beam; dispensing a second plurality of beads into the space between the first mold portion and the structural plastic beam; injecting steam into the second plurality of beads causing expansion of the second plurality of beads to form a second in-situ foam core having a second thermal bond to the structural plastic beam forming the energy management system; and opening the mold to remove the energy management system, wherein the step of separating the first mold portion from the structural plastic beam to create the space between the first mold portion and the structural plastic beam consists of moving the first mold portion away from the second mold portion and the wall.