GB1567836A

GB1567836A - Moulded article reinforcing

Info

Publication number: GB1567836A
Application number: GB275477A
Authority: GB
Original assignee: Altulor
Current assignee: Altulor
Priority date: 1976-03-09
Filing date: 1977-01-24
Publication date: 1980-05-21
Also published as: FR2343580B1; PT66277A; BE850306A; IT1079454B; LU76896A1; IE44523L; DE2705548C2; ES461457A1; GR62475B; NL7702133A; AT383306B; ES455763A1; IE44523B1; ATA158877A; FR2343580A1; PT66277B; CH597999A5; DE2705548A1; NL186622C

Description

(54) MOULDED ARTICLE REINFORCING (71) We, ALTULOR a French Corporation of 5, rue du General Foy Paris 8 eme France, organised under the laws of France, 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 following statement: The present invention relates to a method and apparatus for reinforcing an object or article essentially comprising a hot-shaped shell, and more particularly to reinforcing a shell made from a hot-shaped thermoplastic resin sheet with a resin glass fibre laminate.

French Patent n" 75/29 312 discloses reinforcing a hot-shaped shell with a resin/glass fibre laminate, the operation being carried out by "contact", i.e. by manually applying cloth and brushing on resin, or by spraying glass fibres and polyester resin simultaneously or consecutively.

The first such mode of preparation is rather slow in execution and unsuited for mass production;as for the second mode of preparation, it has been found to be hard to perform on small-sized articles, especially those with reentrant or necked portions.

An aim of the invention is a method and apparatus for the industrial manufacture of articles especially comprising a resin-reinforced hot-shaped shell.

According to the invention there is provided a method for reinforcing an article or object which essentially comprises a hot-shaped shell, comprising supporting a surface of the shell on an elastically deformable pad intimately matable therewith, placing a mould part having a working surface of shape complementary to the other surface of the shell so that a free space is formed between the mould part and the shell, injecting a reinforcing resin into the free space and then demoulding the thus-rein forced shell.

According to the invention there is also provided an apparatus for carrying out the method, comprising an elastically deformable pad adapted to support and intimately matable with a surface of a hot-shaped shell, a mould part complementary to the shape of the other surface of the shell, and means for injecting resin under pressure into the free space formed between the mould part and the shell when in assembled position.

The present method and apparatus permit the industrial manufacture of reinforced hotshaped shell articles and more particularly articles of small size, the injection under pressure of reinforcing resin being made possible by using an elastic pad which distributes stress over the shell and thereby avoids the formation of tiny cracks and reduces the risk of splits in the shell.

Moreover, if the mould part working surface is elastically deformable it is possible to reinforce shell articles have re-entrant or necked portions, and it makes it easy to demould them.

The invention will now be described in greater detail having reference to a preferred embodiment, given by way of non limiting example, and illustrated in the accompanying drawings, in which: Figure 1 shows a cross-sectional view of an apparatus for strengthening a hot-shaped shell; and Figure 2 shows a cross-sectional view of an apparatus for positioning the deformable member of the male part in the mould.

The description which follows relates to the manufacture of a motorcycle helmet; it is an article of relatively small dimensions which comprises a reinforced hot-shaped shell with a reentrant or necked portion, which is rather hard to produce according to known methods.

To carry out the method or reinforcing the shell, the apparatus represented in figure 1 is employed, which apparatus essentially comprises two main mould parts or units, a female or negative mould part 2 accommodating the hot-shaped shell 1 for the helmet and a male or positive mould part 3 which is disposed substantially inside the shell when in position.

The male and female mould parts 3 and 2 are of complementary shape to the inner and outer surface of the shell 1 so that the female mould part 2 closely mates with the outer surface of the shell while the male mould part 3 forms with the inner surface of the shell a free space 4.

Each mould part comprises a rigid support bearing an elastically deformable, pliable member which lines the rigid support.

Thus the female mould part 2 essentially comprises a rigid support 5 comprising a cup with a slightly flaring side wall lined with an elastically deformable member 6 which is in intimate mating contact with the outer surface of the shell 1. The rigid support S is, for example, made of laminated polyester and the elastically deformable member 6 is preferably polynorbornene rubber, sold under the mark "Norsorex"; the support may be of any other rigid material, metal or monmetal, and the elastically deformable member may be made of another elastomer which is sufficiently firm to effectively support the shell but also sufficiently elastically deformable to conform intimately with the shape of the shell. The male or positive mould part or unit 3 likewise comprises a rigid support 7 with a tapering central wall covered with an elastically deformable member 8 preferably made of polymerised silicon resin, sold under the mark "Silastene", the support 7 being made, for example, of laminated polyester. In order to reduce the weight of the apparatus, the support 7 is hollow and has a central cavity 9 communicating with an injection orifice 10 which extends through the portion of the deformable member 8 forming the bottom of the cavity 9; the bore of the orifice 10 is slightly conical to improve the sealing connection with a conduit supplying reinforcing resin (not shown).

The rigid support 5 of the female mould part 2 has at least one aperture 11 for facilitating the unsticking and removal of the deformable member 6 from its rigid support 5.

Locating teats 12 and 13 are provided for positioning the elastically deformable members 6, 8 on their respective supports 5, 7, the teats being received in corresponding locating recesses in their supports. The supports 5 and 7 are in turn located with respect to each other by positioning studs 14 passing through a flange 15 on the rigid support 5 and received in corresponding positioning holes 16 in a flange 17 on the rigid support 7. During the injection of the reinforcing resin, the rigid supports are joined to each other by conventional clamping means, e.g. bolts or clamps.

During the injection of the reinforcing resin between the male mould part 3 and the hotshaped shell, the latter is subjected to relatively high pressure forces which produce substantial stressing. Since the shell is preferably formed of polymethyl thacrylate, it is rather fragile and therefore risks rupture or cracking where it is inadequately supported and where stressing is critical. It is therefore important for the shell to be completely and uniformly supported at all points, which will only be the case where the female mould part 2 intimately mates with the outer surface or the shell which has a necked or re-entrant portion.

Likewise, in order that the free space formed between the male mould part 3 and the shell may be of substantially constant height throughout, it will be important for the outer surface of the male mould part to be of complementary shape to the inner surface of the shell even for necked portions 8 of the deformable member.

For these various reasons the male and female mould parts 3 and 2 of the present apparatus have elastically deformable members 6 and 8 which allow them to adapt themselves completely to the shape of the hot-shaped shell 1, to distribute the stresses uniformly owing to the give of the elastically deformable material and to permit easy denioulding; the mould parts or units are constructed in the following manner.

For the elastically deformable member 6 to perfectly mate with the shell, the elastically deformable material is "poured" around the outer surface of the shell; in other words it is covered with a layer of polynorbornene rubber which is sufficient to eliminate the necked or re-entrant portions of at least 5 mm, then, after gelling, the covering is reinforced with a polyester laminate forming the rigid support 5, and since it is impossible to couple these two materials locating teats and recesses 12 are provided for positioning the elastically deformable member with respect to the rigid support.

As the assembly is fixed in position and rigidified, the interior of the shell is coated with a calibrating layer of wax the thickness of which corresponds to glass fibre resin laminate which is desired on the shell.

Moreover, care is taken in making the rigid support 7 of laminated polyester so that there is no necked or re-entrant portion. The silicon resin, for example, is poured into the assembly comprising the cup-shaped rigid support 5, the elastically deformable member 6 and the shell covered with the layer of calibration wax; the rigid support 7 is pushed into position, forcing the silicon resin to flow along the wall of the shell up to the point at which it flows out through vent holes drilled in the rigid support 7 and it is positioned by means of positioning studs 14 extending into holes 16 so that it takes the same position after demoulding. After polymerization the assembly is taken apart, the calibrating layer of wax is removed and orifices 10 and 11 are provided in the elastically deformable member 8 and the rigid support 5.

The "mould" thus constructed comprises a "die" consisting of the hot-shaped shell 1 supported by its pad 6 of polynorbornene rubber which is in tum supported by the rigid support 5 and a male part 3 made up of a rigid support 7 covered with an elastically deformable member 8 which, when closing the mould, is introduced first alone and deformed in the shell 1, then shaped by the introduction of the support 7 which is received in the last-mentioned elastically deformable member.

The elastically deformable member 8 is introduced aid removed with the help of the device shown in figure 2, simply comprising a plate 20 with locating recesses 21 at its periphery adapted to receive teats 13 of the elastically deformable member 8 through which passes a central tube 22. One end of the tube 22 is closed off by a frustoconical tip 23 adapted to be fitted in the injection orifice 10 in the elastically deformable member 8, and an opening 24 is provided in tube 22 in the vicinity of the tip 23;the other end of the tube is connected to a vacuum pump (not illustrated) and a sealing member 25 provides fluidtightness at the junction of the tube 22 and the plate 20. When the mould is to be closed the elastically deformable member 8 is mounted on the plate 20 with its locating teats 13 in the recesses 21 and the tip 23 closing off the injection orifice 10, then the sealed space 26 between the plate and the member 8 is brought under partial vacuum; the deformable member 8 collapses and its necked or reentrant portion disappears, so that it is easy to introduce it into the hot-shaped shell 1. Once in position, the space 26 is allowed to regain ambient pressure so that the outer deformable member takes on again its normal shape, with its necked portion restored; thereafter the plate 20 is taken off and the rigid support 7 is put into position to maintain the desired shapes of the deformable members.

The reinforcing of the hot-shaped shell is effected in the following manner.

Once the shell 1 is surrounded by the elastically deformable member 6 and put into place in the rigid female support 5, glass fibre mats and/or glass fibres are appropriately cut to overlie one another and the mould is closed, placing the outer deformable member 8 and the rigid male support 7 as described above; the rigid supports 5 and 7 are then clamped together. It is important for the assembly not to be hermetically sealed; this is done either by clamping the glass fibre between the rigid male support 7 and the hot-shaped shell 1 or by forming striations in the surface of the rigid male support 7 in contact with the shell.

By means of an injection machine, resin is introduced under a pressure of 1 to 10 bars through the injection orifice 10 in the elastically deformable member 8; care is taken so that this step is carried out as slowly as possible so as to eliminate bubbles and voids in the glass fibres and to avoid the formation of air pockets, the injection continuing until the resin flows out, for example through radial striations in the rigid support 7.

The give of the elastically deformable members 6 and 8 allows the pressures to be absorbed and stress distributed over the hot-shaped shell; the sheet is uniformly supported by the member 6 which serves as a pressure distributing pad, preventing tiny cracks.

When the polymerization of the reinforcing resin is completed, the reinforced shell is demoulded by withdrawing the rigid male support 7 which, owing to its tapered configuration, is removed easily, then the elastically deformable member 8 is collapsed by means of the device illustrated in figure 2 and the resin-reinforced shell, together with elastically deformable member 6, is removed from the cup-shaped female support 5. The elastically deformable member 6 is then pulled off the shell like a sock.

With the injection moulding method taught herein, which employs the pressure distributing pad 6 to support the hot-shaped shell, the shell can be quickly and easily reinforced despite the pressure of necked or l entrant portions.

The scope of the invention is of course not limited to the illustrated embodiment but covers all modifications falling within the clairns which follow this description.

It goes without saying that the present invention is not only applicable to the manufacture of motorcycle helmets but also concerns the manufacture of all objects and articles comprising a hot-shaped shell requiring reinforcement or a simple inner or outer covering.

WHAT WE CLAIM IS: 1. A method for reinforcing an object or article which essentially comprises a hot-shaped shell, comprising supporting a surface of the shell on an elastically deformable pad intimately matable therewith, placing a mould part having a working surface of shape complementary to the other surface of the shell so that a free space is formed between the mould part and the shell, injecting a reinforcing resin into the free space and then demoulding the thus-reinforced shell.

2. A method according to claim 1, wherein, before placing the mould part opposite the shell, fibres and/or fibre mats are deposited on the shell in mutually overlying relation.

3. A method according to claim 1 or 2, wherein the reinforcing resin is slowly injected into the free space to prevent the formation of bubbles or voids in the fibres.

4. A method according to any of claims 1 to

**WARNING** end of DESC field may overlap start of CLMS **.

Claims

**WARNING** start of CLMS field may overlap end of DESC **. through vent holes drilled in the rigid support 7 and it is positioned by means of positioning studs 14 extending into holes 16 so that it takes the same position after demoulding. After polymerization the assembly is taken apart, the calibrating layer of wax is removed and orifices 10 and 11 are provided in the elastically deformable member 8 and the rigid support 5. The "mould" thus constructed comprises a "die" consisting of the hot-shaped shell 1 supported by its pad 6 of polynorbornene rubber which is in tum supported by the rigid support 5 and a male part 3 made up of a rigid support 7 covered with an elastically deformable member 8 which, when closing the mould, is introduced first alone and deformed in the shell 1, then shaped by the introduction of the support 7 which is received in the last-mentioned elastically deformable member. The elastically deformable member 8 is introduced aid removed with the help of the device shown in figure 2, simply comprising a plate 20 with locating recesses 21 at its periphery adapted to receive teats 13 of the elastically deformable member 8 through which passes a central tube 22. One end of the tube 22 is closed off by a frustoconical tip 23 adapted to be fitted in the injection orifice 10 in the elastically deformable member 8, and an opening 24 is provided in tube 22 in the vicinity of the tip 23;the other end of the tube is connected to a vacuum pump (not illustrated) and a sealing member 25 provides fluidtightness at the junction of the tube 22 and the plate 20. When the mould is to be closed the elastically deformable member 8 is mounted on the plate 20 with its locating teats 13 in the recesses 21 and the tip 23 closing off the injection orifice 10, then the sealed space 26 between the plate and the member 8 is brought under partial vacuum; the deformable member 8 collapses and its necked or reentrant portion disappears, so that it is easy to introduce it into the hot-shaped shell 1. Once in position, the space 26 is allowed to regain ambient pressure so that the outer deformable member takes on again its normal shape, with its necked portion restored; thereafter the plate 20 is taken off and the rigid support 7 is put into position to maintain the desired shapes of the deformable members. The reinforcing of the hot-shaped shell is effected in the following manner. Once the shell 1 is surrounded by the elastically deformable member 6 and put into place in the rigid female support 5, glass fibre mats and/or glass fibres are appropriately cut to overlie one another and the mould is closed, placing the outer deformable member 8 and the rigid male support 7 as described above; the rigid supports 5 and 7 are then clamped together. It is important for the assembly not to be hermetically sealed; this is done either by clamping the glass fibre between the rigid male support 7 and the hot-shaped shell 1 or by forming striations in the surface of the rigid male support 7 in contact with the shell. By means of an injection machine, resin is introduced under a pressure of 1 to 10 bars through the injection orifice 10 in the elastically deformable member 8; care is taken so that this step is carried out as slowly as possible so as to eliminate bubbles and voids in the glass fibres and to avoid the formation of air pockets, the injection continuing until the resin flows out, for example through radial striations in the rigid support 7. The give of the elastically deformable members 6 and 8 allows the pressures to be absorbed and stress distributed over the hot-shaped shell; the sheet is uniformly supported by the member 6 which serves as a pressure distributing pad, preventing tiny cracks. When the polymerization of the reinforcing resin is completed, the reinforced shell is demoulded by withdrawing the rigid male support 7 which, owing to its tapered configuration, is removed easily, then the elastically deformable member 8 is collapsed by means of the device illustrated in figure 2 and the resin-reinforced shell, together with elastically deformable member 6, is removed from the cup-shaped female support 5. The elastically deformable member 6 is then pulled off the shell like a sock. With the injection moulding method taught herein, which employs the pressure distributing pad 6 to support the hot-shaped shell, the shell can be quickly and easily reinforced despite the pressure of necked or l entrant portions. The scope of the invention is of course not limited to the illustrated embodiment but covers all modifications falling within the clairns which follow this description. It goes without saying that the present invention is not only applicable to the manufacture of motorcycle helmets but also concerns the manufacture of all objects and articles comprising a hot-shaped shell requiring reinforcement or a simple inner or outer covering. WHAT WE CLAIM IS:

1. A method for reinforcing an object or article which essentially comprises a hot-shaped shell, comprising supporting a surface of the shell on an elastically deformable pad intimately matable therewith, placing a mould part having a working surface of shape complementary to the other surface of the shell so that a free space is formed between the mould part and the shell, injecting a reinforcing resin into the free space and then demoulding the thus-reinforced shell.

4. A method according to any of claims 1 to

3, wherein the free space between the mould part and the shell is not fluid-tight, the injection of the resin being continued until the resin flows out of the mold at the interface of the mould part with the shell.

5. A method according to any of claims 1 to 4, for reinforcing an article having a reentrant or necked portion, the working surface of said mould part being provided on an elastically deformable member, further comprising collapsing the elastically deformable member when assembling the mould and unmoulding the reinforced shell.

6. A method substantially as herein described with reference to the accompanying drawings.

7. Apparatus for carrying out the method of claim 1, comprising an elastically deformable pad adapted to support and intimately matable with a surface of a hot-shaped shell, a mould part complementary to the shape of the other surface of the shell, and means for injecting resin under pressure into the free space formed between the mould part and the shell when in assembled position.

8. Apparatus according to claim 7 for carrying out the method of claim 5, wherein the working surface on said mould part is provided on an elastically deformable member.

9. Apparatus according to claim 8, wherein said mould part essentially comprises a rigid support having a tapering central wall portion covered with said elastically deformable member which is separable therefrom.

10. Apparatus according to any of claims 7 to 9, wherein said elastically deformable pad is made of polynorbornene rubber.

11. Apparatus according to claim 8 or 9, wherein said elastically deform able member of said mould part is made of polymerized silicon resin.

12. Apparatus for carrying out the method of claim 1 substantially as herein descrived with reference to the drawings.