GB1603336A - Creación de Inventos y Patentes con Inteligencia Artificial

GB1603336A – Modular slush moulding machine
– Google Patents

GB1603336A – Modular slush moulding machine
– Google Patents
Modular slush moulding machine

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Publication number
GB1603336A

GB1603336A
GB14938/78A
GB1493878A
GB1603336A
GB 1603336 A
GB1603336 A
GB 1603336A
GB 14938/78 A
GB14938/78 A
GB 14938/78A
GB 1493878 A
GB1493878 A
GB 1493878A
GB 1603336 A
GB1603336 A
GB 1603336A
Authority
GB
United Kingdom
Prior art keywords
heat
liquid
mould
fusing material
temperature
Prior art date
1977-04-21
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)

Expired

Application number
GB14938/78A
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)

McCord Corp

Original Assignee
McCord Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
1977-04-21
Filing date
1978-04-17
Publication date
1981-11-25

1978-04-17
Application filed by McCord Corp
filed
Critical
McCord Corp

1981-11-25
Publication of GB1603336A
publication
Critical
patent/GB1603336A/en

Status
Expired
legal-status
Critical
Current

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Classifications

B—PERFORMING OPERATIONS; TRANSPORTING

B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL

B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING

B29C33/00—Moulds or cores; Details thereof or accessories therefor

B29C33/02—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means

B29C33/04—Moulds or cores; Details thereof or accessories therefor with incorporated heating or cooling means using liquids, gas or steam

B—PERFORMING OPERATIONS; TRANSPORTING

B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL

B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING

B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor

B29C35/007—Tempering units for temperature control of moulds or cores, e.g. comprising heat exchangers, controlled valves, temperature-controlled circuits for fluids

B—PERFORMING OPERATIONS; TRANSPORTING

B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL

B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING

B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor

B29C41/02—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of definite length, i.e. discrete articles

B29C41/18—Slush casting, i.e. pouring moulding material into a hollow mould with excess material being poured off

B—PERFORMING OPERATIONS; TRANSPORTING

B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL

B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING

B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor

B29C41/22—Making multilayered or multicoloured articles

B—PERFORMING OPERATIONS; TRANSPORTING

B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL

B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING

B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor

B29C41/34—Component parts, details or accessories; Auxiliary operations

B29C41/46—Heating or cooling

B—PERFORMING OPERATIONS; TRANSPORTING

B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL

B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING

B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor

B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould

B29C35/04—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam

B29C35/041—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam using liquids

B29C2035/042—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam using liquids other than water

B29C2035/043—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould using liquids, gas or steam using liquids other than water oil

B—PERFORMING OPERATIONS; TRANSPORTING

B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL

B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS

B29K2105/00—Condition, form or state of moulded material or of the material to be shaped

B29K2105/0058—Liquid or visquous

B29K2105/0061—Gel or sol

B—PERFORMING OPERATIONS; TRANSPORTING

B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL

B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS

B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds

B29K2995/0018—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular optical properties, e.g. fluorescent or phosphorescent

B29K2995/002—Coloured

Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS

Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC

Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS

Y10S264/00—Plastic and nonmetallic article shaping or treating: processes

Y10S264/60—Processes of molding plastisols

Description

PATENT SPECIFICATION
( 11) 1 603 336 ( 21) Application No 14938/78 ( 22) Filed 17 Ap ( 31) Convention Application Nos.
789410 ( 32) Filed 21 A:
832 640 12 Se ( 33) United States of America (US) ( 44) Complete Specification published 25 Nov 1981 ( 51) INT CL 3 B 29 C 5/00 ( 52) Index at acceptance B 5 A 1 R 314 C 2 XT 8 P wril 1978 wril 1977 pt 1977 in ( 54) MODULAR SLUSH MOLDING MACHINE ( 71) We, MCCORD CORPORATION, a corporation of the State of Michigan, United States of America, of 2850 West Grand Boulevard, Detroit, Michigan 48202, United States of America, do hereby declare the invention, for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the followingstatement:-
This invention relates to a method and an assembly for practising the method of molding hollow thin-walled articles from a heatfusing material such as vinyl plastisol by slush molding.
Various vinyl plastisol compositions are known and used in various slush molding methods in various assemblies for performing those methods Typically, an open hol0 low mold is filled with liquid plastisol and heat is applied to the mold surface and transferred to the liquid plastisol to gel a layer of plastisol adjacent the mold surface.
The thickness of the gelled layer depends upon the temperature to which the plastisol layer is subjected and the time the plastisol is maintained at that temperature After the layer adjacent the mold surface is gelled, the ungelled liquid plastisol remaining is dumped or poured out of the mold.
In one well-known method, the mold temperature is maintained relatively low to prevent gelling as a very thin initial layer or coating of plastisol is applied to the mold to prevent bare spots and to prevent the entrapment of air bubbles, thereby providing a thin coating which strictly conforms to the mold configuration Such a coating is applied by filling and emptying the mold.
For example, automotive dashboard or instrument panel covers are made in this fashion and the molds frequently include details to define imitation stitching in the finished product as well as undercuts and other intricate detail The very thin coating is first applied to conform to the mold and to prevent irregularities in the outer surface of the finished product After this very thin coating is applied, the mold is again filled with additional plastisol and the entire mold is heated to gel the plastisol and increase the thickness of the finished product After the desired thickness is attained, the mold is again dumped or emptied and thereafter the mold is subjected to additional heat for cur 55 ing the product.
An example of such a method and an assembly for practising same is shown in our U.S Patent 3,728,429 That patent discloses such a method for slush molding arti 60 cles wherein the mold is heated by the exterior surfaces thereof being exposed to impinging streams of hot gas and, after the product is finished, the mold is cooled by being subjected to cooling water from water 65 spray nozzles, after which the fused finished article is stripped from the mold In addition, an endless conveyor moves a plurality of molds through various stations in the performance of the method Although the 70 method and assembly shown in this patent have proven to be very satisfactory, there are disadvantages such as the open flame adjacent the molds, which produces the hot gas for heating of the molds, and the use of 75 water or liquid for cooling the molds and which can be incompatible with the plastisol Further, the assembly, because of its long conveyor and multiple molds, is suited for long runs of a plastisol of a particular 80 color but is not well suited for short runs or quick or efficient changeovers.
Other methods of heating in a slush molding process have been utilized in the prior art; for example, the molds may be moved 85 through heating ovens as exemplified in U.S Patent 3,002,230 Alternatively, the molds may be subjected to induction heaters as exemplified in our U S Patent 3,315,016.
Another method for heating the mold is 90 exemplified in our U S Patent 3,680,629 which teaches the heating of a mold by incorporating tubes in the mold and flowing a heated fluid such as steam through the tubes for heating the mold It is also known 95 in the slush molding art to heat the mold by such tubes for conveying liquid through the mold wherein there are multiple circuits of the tubes with each circuit having an inlet and an outlet, but with each circuit sub 100 0 n 1 603 336 jected to the same fluid medium, i e, the same temperature.
One of the problems associated with the prior art methods is that in many articles which are manufactured by slush molding where the mold is filled with plastisol, some areas of the filled mold are at a lower liquid level of the plastisol and are salvage or trim areas which are not used in the final product and therefore do not require the thickness of the other finished areas in the product.
Yet, when the entire mold surface is heated uniformly the entire finished article has approximately the same thickness even though some areas are trim or non-usable.
There is known in the slush molding art the technique of varying the thickness by heating different areas of the mold to a higher degree to increase the thickness of the article in certain areas Such a technique is exemplified in U S Patent 2,588,571 which discloses the technique of slush molding a boot by utiliziation of infrared lamp heating and shielding the heating from certain portions of the mold to prevent the build-up of the plastisol thickness and to increase the thickness of the sole of the boot by increased heating.
According to the present invention there is provided a method for moulding an article of heat-fusing material in a mould having first and second groups of passages disposed adjacent the mould surface and adapted to control the temperature over respective first and second areas of the mould surface, said method comprising the steps of: supplying all of the passages with liquid for maintaining the temperature of the first and second areas of the mould surface at a non-gelling temperature below that required to gel any appreciable thickness of the heat-fusing material, disposing liquid heat-fusing material over the first and second areas of the mould surface, supplying the first group of passages with liquid at a temperature sufficient to raise the temperature of the first area to a higher temperature than the second area for gelling a predetermined thickness of the heat-fusing material over the first area, removing non-gelled liquid heat-fusing material from the mould, and supplying the first and second passages with liquid at a temperature sufficient to raise the temperature of the first and second areas to a cure temperature for curing the heat-fusing material disposed thereover.
Also according to the present invention, there is provided an article of heat-fused material when moulded by the method described in the immediately preceding paragraph.
By the method of the present invention, the moulded article will have a greater thickness over the first area which defines the finished area of the article, whereas the thickness of the article over the second area of the mould surface will be much thinner and may define the scrap or trim areas Consequently, significant amounts of material may be saved Accordingly, the liquid in the 70 second group of passages is preferably maintained at a temperature to inhibit the gelling of the liquid heat-fusing material over the second area until the first and second passages are supplied liquid for raising the first 75 and second areas to a cure temperature.
Preferably, the mould surface is maintained at a non-gelling temperature in the range of F to 180 F prior to disposing the firstmentioned heat-fusing material over the 80 first and second areas, the first area of the mould surface is heated with liquid in the first group of passages to a temperature in the range of 2500 F to 2900 F for gelling the heat-fusing material over the first area of 85 the mould surface, and the first and second areas of the mould surface are thereafter heated with liquid in the passages to a temperature in the range of 350 Sto 4000 F for the curing of the heat-fusing material 90 Conveniently, a coating of liquid heatfusing material is applied to the first and second areas while the first and second areas are at said non-gelling temperature and prior to disposing the first-mentioned liquid 95 heat-fusing material over said first and second areas for the gelling thereof over the first area, such coating being applied by, for example, filling the mould with liquid heatfusing material and emptying the mould to 100 leave the coating in the mould The coating of plastisol is applied to ensure the picking up by moulding of small detail and to generally provide a blemish-free surface.
Further according to the present inven 105 tion there is provided an assembly for moulding an article of heat-fusing material comprising: a mould presenting a mould surface, a first group of liquid passages disposed adjacent the mould surface over a 110 first area thereof and adapted to control the temperature over said first area of the rrmould surface, a second group of liquid passages disposed adjacent the mould surface over a second area thereof and adapted to 115 control the temperature over said second area of the mould surface, and control means for sequentially supplying liquid to said first and second groups of passages for maintaining the temperature of said first 120 and second areas at a non-gelling temperature below that required to gel any appreciable thickness of the heat-fusing material and for thereafter heating said first area of said mould surface to a higher temperature 25 than said second area for gelling a pre determined thickness of the heat-fus g material over said first area of said mould surface.
Still further according to the present 130 1 603 336 invention there is provided an assembly for moulding an article of heat-fusing material comprising: a mould presenting a mould surface, closed liquid passage means disposed adjacent the nould surface and adapted to separate different temperatures of liquid for differentially controlling the temperatures over first and second areas of the mould surface, and control means adapted to sequentially supply liquid to said passage means to maintain the temperature of said first and second areas at a nongelling temperature below that required to gel any appreciable thickness of the heatCsing material and to thereafter heat said first area of said mould surface to a higher temperature than the second area to gel a predetermined thickness of the heat-fusing material over said first area of said mould surface.
Preferably, the assembly includes mould support means supporting said mould, first manifold means supported by said mould support means and adapted to distribute liquid to and collect liquid from said first group of passages, and second manifold means supported by said mould support means and adapted to distribute liquid to and collect liquid from said second group of passages Pedestal means may be provided to support the mould support means for rotation about an axis for emptying said mould of liquid heat-fusing material, in which case there is conveniently provided a first manifold means and a second supply line in communication with said second manifold means, a first swivel means disposed on said axis for allowing said first supply line to rotate with said mould support means and second swivel means disposed on said axis in axially spaced relationship to said first swivel means for allowing said second supply line to rotate with said support means.
ply line to rotate with said support means.
There may conveniently be provided a heat-fusing material supply and retrieval module capable of supplying liquid heatfusing material to said mould surface and of retrieving liquid heat-fusing material emptied from said mould, and the module preferably includes conveyance means to facilitate movement thereof away from said pedestal means and said mould support means.
Generally the module will include a dump tank adapted to be positioned below said mould support means for receiving and retrieving liquid heat-fusing material emptied from said mould, and may be in the form of a frame structure supporting a heat-fusing material storage tank, a heatfusing material heat exchanger adapted to heat the heat-fusing material supply conduit means for supplying heat-fusing material to said mould, return conduit means for returning heat-fusing material from said dump tank to said storage tank, pump means adapted to circulate the heat-fusing material, and valve means adapted to control the circulation of heat-fusing material through said storage tank, said heat exchanger and 70 said conduit means Conveniently, the first-mentioned control means includes a hot liquid circuit having control valves, a pump and first heat exchange means capable of sequentially supplying liquid to said 75 first and second groups of liquid passages and a cold liquid circuit having control valves, a pump and second heat exchange means capable of sequentially supplying liquid to said first and second groups of 80 liquid passages.
One embodiment of a method and assembly in accordance with the present invention will now be described by way of example only, with reference to the accom 85 panying drawings, in which:
FIG U RE 1 is a perspective view of a preferred embodiment of an assembly constructed in accordance with the subject invention; 90 FIGURE 2 is a fragmentary crosssectional view showing a mold supported in a mold support means for utilization with the subject invention; FIGURE 3 is a schematic view of the 95 liquid circuits utilized to heat and cool a mold in accordance with the subject invention; and FIGURE 4 is a schematic view showing a plastisol supply and retrieval circuit utilized 100 with the subject invention.
FIGURE 1 shows an assembly generally indicated at 10 and constructed in accordance with the subject invention The assembly 10 includes a stationary pedestal 105 generally indicated at 12 for rotatably supporting a mold support means generally indicated at 14 The pedestal 12 rotatably supports the mold support means for rotation about the axis A-A The mold support 110 means 14 is a box or coffin-like structure which receives and supports a mold 16 The mold 16 has a mold cavity defining a mold surface.
The pedestal 12 is stationary and includes 115 a base 18 and spaced support legs 2 ( O The support legs 20 rotatably support the mold support means 14 through large circular bearings (not shown) disposed on collars or sleeves 22, which collars or sleeves 22 have 120 accesses or openings through the center thereof, the purpose of which will be explained hereinafter The mold support means 14 is rotated through a large chain sprocket disposed within the housing 24 and 125 secured to the sleeve 22 A chain is entrained about the large sprocket and is entrained about a drive sprocket rotated by a motor supported upon the base 18.
The assembly 10 also includes a movable 130 1 603 336 modular unit generally shown at 26 for supplying liquid heat-fusing material such as a plastlsol to the open mold 16 The entire unit 26 is supported on a plurality of rollers 28 and includes a dump tank 30 The dump tank 30 is movable with the entire unit 26 and is normally disposed under the mold support means 14 when the unit 26 is in the operating position illustrated in FIGURE 1 relative to the pedestal 12 for receiving plastisol emptied from the mold 16 as the mold 16 is rotated for dumping or emptying into the dump tank 30 As alluded to above, the mold 16 may be supplied with a different plastisol or the same plastisol of a different color merely by moving the modular unit 26 away trom the mold and inserting or placing a different modular unit in position having a different plastisol Further, and as will become clear hereinafter, the preferred embodiment of the unit 26 includes two modules for supplying two different plastisols whereby two different plastisols may be sequentially supplied to the mold This can result in a continuous production cycle utilizing a particular mold 16 to make the same product or article of different colors.
The modular unit 26 is a plastisol supply and retrieval module for supplying liquid plastisol to the mold surface of the mold 16 and for retrieving liquid plastisol emptied or dumped from the mold 16 The rollers 28 define a conveyance means for fascilitating the movement of the unit 26 away from the pedestal 12 and the mold support means 14.
The mold 16 has a molding surface on the interior thereof which must be heated for the plastisol to gel A first group of liquid passages 32 are disposed adjacent the mold surface over a first area 34 of the mold surface for controlling the temperature over the first area 34 of the mold surface Additionally, a second group of liquid passages 36 are disposed adjacent the mold surface over a second area 38 of the mold surface for controlling the temperature over the second area 38.
A first manifold means, including a pair of manifolds 40 are supported by the mold support means for distributing liquid to and collecting liquid from the first group of passages 32 More specifically, a manifold 40 is disposed at each end of the mold support means 14 and the respective liquid passages 37 extend between the two manifolds 40.
Each passage 32 is connected to the manifold through a regulating valve 42 having a manual adjustment 44 whereby the liquid flow in each respective passage 32 may be manually adjusted In a similar fashion, the assembly includes a second manifold means comprising a pair of manifolds 46 disposed at the respective ends of the mold support means 14 for distributing liquid to and collecting liquid from the second group of passages 36 Further, each passage 36 is connected to the manifold 46 through a regulating valve 42 having a manual adjustment 44.
It will be appreciated that the regulating valves 42 need only be disposed at one end 70 of the mold support means 14 for regulating the fluid flow through the respective passages 32 and 36.
As used herein, the term first group of liquid passages and/or the term second 75 group of liquid passages may include any number of passages including one singular passage Further, the terminology that the passages are disposed adjacent the mold surface is intended to cover 80 embodiments where the tubes defining the passages 32 and 36 are welded, braised or otherwise attached to the surfaces of the mold, as illustrated, or partially or completely embedded in the walls of the mold 85 section Additionally, the groups of passages may be defined other than by the tubes illustrated so long as the passages are defined to supply liquid at different temperatures to differentially heat the areas of the mold and 90 to retrieve the liquid for recirculation, i e, a closed system for the liquid.
The first supply line 48 is in communication with the manifolds 40 of the first manifold means and a second supply line 50 is in 95 communication with the manifolds 46 of the second manifold means As alluded to above, the rotatable supports or sleeves for the mold support means 14 on the legs 20 have circular openings therethrough at each 100 end and the lines 48 and 50 extend therethrough, as illustrated in FIGURE 1 A first swivel means or joint 52 is associated with each end of the line 48 and is disposed on the axis A-A for allowing the first supply 105 line 48 to rotate with the mold support means 14 In a similar fashion, the lines 50 extend through two 900 elbows to a second set of swivels 54 defining a second swivel means disposed on the axis A-A in axially 110 spaced relationship to the swivels 52 for allowing both ends of the second supply line to rotate with the mold support means 14 As will be appreciated from viewing FIGURE 1, the supply line 50 moves about 115 the axis of the supply line 48 and, therefore, the degree of rotation of the mold support means 14 is limited to approximately 2700.
There is also included a control means generally shown in FIGURE 3 for sequen 120 tially supplying liquid to the first and second groups of passages 32 and 36 for maintaining the temperature of the first and second areas 34 and 38 of the mold surface at a non-gelling temperature below that 25 required to gel any appreciable thickness o’ the plastisol over the mold surface and fur thereafter heating the first area 34 of the mold surface to a higher temperature than the second area 38 of the mold surface for 130 1 603 336 gelling additional plastisol to a predetermined thickness over the first area 34 of the mold surface An oil, such as a hydraulic oil, may be utilized in the liquid passages 32 and 36 as the heat conducting medium Preferably, the liquid used is made by Dow Chemical under the trademark «DOWTHERM A’ and comprises 26 5 % diphenyl 1 C H 5 Cs Hsl and 73 5 % diphenyl oxide l(Co H 5)20 l When the mold 16 is first filled with plastisol, the solenoid-actuated control valves V,, V 2, V 3 and V 4 are closed and the valves Vs, V 6, V 7 and V 8 are open and oil is circulated through both manifolds 40 and 46 by the pump P 2 and the oil is heated by the heater I which is a gas burning heat exchanger A thermo couple or thermistor is associated with the mold surface of the mold 16 and when the mold surface reaches approximately 1500 all of the valves are closed and the mold support means 14 is rotated to dump or empty the mold 16 into the dump tank 30 When the first and second areas 34 and 38 of the mold surface are heated to a range of approximately 130 TF to ‘F a thin coating is applied over the mold surface This coating or layer is actually applied as the mold 16 is filled and emptied of plastisol, as some of the liquid plastisol covers the mold surface or flows into the intricacies thereof during the emptying motion After the mold is emptied, it is returned to the upright position A limit switch is associated with the mold support means to provide a signal when the mold support means is returned to the upright position illustrated in FIGURE 1 When the mold support means returns to the upright position, only the solenoid-actuated valves Vf and V 7 are open to supply hot oil through the manifold 40 and to the liquid passages 32 for heating the first areas 34 of the mold surface The oil is approximately 400 TF and heats the first areas 34 of the mold surface to a range of 250 ‘F to 260 ‘F as the mold is refilled or additional plastisol placed in the mold, for gelling the plastisol in the first areas 34 of the mold surface During this period the temperature of the mold surface in the second area is maintained at a nongelling temperature Another thermocouple provides a signal when the mold surface temperature is approximately 250 TF to provide a signal for pouring the additional plastisol into the mold 16 It will be appreciated by those skilled in the art that the temperature of the first areas may be raised for gelling before or during or after the re-filling of the mold depending upon the design of the mold and the other factors A timer may be provided to provide a predetermined time the plastisol is subjected to the 250 temperature of the mold for providing a predetermined thickness in the article before the mold support means 14 is again rotated for emptying the additional plastisol into the dump tank 30 When the mold support means 14 is rotated back to the upright position, valves Vs, V 6, W 7 and Vs are opened to supply the 450 » oil through both liquid pas 70 sages 32 and 36 so the mold surface temperature in all areas reaches a range of 350 ‘F to 400 ‘F for gelling the plastisol over the second areas and curing or fusing the entire finished plastisol article over both the first 75 and second areas After the curing, the mold support means rotates to a position where the mold faces outwardly or is in a generally perpendicular position and valves Vs, Vs, V 7 and V 8 are closed and valves V,, V 2, V 3 and 80 V 4 are opened to supply cool oil through liquid passages 32 and 36 for cooling the mold surface whereby the article may be manually stripped from the mold This cooling brings the mold temperature down to 85 approximately 1500, a temperature desired for the first filling of the mold in making the next article The oil flow in the cooling circuit passes through the cooler and pump Pl and is preferably at a temperature of 90 approximately 80 TF An appropriate electrical control circuit actuates the valves and the drive mechanism for rotating the mold support means in the proper sequence.
Alternatively, the thermocouples and other 95 controls may provide signals to an operator who m-ay, in turn, manually actuate each successive sequence.
The modular unit 26 includes a frame structure of structural beams supported on 100 the rollers 28 As alluded to above, the frame structure supports two complete plastisol supply systems or modules, only one of which will be described in conjunction with FIGURES 1 and 4 The frame structure 105 supports a plastisol storage tank 56 and a plastisol heat exchanger 58 The plastisol heat exchanger 58 has a heating coil passing therethrough through which hot liquid may be passed for heating the plastisol to main 110 tain its proper viscosity.
There is also included a pump 60 for circulating the plastisol through the system.
There is also included a supply conduit means 62 for supplving plastisol to the mold 115 16 The conduit 6 ‘ has a swivel 64 therein so the end of the conduit 62 may be moved upwardly and out of the way by an actuator 66 The flow of plastisol to the mold 16 is controlled by a valve 68 The bottom of the 120 plastisol tank 56 has a conduit leading to the valve 68 and teed off that conduit is a line which extends to a valve 72 adjacent the top of the heat exchanger 58 A drain line 74 leads from the bottom of the dump tank 125 into the pump 60 to the heat exchanger 58 Another conduit 76 extends from the dump tank 30 upwardly to a valve 78 with a conduit 80 connected thereto and to a valve 82 In certain modes of operation the valves 130 1 603 336 72 and 82 will be closed and the valve 78 will be open whereby liquid plastisol will be circulated from the drain line 74 through the pump 60, heat exchanger 58, the valve 78 and back through the line 76 into the dump tank for circulation and heating thereof.
Alternatively, the valve 78 and the valve 82 may be closed whereby liquid plastisol moves from the dump tank through the pump 60, the heat exchanger 58, the valve 72, line 70 and to the plastisol tank 56 or through the valve 68 to be dumped from the conduit 62 into the mold 16 The conduits 74 and 76 define return conduit means for returning the plastisol from the dump tank to the storage tank 56 As explained hereinbefore, when the mold support means 14 is rotated, plastisol in the mold 16 is dumped into the dump tank 30.
The modular unit includes another independent plastisol supply and retrieval means or module with-its circuit heating, storing, etc, components, and is generally shown at 84 in FIGURE 1 The module or system 84 is identical to the module having the components described immediately above The advantage of having two independent modules or systems on one modular unit is that two different plastisols may be utilized for the initial layer or coating as distinguished from the subsequent gelling of an additional thickness in the article Further, with one modular unit, an article of two different plastisols or a plastisol of two different colors may be made in short consecutive runs.
Because two different plastisols may be utilzed, the top of the dump tank 30 includes channels 86 at either end into which rollers are slidably disposed The rollers are attached to a cover plate which is actuated bv a pulley cable s,,stem 988 Another dump tank wvhich is not shown is disposed immediately rearwardly of the dump tank 30 and when a second plastisol is utilized which is incompatible with the plastisol in the tank 30, the plate is moved by the cable pulleysystem 88 to a position to cover the dump Lank 30 so that when the mold is emptied, the plastisol will ‘low over the cover pla e rearwardly and downwardly and into the secondary dump tank disposed rearwardlv of the dump tank 30 Additionally, another complete modular unit including one or more modules may be moved into position for making articles of additional different plastisols.
Thus, the control means includes a hot liquid circuit having control valves, a pump P, a first heat exchange means, comprising the heater I, for sequentially supplying liquid to the first and second supply lines 48 and 50 and a cold liquid circuit having control valves, a pump Pl and a secold heat exchange means, comprising the cooler, for sequentially supplying liquid to the first and second supply lines 48 and 50.
Thus, in accordance with the subject invention, initially all of the passages 32 and 36 are supplied with liquid oil to heat or cool the first and second areas 34 and 38 of 70 the mold surface to maintain a non-gelling temperature and a liquid plastisol is poured into the mold to define a coating or layer.
To accomplish this, the mold is filled and emptied into the dump tank 30 As men 75 tioned above, the liquid coating is applied to avoid surface defects in the finished product Depending upon the mold configuration it may not always be necessary to perform this liquid coating step In other words, 80 in some cases it may be possible to first gel the plastisol over the first areas while maintaining the plastisol over the second areas in a non-gelled condition After the coating is applied, the first group of passages 32 are 85 supplied with a liquid oil at a temperature higher than the temperature of the liquid oil in the second group of passages 36 for heating the first area 34 to a higher temperature than the second area 38 Additional liquid 90 plastisol is disposed over the coating or layer and gelled over the first area 34 of the mold which is heated with the heat supplied by the liquid in the first group of passages 32 to gel a predetermined thickness of the article 95 over the first area 32 The temperature of the liquid in the second group of passages 36 is maintained and arranged to prevent any appreciable gelling of liquid plastisol over the area 38 of the mold heated by the sec 100 ond group of passages 36 to prevent the build-up of gelled plastisol in those areas of the finished article where the additional thickness is not necessarily required and is often wasteful As mentioned above, the 105 temperature of the first area may be raised to a gelling temperature before or during or after the mold is filled with plastisol After the mo Id 16 is emptied the second time when the plastisol has gelled in the first area 1 O 34 to the desired thickness, both the first and second groups of passages 32 and 36 are supplied with heated liquid to heat the first and second areas 34 and 38 for gelling the plastisol in the second area and curing 115 and fusing the plastisol over both the first and second areas Hteating and/or cooling of the mold may be accomplished as the plastisol is added or dumped.
As will be appreciated, by preventing the 120 build-up of the thickness of the finished article in the areas of the finished article which may be trimmed or which may not be used, a great deal of plastisol may be used and recirculated and therefore does not end up 25 in the finished article, thereby providing significant saving in material costs Furthe because of the method and system employed, the plastisol is not subjected to any open flame heat, as the heat is supplied in a closed 130 7 1 603 336 7 circuit and, in a similar fashion, the mould may be cooled by a closed system instead of being subjected to sprayed water, or the like.
An example of an article which may be made in accordance with the subject invention is disclosed in the above-mentioned U.S Patent 3,315,016 which includes information relevant to the present invention.
The method and assembly disclosed herein for moulding articles of heat-fusing material in a modular manner are described and claimed in our co-pending application no 8034570 (serial no 1 603 337) which is divided out of this application.

Claims (19)

WHAT WE CLAIM IS:-

1 A method for moulding an article of heat-fusing material in a mould having first and second groups of passages disposed adajcent the mould surface and adapted to control the temperature over respective first and second areas of the mould surface, said method comprising the steps of: supplying all of the passages with liquid for maintaining the temperature of the first and second areas of the mould surface at a non-gelling temperature below that required to gel any appreciable thickness of the heat-fusing material, disposing liquid heat-fusing material over the first and second areas of the mould surface, supplying the first group of passages with liquid at a temperature sufficient to raise the temperature of the first area to a higher temperature than the second area for gelling a predetermined thickness of the heat-fusing material over the first area, removing non-gelled liquid heat-fusing material from the mould, and supplying the first and second passages with liquid at a temperature sufficient to raise the temperature of the first and second areas to a cure te perature for curing the heat-fusing material disposed thereover.

2 A method as set forth in claim 1 which comprises maintaining the temperature of the liquid in the second group of passages to inhibit the gelling of the liquid heat-fusing material over the second area until the first and second passages are supplied liquid for raising the first and second areas to a cure temperature.

3 A method as set forth in claim 1 or -laim 2 in which the mould surface is maintained at a non-gelling temperature in the range of 130 ‘F to 1800 F prior to disposing the first-mentioned heat-fusing material over the first and second areas, the first area of the mould surface is heated with liquid in the first group of passages to a temperature in the range of 250 F to 29017 for gelling the heat-fusing material over the first area of the mould surface, and the first and second areas of the mould surface are thereafter heated with liquid in the passages to a temperature in the range of 350 ‘F to 400 TF for the curing of the heat-fusing material.

4 A method as set forth in any one of claims 1 to 3 including applying a coating of liquid heat-fusing material to the first and 70 second areas while the first and second areas are at said non-gelling temperature and prior to disposing the first-mentioned liquid heat-fusing material over said first and second areas for the gelling thereof over the 75 first area.

A method as set forth in claim 4 in which the coating is applied by filling the mould with liquid heat-fusing material and emptying the mould to leave the coating in 80 the mould.

6 A method as set forth in claim 5 in which disposing liquid heat-fusing material comprises filling the mould a second time with the first-mentioned heat-fusing mater 85 ial and emptying the mould a second time of non-gelled heat-fusing material subsequent to the gelling of the material to the predetermined thickness over the first area.

7 A method for moulding an article of 90 heat-fusing material, substantially as herein described with reference to the accompanying drawings.

8 An article of heat-fused material when moulded by the method claimed in 95 any one of the preceding claims.

9 An assembly for moulding an article of heat-fusing material comprising: a mould presenting a mould surface, a first group of liquid passages disposed adjacent the mould 100 surface over a first area thereof and adapted to control the temperature over said first area of the mould surface, a second group of liquid passages disposed adjacent the mould surface over a second area thereof and 105 adapted to control the temperature over said second area of the mould surface, and control means for sequentially supplying liquid to said first and second groups of passages for maintaining the temperature of 110 said first and second areas at a non-gelling temperature below that required to gel any appreciable thickness of the heat-fusing material and for thereafter heating said first area of said mould surface to a higher temp 115 erature than said second area for gelling a predetermined thickness of the heat-fusing material over said first area of said mould surface.

An assembly as set forth in claimt 9 120 including mould support means supporting said mould, first manifold means supported by said mould support means and adapted to distribute liquid to and collect 1 iquid from said first group of passages, and second 125 manifold means supported by said mould support means and adapted to distribute liquid to and collect liquid from said second group of passages.

11 An assembly as set forth in claim 10 130 1 603 336 8 1 603 336 including pedestal means which rotatably supports said mould support means for rotation about an axis for emptying said mould of liquid heat-fusing material.

12 An assembly as set forth in claim 11 including a first supply line in communication with said first manifold means and a second supply line in communication with said second manifold ‘means, a first swivel means disposed on said axis for allowing said first supply line to rotate with said mould support means and second swivel means disposed on said axis in axially spaced relationship to said forst swivel means for allowing said second supply line to rotate with said support means.

13 An assembly as set forth in claim 11 or claim 12 including a heat-fusing material supply and retrieval module capable of supplying liquid heat-fusing material to said mould surface and of retrieving liquid heatfusing material emptied from said mould.

14 An assembly as set forth in claim 13 in which said module includes conveyance means to facilitate movement thereof away from said pedestal means and said mould support means.

An assembly as set forth in claim 13 or claim 14 in which said module includes a dump tank adapted to be positioned below said mould support means for receiving and retrieving liquid heat-fusing material emptied from said mould.

16 ‘ An assembly as set forth in any one of claims 13 to 15 in which said module includes a frame structure supporting a heat-fusing material storage tank, a heatfusing material heat exchanger adapted to heat the heat-fusing material supply conduit means for supplying heat-fusing material to said mould, return conduit means for returning heat-fusing material from said dump tank to said storage tank, pump means adapted to circulate the heat-fusing material, and valve means adapted to control the circulation of heat-fusing material through said storage tank, said heat exchanger and said conduit means.

17 An assembly as set forth in any one of claims 9 to 16 in which said first so mentioned control means includes a hot liquid circuit having control valves, a pump and first heat exchange means capable of sequentially supplying liquid to said first and second groups ot liquid passages and a cold 55 liquid circuit having control valves, a pump and second heat exchange means capable of sequentially suprlyiug liquid to said first and second groups o liquid passages.

18 An assembly for moulding an article 60 of heat-fusing material comprising: a mould presenting a mould surface, closed liquid passage means disposed adjacent the mould surface and adapted to separate different temperatures of liquid for differentially con 65 trolling the temperatures over first and second areas of the mould surface, and control means adapted to sequentially supply liquid to said passage means to maintain the temperature of said first and second areas at a 70 non-gelling temperaure below that required to gel any appreciable thickness of the heatfusing material and to thereafter heat said first area of said mould surface to a higher temperature than the second area to gel a 75 predetermined thickness of the heat-fusing material over said first area of said mould surface.

19 An assembly for moulding an article of heat-fusing material, substantially as 80 herein described with reference to the accompanying drawings.
URQUHART-DYKES & LORD, 1 1 th Floor, St Martin’s House, Tottenham Court Road, London, W 1 P JN.
and 3rd Floor, Essex House, 27 Temple Street, Birmingham, B 2 5 DD.
Chartered Patent Agents.
Printed for Her Majesty’s Stationery Office by The Tweeddale Press Ltd, Berwick-upon-Tweed 1981 Published at the Patent Office 25 Southampton Buildings London, WC 2 A IAY, from which copies may be obtained.
1 603 336

GB14938/78A
1977-04-21
1978-04-17
Modular slush moulding machine

Expired

GB1603336A
(en)

Applications Claiming Priority (2)

Application Number
Priority Date
Filing Date
Title

US78941077A

1977-04-21
1977-04-21

US05/832,640

US4217325A
(en)

1977-04-21
1977-09-12
Method using modular slush molding machine

Publications (1)

Publication Number
Publication Date

GB1603336A
true

GB1603336A
(en)

1981-11-25

Family
ID=27120911
Family Applications (2)

Application Number
Title
Priority Date
Filing Date

GB34570/80A
Expired

GB1603337A
(en)

1977-04-21
1978-04-17
Modular slush moulding machine

GB14938/78A
Expired

GB1603336A
(en)

1977-04-21
1978-04-17
Modular slush moulding machine

Family Applications Before (1)

Application Number
Title
Priority Date
Filing Date

GB34570/80A
Expired

GB1603337A
(en)

1977-04-21
1978-04-17
Modular slush moulding machine

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US4217325A
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JP
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JPS53132062A
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DE
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FR
(1)

FR2387754A1
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GB
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1978

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patent/GB1603337A/en
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patent/GB1603336A/en
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Also Published As

Publication number
Publication date

FR2387754A1
(en)

1978-11-17

JPS5410581B2
(en)

1979-05-08

JPS53132062A
(en)

1978-11-17

GB1603337A
(en)

1981-11-25

US4217325A
(en)

1980-08-12

DE2817030C2
(en)

1985-06-27

FR2387754B1
(en)

1983-10-14

DE2817030A1
(en)

1978-10-26

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