Abstract:
A method for restoring the finish of injection molded parts includes the steps of scuffing a surface of an unrestored injection molded plastic part with a scuff pad formed of an abrasive material, cleaning the scuffed surface with a cleaner substance, applying a base coat material to the scuffed and cleaned surface, applying a finish coat material over the base coat material on the surface, and blending the base coat material and the finish coat material with a cloth member to produce a desired appearance for the surface.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     The present invention relates generally to the restoration of plastic automotive parts and, in particular, to a method for restoring such parts.  
         [0002]     Injection molded parts are well known. The automotive industry in particular has been utilizing these parts for many years to decrease the weight and price of certain vehicular components including, but not limited to, air intake systems and the like. A popular hobby is the restoration of automobiles, especially classic automobiles. This hobby has spawned an industry of businesses that specialize in restoring cars and the original parts for these cars. The hobbyists and the industry conduct competitions to determine which of the vehicles have been restored most accurately, including details such as correct color shades and the number of original parts utilized, among others.  
         [0003]     A common problem associated with restoring vehicles is the finish on the exterior surfaces of vehicle interior and engine compartment injection molded parts including, but not limited to, air grabbers, fan shrouds, heater boxes, and the like. When new, these injection molded parts often have a metallic or a satin-like appearance due to the injection molding process. After many years, however, these parts lose their original appearance and disadvantageously appear flat and discolored. In restoration competitions, those individuals involved in restoring vehicles may lose points in competition as a result of poor or unrestored finish, or finish not nearly complete as the original finish on the injection molded parts. In addition, not many of these injection parts are produced as reproduction items.  
         [0004]     It is desirable, therefore, to restore these factory-original parts of the vehicles to their original “factory-new” appearance and condition. It is also desirable to provide a method for restoring the finish of injection molded parts.  
       SUMMARY OF THE INVENTION  
       [0005]     A method for restoring the finish of injection molded parts includes the steps of scuffing a surface of an unrestored injection molded plastic part with a scuff pad formed of an abrasive material, cleaning the scuffed surface with a cleaner substance, applying a base coat material to the scuffed and cleaned surface, applying a finish coat material over the base coat material on the surface, and blending the base coat material and the finish coat material with a cloth member to produce a desired appearance for the surface.  
         [0006]     The system and method in accordance with the present invention will provide an effective system and method for restoring the finish of the surfaces of injection molded parts. 
     
    
     DESCRIPTION OF THE DRAWINGS  
       [0007]     The above, as well as other advantages of the present invention, will become readily apparent to those skilled in the art from the following detailed description of a preferred embodiment when considered in the light of the accompanying drawings in which:  
         [0008]      FIG. 1  is a perspective view of a finish restoring kit in accordance with the present invention;  
         [0009]      FIG. 2  is a perspective view of a plastic part having a surface to be refinished in accordance with the present invention;  
         [0010]      FIG. 3  is a perspective view of a cloth member used with the kit shown in  FIG. 1 ;  
         [0011]      FIG. 4  is an enlarged fragmentary sectional view of the part of  FIG. 1  showing first and second layers of a coating according to the present invention;  
         [0012]      FIG. 5  is a view of the part of  FIG. 4  showing the first and second layers blended; and  
         [0013]      FIG. 6  is a flowchart of the steps of a method in accordance with the present invention. 
     
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0014]     Referring now to  FIG. 1 , a kit in accordance with the present invention is indicated generally at  10 . The kit  10  includes at least one abrasive scuff pad  12 , a container  14  of liquid cleaner substance, a first paint coating applicator  16 , and a second paint coating applicator  18 . The kit  10  is used for restoring the finish of an exterior surface  22  of an injection molded part  20 , such as a fan shroud shown in  FIG. 2 . Alternatively, the part  20  is an air grabber (not shown), a heater box (not shown), or any other plastic part where it is desirable to restore the finish of the exterior surface thereof.  
         [0015]     The at least one abrasive scuff pad  12  is preferably formed of an abrasive material including, but not limited to, Scotch-Brite® abrasive hand pads, available commercially from the 3M Corporation. The coarseness of an exterior surface of the scuff pad  12  is operable to abrade the exterior surface  22  of the part  20  to prepare the surface  22  for the paint coating, discussed in more detail below. Preferably, the coarseness of the scuff pad  12  is less than that of a steel wool or similar material.  
         [0016]     The cleaner container  14  preferably contains a commercially available lacquer thinner, such as, but not limited to, Klean-Strip® automotive surface preparation thinner available from the W.M. Barr Company, Inc. Such a cleaner substance is suitable for cleaning and degreasing the surface  22 .  
         [0017]     The first paint coating applicator  16  is preferably adapted to dispense a fast drying acrylic enamel paint material having a flat finish, discussed in more detail below, such as a paint applicator and material commercially available from Seymour of Sycamore, Inc. Similarly, the second paint coating applicator  18  is preferably adapted to dispense a fast drying acrylic enamel paint material having a gray cast metallic finish, discussed in more detail below, such as a paint applicator and material commercially available from Seymour of Sycamore, Inc.  
         [0018]     Referring now to  FIG. 3 , a cloth member  30  is preferably a shop rag or similar type natural fabric member. Alternatively, the cloth member  30  is formed of a lint-free material or a synthetic material.  
         [0019]     In operation, the surface  22  of the part  20  is cleaned by using a detergent and hot water solution (not shown). The detergent may be any type of detergent including, but not limited to, Tide®, or a dishwashing detergent. After cleaning with the detergent and after the surface  22  has dried sufficiently, the scuff pad  12  is utilized to abrade the surface  22  of the part  20 , which prepares the surface  22  to accept and adhere to the paint dispensed from the applicators  16  and  18 .  
         [0020]     After the scuff pad  12  has been used to abrade the surface  22 , the lacquer thinner of the cleaner container  14  is utilized to remove any debris, petroleum products such as grease, or the like from the surface  22 . The lacquer thinner of the cleaner container  14  may be applied to the surface  22  utilizing a cloth member, such as the cloth member  30  of  FIG. 3 , or by any other type of cleaning device. After cleaning, the surface  22  is allowed to dry.  
         [0021]     Referring now to  FIGS. 4 and 5 , the part  20  is shown in partial cross section. In  FIG. 4 , a first paint material  24 , dispensed from the first paint coating applicator  16 , is disposed on the surface  22  after the surface  22  and the lacquer thinner of the cleaner container  14  has dried sufficiently. Preferably, the first paint material  24  has a flat finish appearance when dry. The first paint material  24  is applied to the surface  22  to form a relatively thick layer on the surface  22 , best seen in  FIG. 4 . The first paint material  24  is allowed to dry, after which a second paint material  26  is dispensed from the second paint coating applicator  18  to adhere to the flat finish first paint material  24 . Preferably, the second paint material  26  has a satin/metallic finish appearance when dry. The second paint material  26  is applied to the first paint material  24  in a layer that is thinner than the layer of the first paint material  24 , best seen in  FIG. 4 . During application, the second paint material  26  is preferably misted onto the first paint material  24  and allowed to at least partially dry.  
         [0022]     After the second paint material  26  has at least partially dried, a blending member, such as the cloth member  30  of  FIG. 3 , is utilized to blend the first paint material  24  and the second  26  paint material. When blended with the blending member, the first paint material  24  and the second paint material  26  form a coating layer  28  having a resulting exterior surface  32 , best seen in  FIG. 5 . The first paint material  24  and the second paint material  26  are blended until the coating surface  32  has the desired appearance. Preferably, the desired appearance of the exterior surface  32  of the coating layer  28  is a combination of the flat finish of the first paint material  24  and the satin/metallic finish of the second paint material  26 . Preferably, the exterior surface  32  is visually similar to the finish of the exterior surface  22  of the part  20  when new. The second paint material  26  of the second paint applicator  18  may be misted onto the coating surface  32  at least once more and blended further in order to produce the desired visual appearance of the surface  32 .  
         [0023]     Referring now to  FIG. 6 , a flowchart is shown that describes in detail how a method in accordance with the present invention may be practiced. In a step  100 , the part, such as the fan shroud  20  of  FIG. 2 , is cleaned with a detergent. In a step  102 , the part is cleaned and degreased, such as with the lacquer thinner of the cleaner in the container  14  of  FIG. 1 . In a step  104 , a base coat, such as the first paint material  24  from the first paint applicator  16 , is applied to the exterior surface of the part. In a step  106 , a finish coat, such as the second paint material  26  from the second paint applicator  18 , is applied to the base coat. In a step  108 , the finish coat and the base coat are blended, such as by the use of the cloth member  30  of  FIG. 3 .  
         [0024]     In accordance with the provisions of the patent statutes, the present invention has been described in what is considered to represent its preferred embodiment. However, it should be noted that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit or scope.