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
  • B29C33/30—Mounting, exchanging or centering
• • 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
  • B29C33/0011—Moulds or cores; Details thereof or accessories therefor thin-walled moulds
• • 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
  • B29C33/12—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels
  • B29C33/123—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels for centering the inserts
  • B29C33/126—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels for centering the inserts using centering means forming part of the insert
• • 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
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
  • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
  • B29C44/1204—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements and giving the material during expanding the shape of a particular article to be supported, e.g. a human body-part
• • 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
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
  • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
  • B29C44/1252—Removing portions of the preformed parts after the moulding step
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
  • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
  • B63B22/00—Buoys
• • 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
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
  • B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
  • B29C44/1209—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements by impregnating a preformed part, e.g. a porous lining
• • 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
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/34—Auxiliary operations
  • B29C44/35—Component parts; Details or accessories
  • B29C44/351—Means for preventing foam to leak out from the foaming device during foaming
• • 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
  • B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
  • B29C44/34—Auxiliary operations
  • B29C44/36—Feeding the material to be shaped
  • B29C44/38—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length
  • B29C44/40—Feeding the material to be shaped into a closed space, i.e. to make articles of definite length by gravity, e.g. by casting
• • 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
  • B29K2075/00—Use of PU, i.e. polyureas or polyurethanes or derivatives thereof, as moulding material
• • 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
  • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
  • B29L2031/00—Other particular articles
  • B29L2031/706—Buoys
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B63—SHIPS OR OTHER WATERBORNE VESSELS; RELATED EQUIPMENT
  • B63B—SHIPS OR OTHER WATERBORNE VESSELS; EQUIPMENT FOR SHIPPING 
  • B63B2231/00—Material used for some parts or elements, or for particular purposes
  • B63B2231/40—Synthetic materials
  • B63B2231/52—Fibre reinforced plastics materials

Definitions

• the present invention relates to a method for manufacturing a molded article, in particular a buoy, the molded article comprising at least one cavity for arrangement and securing of one or more components within said cavities.
• the invention further relates to a mould for manufacturing the molded article with an integrated watertight tubular enclosure within an interior of the molding article.
• the foamed material is a low-temperature foaming material, and the molding temperature is not higher than 80 °C, preferably a polyurethane material such as a polyurethane composite material.
• Marine buoy is a widely used marine hydrometeorological observation platform, which is placed on the sea surface and connected to the seabed through an anchor chain system.
• Various observation equipment can be carried on the buoy to measure various meteorological elements at sea (such as wind speed, wave parameters, etc.).
• the deployment cycle can reach several years and the maintenance cost is high. Therefore, it is a buoy to be able to supply power to various devices continuously, safely and reliably for a long time.
• the marine buoy device that uses various renewable energy sources such as solar energy and wind energy in the surrounding environment of the buoy to provide self-supply power has become the focus of attention.
• a crucial aspect when making platform instrumentation sensor buoys is the cost involved access to the sea, so it is necessary to make a design that minimizes the cost of deployment, maintenance and withdrawal network of buoys.
• Most common maintenance tasks include the replacement of the batteries that supply power to the buoy.
• the sensor buoys must be equipped with (usually solar or wind) energy recovery systems that allow recharging batteries, and ensure energy independence.
• An alternative widely used to impart energy independence sensor buoys is the combined use of rechargeable batteries and photovoltaic solar panels.
• WO2022149140 discloses rubber molded articles that integrally incorporate an operable photovoltaic device, and method and system for producing such articles, wherein the operable photovoltaic device is integrally held on top of the rubber body, via a molded connection and holding mechanism which molds together the rubber body and the operable photovoltaic device.
• US8142705 discloses a method for producing a cast membrane and a mold for it.
• silicone is, for example, suitable as a material for the insert or mold inserts.
• Difference between the present invention and US8142705 is that the manufacturing technology is intended for the production of a different type of product (larger thickness and defined closed shape), whereby it enables the creation of grooves (or protrusions) in technologically unfeasible positions with regard to the dividing line (only one) between two parts of the mold.
• the method according to the present invention is further distinguished by the use of frames, which have a dual role.
• the first purpose of frame is to enable the exact positioning of an insert inside the mold, and the second is that after removing the insert from the frames, the frames remain permanently in a molded article and facilitates further positioning and fixing a component part of the final product (such as solar panel). Further, since polyurethane foam is a relatively sensitive material, use of frames that permanently remain in the molded article it is achieved that edges of cavities, which are fragile, are not torn off.
• US9599094 discloses a method of manufacturing an aerodynamic shell part for a wind turbine blade is described.
• the aerodynamic she part comprises a recess for arrangement and connection of a spar cap within said recess.
• US9599094 is directed to use of inserts to achieve a shape that follows the contours of the product. The inserts do not allow the end product to have grooves/contours of the product that are unfavorable in relation to the parting line.
• Polyurethane foam is used in the production of buoys as is the case with Resinex or Nautic EXPO, for example. But these buoys are mostly not intended for the integration of electronic components to realize certain functionalities, although there are examples.
• the present invention uses a mold with an internal flexible membrane (coating), which makes it easier to remove a molded article from a mold.
• the polymer or resin applied is polyester, vinyl ester or epoxy, but may also be PUR or pDCPD.
• Epoxies have advantages with respect to various properties, such as shrinkage during curing (in turn potentially leading to less wrinkles in the laminate), electrical properties and mechanical and fatigue strengths.
• Polyester and vinyl esters have the advantage that they provide better bonding properties to gelcoats.
• the present technology of making a molded article enables more functionality within one method and mould.
• the invention provides a method for manufacturing a molded article comprising at least one cavity that defines a part of an outer surface of the molded article for arrangement and securing of one or more components.
• the invention provides a method for manufacturing a molded article comprising at least one cavity that defines a part of an outer surface of the molded article for arrangement and securing of one or more components within the respective cavities, said method comprising the steps of: providing a first mould part having a first forming surface that defines a first part of the outer surface of the molded article, providing a second mould part having a second forming surface that defines a second part of the outer surface of the molded article, arranging and mechanically fixing at least one frame to the first and/or second forming surface of the first and/or second mould part, each frame having an inner perimeter size and shape being complementary to an outer perimeter size and shape of a bottom surface of the component being installed, arranging one or more removable flexible inserts within each of the respective frames and mechanically fixing each removable flexible insert to the respective frame, each removable flexible insert having an outer perimeter size and shape being complementary to the inner perimeter size and shape of the respective frame, mutually firmly connecting the first mould part and the second mould part into a closed mould, pouring a foam
• This manufacturing method provides a simple way of forming the molded article with cavities at the correct position and for connecting the components at the correct position to an outer surface of the molded article. Further, the frames ensures that inserts do not slide down from an inner sides of the mould and cause wrinkles in the layup. This provides for a simple way of ensuring that the shape of the framed inserts substantially corresponds to the shape of the components.
• each frame remains permanently in a molded article and facilitates further positioning and fixing a component to the molded article.
• the one or more removable inserts have an outer perimeter size and shape being complementary to a bottom surface of the component being installed.
• each frame has an inner perimeter size and shape being complementary to the outer perimeter size and shape of the bottom surface of the respective component being installed.
• a releasing material such as a waxy substance, is applied to said one or more insert in order to prevent said one or more inserts to adhere to the foaming material of the molded article.
• a gel coat will be applied to the forming surface of a mould prior to a foamable composition being poured in a closed mould.
• the invention provides disposing a watertight tubular enclosure within an interior of the molded article, the watertight tubular enclosure is hermetically closed and configured for location of electronic components.
• the invention also provides a mould for manufacturing a molded article, the molded article comprising at least one cavity that defines a part of an outer surface of the molded article for arrangement and securing of one or more components within the respective cavities, the mould comprises a first mould part having a first forming surface that defines a first part of the outer surface of the molded article and a second mould part having a second forming surface that defines a second part of the outer surface of the molded article, the first and/or second forming surface of the first and/or second mould part is/are configured for arranging and mechanically fixing at least one frame, each frame having an inner perimeter size and shape being complementary to an outer perimeter size and shape of a bottom surface of the respective component being installed, each frame is configured for arranging and mechanically fixing a removable flexible insert within and between inner side walls of the frame leaving no air
• each frame has a shape configured to tightly adhere to the first and/or second forming surface that defines the outer surface of the molded article.
• a foamable composition is selected from the group consisting of foamed polyurethane, vinyl ester or epoxy resins.
• the invention is particularly suited for floating article selected from the group consisting of: a buoy, a floating marker; wherein the floating article comprises at least one operable photovoltaic device antennas, sensors, and combinations thereof. Accordingly, the invention preferably relates to buoys with installed photovoltaic devices, antennas, sensors, and combinations thereof.
• the invention also contemplates a buoy comprising a number of components such as photovoltaic devices, antennas, sensors, and combinations thereof, e.g., two, three or four, according to any of the aforementioned aspects and embodiments.
• a perimeter shape and size of an outer bottom surface of a component with which the component is arranged within a cavity is being complementary to an inner perimeter size and shape of the frame.
• a perimeter shape and size of an outer surface of a removable flexible insert is being complementary to the inner perimeter size and shape of the frame and to the perimeter shape and size of the outer bottom surface of the installed component.
• FIG. 1 shows an isometric view of a buoy comprising arranged and secured photovoltaic solar panels within a cavity that defines a part of an outer surface of the buoy according to the invention
• FIG. 2 shows a side view of a buoy comprising cavities that defines a part of an outer surface of the buoy according to the invention
• FIG. 3 is an expanded view of a mould according to the invention
• FIG. 4 shows a first mould part and a watertight tubular enclosure disposed within an interior of the first mould part according to the invention
• FIG. 5 shows a first and second mould part and a watertight tubular enclosure disposed within an interior of the first and second mould part before closing a mould according to the invention.
• buoys molded articles
• present invention is not restricted to buoys, and may be used in conjunction with other forms of molded article. Nevertheless, the present disclosure finds particular application in the context of buoys, i.e., buoys configured to have permanently installed components such as photovoltaic devices.
• the present invention provides a new method for manufacturing molded article 11 which comprises at least one cavity 12 that defines a part of an outer surface of the molded article 11 for arrangement and securing of one or more components 14 within the respective cavities 12.
• the molded article 11 is for example a buoy, a floating marker; wherein the floating article comprises at least one operable photovoltaic device.
• the invention preferably relates to buoys with installed photovoltaic devices, but also other components 14 may be arranged and affixed to the outer/exterior surface of the molded article 11 .
• Examples of the components 14 may include, but are not limited to, photovoltaic cell panels, antennas, sensors, and combinations thereof. Therefore, an inner perimeter size and shape of at least one cavity 12 is being complementary to an outer perimeter size and shape of a bottom surface of the component 14 being installed.
• FIGS. 1 and 2 illustrate the molded article 11 such as a conventional buoy with cavities 12 and an opening 15.
• the opening 15 has substantially a circular shape configured to be opened and closed by a lid 21 (cover), however the opening 15 may have other shapes.
• FIG. 1 shows an isometric view of the molded article 11 such as conventional buoy comprising installed components 14 such as photovoltaic solar panels.
• the method according to the present invention comprising the steps of: providing a first mould part 1 having a first forming surface that defines a first part of the outer surface of the molded article 11 , providing a second mould part 10 having a second forming surface that defines a second part of the outer surface of the molded article 11 , arranging and mechanically fixing at least one frame 2 to the first and/or second forming surface of the first and/or second mould part 1 ; 10, each frame 2 having an inner perimeter size and shape being complementary to an outer perimeter size and shape of the bottom surface of the respective component 14 being installed.
• the method further comprises arranging one or more removable flexible inserts 3 within each of the respective frames 2 and detachably fixing each removable flexible insert 3 to the respective frame 2, each removable flexible insert 3 having an outer perimeter size and shape being complementary to the inner perimeter size and shape of the respective frame 2, mutually firmly connecting the first mould part 1 and the second mould part 10 into a closed mould, pouring a foamable composition in the closed mould, curing the foamable composition, and removing the molded article 11 from the mould and one or more removable flexible inserts 3 from said frames 2.
• Each frame 2 has the shape configured to tightly adhere to the first and/or second forming surface that defines the outer surface of the molded article 11 .
• the frames 2 are secured in place by removable fixing means, such as screws, threaded through the frames 2 and into said first mould part 1 and /or second mould part 10 having the first and/or second forming surface that defines the outer surface of the molded article 11 .
• the frames 2 have a dual role.
• the first purpose is to enable the exact positioning of the removable flexible inserts 3 inside the first and second mould part 1 ; 10, and the second is that after removing the flexible inserts 3 from the frames 2, the frames 2 remain permanently in the molded article 11 and facilitates positioning and securing the component 14 (such as solar panel). Since the frames 2 remain permanently in the molded article 11 , surface characteristics of edges of the cavities 12 being fragile, are not torn off.
• the first mould part 1 and the second mould part 10 are made of composite materials, where inner surfaces of said mould parts 1 ; 10 are provided with a coating which makes it easier to release the molded article 11 from the mold.
• the frames 2 are made with 3D printing technology preferably from PLA material. It is also possible to use other materials that adhere well with polyurethane foam such as metal, plastic, or polyurethane materials.
• Each frame 2 has the inner perimeter and shape corresponding to an outer perimeter and shape of the bottom surface of the component 14 being installed.
• the components 14 are photovoltaic solar panels, as illustrated in FIG. 1.
• the frames 2 have a rectangular shape and a size being complementary to the photovoltaic solar panels, but components 14 may have different shapes and sizes, accordingly shapes and sizes of the frames 2 conform to the shapes and sizes of the bottom surfaces of the components 14 being installed.
• the components 14 are mechanically fixed to the frames 2 being fixedly arranged in the cavities 12.
• frames 2 have the rectangular shape and a height corresponding to a thickness of the photovoltaic solar panels.
• Each frame 2 comprises a groove configured for disposing the removable flexible insert 3 within the groove of the frame 2, an inner groove perimeter size and shape matching the outer perimeter size and shape of the removable flexible insert 3.
• the groove has an L-shaped profile.
• the removable flexible inserts 3 are fully inserted and fitted into grooves of each frame 2 and abut to surfaces of the first and second forming surface of the first and/or second mould part 1 ; 10. Further, each removable flexible insert 3 when disposed within corresponding groove of the frame 2 fits leaving no airgaps.
• the removable flexible inserts 3 are made of silicone reinforced with glass fibers.
• Each frame 2 also comprises elements 23, being integral part of the frame 2, configured for mechanically fixing the frame 2 to the first and/or second forming surface of the first and/or second mould part 1 ; 10, further for detachably fixing removable flexible insert 3 within the frame 2, and after removing the removable flexible insert 3 from the frames 2, the elements 23 are configured for mechanically fixing the component 14 to the frame 2 and accordingly to the molded article 11 .
• the elements 23 are for example in a form of triangular elements, arranged on a side of the frame 2 in a way to abut to a surface of the cavity 12 arranged on the outer surface of the molded article 11.
• the elements 23 are provided with threaded holes for detachably fixing the removable flexible insert 3, fixing the frame 2 to the first mould part 1 and/or the second mould part 10, and tightly fixing the component 14 by means of screws. Therefore, each frame 2 is mechanically fixed to at least one of the first or second forming surface that defines the outer surface of the molded article 11 .
• the elements 23 may be arranged in corners of the frame 2, but other arrangements are possible depending on a shape of the frame 2 or the respective component 14 to be installed.
• FIG. 3 is an expanded view of a mould for manufacturing the molded article 11 according to the invention.
• the method further comprises disposing a watertight tubular enclosure 7 within an interior of the first mould part 1 and the second mould part 10.
• a bottom part of the first mould part 1 and the second mould part 10 forms a surface 22 provided with a part 19 configured for centrally disposing the watertight tubular enclosure 7.
• the surface 22 may be flat, however may have any other shape.
• the watertight tubular enclosure 7 is hermetically closed with a bottom cover lid 17 including an annular lower wall 20 being configured to receive end encircle the part 19, and a top cover lid 18.
• the method further comprises disposing a seal 16 within the interior of the first mould part 1 and the second mould part 10, where a bottom surface of the seal 16 is disposed on the surface 22 and an inner perimeter of the seal 16 is located around the annular lower wall 20 of the bottom cover lid 17 to seal the bottom cover lid 17 and to prevent entry of the foamable composition into the watertight enclosure 7.
• the inner perimeter of the seal 16 adheres firmly to the annular lower wall 20 and the bottom cover lid 17.
• the seal 16 is made of silicone and in combination with the bottom cover lid 17, with the addition of external pressure, adheres firmly to the annular lower wall 20 and the bottom cover lid 17 to seal the bottom cover lid 17 and to prevent entry of the foamable composition into the watertight enclosure 7.
• the part 19 is fixed to the surface 22.
• the part 19 and the annular lower wall 20 of the bottom cover lid 17 are configured for centrally positioning the watertight tubular enclosure 7 within the interior of the first mould part 1 and the second mould part 10.
• the annular lower wall 20 is made of PLA plastic with 3D printing technology (any other plastic or metal may be used) and serves for a uniform transfer of a pressure to the seal 16 and for centering the watertight tubular enclosure 7 in combination with the part 19 within the interior of the first mould part 1 and the second mould part 10.
• the watertight tubular enclosure 7 is configured for placing of electronic components.
• the watertight tubular enclosure is a tube made of Plexiglas material, but any other tube made of any other material adhering to polyurethane and withstanding temperatures above 80 degrees (during the expansion of the foam, the temperature in the mold rises to 70-80 degrees C) may be used.
• the top cover lid 18 is made of POM plastic with the material requirements same as for the watertight tubular enclosure 7.
• the top cover lid 18 hermetically closes the watertight tubular enclosure 7 from the upper side and enables arrangement of the electronic components within said enclosure 7.
• An upper end the first mould part 1 and the second mould part 10 each forms an opening 13 when the mould is closed, the opening 13 is configured for introducing the foamable composition into the mold, where the closed mould is provided with a cover (not illustrated) configured to enable expanding of the foamable composition.
• a releasing material such as a waxy substance, is applied to said one or more removable flexible inserts 3 in order to prevent said one or more removable flexible inserts 3 to adhere to the foamable composition.
• the components 14 are mechanically fixed to the corresponding frame 2.
• the frames 2 are secured in place by removable fixing means, such as screws, threaded through the frames 2 and into said first and/or second forming surface that defines the outer surface of the molded article 11 .
• the components 14 are secured to frames 2 by removable fixing means, such as screws, threaded through the frames 2.
• the present invention also relates to a mould, illustrated in FIGS. 3 to 5, for use in the method according to the invention.
• the mould for manufacturing a molded article 11 comprising at least one cavity 12 that defines a part of an outer surface of the molded article 11 for arrangement and securing of one or more components 14 within the respective cavities 12, the mould comprises a first mould part 1 having a first forming surface that defines a first part of the outer surface of the molded article 11 and a second mould part 10 having a second forming surface that defines a second part of the outer surface of the molded article 11 .
• the first and/or second forming surface of the first and/or second mould part 1 ; 10 is/are configured for arranging and mechanically fixing at least one frame 2. Particularly, each frame
• Each frame 2 has an inner perimeter size and shape being complementary to an outer perimeter size and shape of a bottom surface of the respective component 14 being installed. Further, each frame 2 is configured for arranging and detachably fixing a removable flexible insert 3 within and between inner side walls of the frame 2 leaving no airgaps, wherein one or more removable flexible inserts 3 having an outer perimeter size and shape being complementary to the inner perimeter size and shape of the respective frame 2.
• Each frame 2 comprises a groove configured for disposing the removable flexible insert 3 within the groove of the frame 2, an inner groove perimeter size and shape matching the outer perimeter size and shape of the removable flexible insert 3.
• Each frame 2 comprises elements 23, being integral part of the frame 2, configured for detachably fixing removable flexible insert 3 and after removing the removable flexible insert
• the elements 23 are configured for mechanically fixing the component 14 to the respective frame 2 and accordingly to the molded article 11 .
• the elements 23 are arranged on a side of each frame 2 in a way to abut to a surface of the cavity 12 arranged the outer surface of the molded article 11 .
• the mould is configured for disposing a watertight tubular enclosure 7 within an interior of the first mould part 1 and the second mould part 10 and accordingly within an interior of the molded article 11.
• a bottom part of the first mould part 1 and the second mould part 10 forms a surface 22 provided with a part 19 configured for centrally disposing the watertight tubular enclosure 7.
• the watertight tubular enclosure 7 is hermetically closed with a bottom cover lid 17 including an annular lower wall 20 being configured to receive end encircle the part 19, and a top cover lid 18.
• the mould is also configured for disposing a seal 16 within the interior of the first mould part 1 and the second mould part 10, where a bottom surface of the seal 16 is disposed on the surface 22.
• An inner perimeter of the seal 16 is located around the annular lower wall 20 of the bottom cover lid 17 to seal the bottom cover lid 17 to prevent entry of the foamable composition into the watertight enclosure 7.
• the part 19 is mechanically fixed to the surface 22.
• the part 19, the annular lower wall 20 of the bottom cover lid 17 and the seal 16 are configured for centrally positioning the watertight tubular enclosure 7 within the interior of the first mould part 1 and the second mould part 10.
• the seal 16 is made of silicone and in combination with the bottom cover lid 17, with the addition of external pressure, adheres firmly to a wall of the watertight tubular enclosure 7 and prevents the foamable composition from penetrating into the space inside the watertight tubular enclosure 7.
• the annular lower wall 20 is made of PLA plastic with 3D printing technology (any other plastic or metal may be used) and serves for a uniform transfer of a pressure to the seal 16 and for centering the watertight tubular enclosure 7 within the interior of the first mould part 1 and the second mould part 10 in combination with the part 19.
• An upper end the first mould part 1 and the second mould part 10 each comprises threads forming an opening 13 when the mould is closed, the opening 13 is configured for pouring the foamable composition into the closed mould, where the closed mould is provided with a cover configured to enable expanding of the foamable composition.
• the seal 16 forms an opening 15 in the molded article 11 as illustrated in FIGS. 1 and 2, the opening 15 has substantially a circular shape configured to be opened and closed by a lid 21 (cover).
• the seal 16 and accordingly the opening 15 may have other shapes.
• the watertight tubular enclosure 7 is configured for the location of electronic components.
• the watertight tubular enclosure is a tube made of Plexiglas material, but any other tube made of any other material adhering to polyurethane and withstanding temperatures above 80 degrees (during the expansion of the foam, the temperature in the mold rises to 70-80 degrees C) may be used.
• the top cover lid 18 is made of POM plastic with the material requirements same as for the watertight tubular enclosure 7.
• the top cover lid 18 hermetically closes the watertight tubular enclosure 7 from the upper side and enables arrangement of the electronic components within said enclosure 7.
• the watertight tubular enclosure 7 is configured for the location of electronic components.
• An upper end the first mould part 1 and the second mould part 10 each forms an opening 13 when the mould is closed, the opening 13 is configured for pouring the foamable composition into the closed mould, where the closed mould is provided with a cover configured to enable expanding of the foamable composition.
• the mould is a two-part mould, namely consisting of the first mould part 1 and the second mould part 10.
• Each mould part 1 and 10 has a flange 24 configured for tightening said parts 1 and 10 into the closed mould.
• Each flange 24 extends perpendicularly along edges of each mould part 1 and 10.
• the first mould part 1 and the second mould part 10 are secured into the closed mould by removable fixing means, such as screws, threaded through the flanges 24.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Combustion & Propulsion (AREA)
• Ocean & Marine Engineering (AREA)
• Casting Or Compression Moulding Of Plastics Or The Like (AREA)

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• 2023
  • 2023-02-27 WO PCT/EP2023/025086 patent/WO2024179652A1/en not_active Ceased
  • 2023-02-27 EP EP23710217.3A patent/EP4673291A1/de active Pending

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