GB2050231A - Improvements in methods and apparatus for forming articles from settable liquid plastics - Google Patents

Improvements in methods and apparatus for forming articles from settable liquid plastics Download PDF

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Publication number
GB2050231A
GB2050231A GB7919043A GB7919043A GB2050231A GB 2050231 A GB2050231 A GB 2050231A GB 7919043 A GB7919043 A GB 7919043A GB 7919043 A GB7919043 A GB 7919043A GB 2050231 A GB2050231 A GB 2050231A
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United Kingdom
Prior art keywords
mould
article
base assembly
liquid plastics
plastics
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Granted
Application number
GB7919043A
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GB2050231B (en
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Individual
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Priority to GB7919043A priority Critical patent/GB2050231B/en
Publication of GB2050231A publication Critical patent/GB2050231A/en
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Publication of GB2050231B publication Critical patent/GB2050231B/en
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
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/70—Completely encapsulating inserts
    • 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
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating 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
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
    • B29C39/12—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
    • B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
    • B29C39/14—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of indefinite length
    • B29C39/20—Making multilayered or multicoloured articles
    • B29C39/203—Making multilayered articles
    • 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
    • B29K2105/0002—Condition, form or state of moulded material or of the material to be shaped monomers or prepolymers
    • 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
    • B29K2995/0026—Transparent
    • 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
    • B29L2031/722—Decorative or ornamental articles

Abstract

A method of forming an article from settable liquid plastics comprises disposing a base assembly 10 with an object 14 to be embedded on the upwardly facing surface thereof, placing over the base assembly 10 an open-bottomed mould 16 having a filling aperture 17 in the uppermost part thereof, sealing the mould around its lower peripheral edge, pouring settable transparent liquid plastics into the mould through the upper filling aperture so as to cover the base assembly 10 and object 14 and at least partly fill the mould, allowing the liquid plastics to set, and removing the mould from the article. A further layer of plastics may be applied to the outer surface of the article by suspending it, inverted, in a larger open-topped mould. The base assembly 10 may be formed from a number of different coloured plastics moulded side-by-side in sequence to give a multi-coloured base effect. <IMAGE>

Description

SPECIFICATION Improvements in methods and apparatus for forming articles from settable liquid plastics The invention relates to methods and apparatus for forming articles from settable liquid plastics and, in particular, articles of the kind comprising a base assembly and a solid body of transparent plastics material formed onto the base assembly, covering the surface thereof and embedding any parts projecting from that surface. The invention sets out to provide improvements over the known methods for forming articles of this kind, and apparatus for use in such methods.
According to the invention a method of forming from settable liquid plastics an article of the kind referred to above comprises disposing the base assembly with said surface thereof facing upwardly, placing over the base assembly an open-bottomed mould having a filling aperture in the uppermost part thereof, sealing the mould around the lower peripheral edge thereof, pouring settable transparent liquid plastics into the mould through said upper filling aperture so as to cover the base assembly and at least partly fill the mould, allowing the liquid plastics to set, and removing the mould from the article.
An article formed in accordance with this method may have an imperfect surface on the transparent plastics when set. Accordingly, a preferred method according to the invention comprises the further step of forming a finishing layer of transparent plastics on the surface of the article by inverting the article so that the base assembly is uppermost, and lowering the article into an op#n-topped mould containing sufficient transparent liquid plastics to form a layer between the outer surface of the article and the interior surface of the mould, allowing the liquid plastics to set, and removing the article from the mould.
The invention also provides a method of incorporating lettering or decorative designs in an article formed from settable liquid plastics and of the kind first referred to above. The method comprises the steps of applying to a part of the base assembly, before the solid body of transparent plastics material is formed thereon, one or more preformed letters or designs, and painting one or more thin layers of the transparent liquid plastics over the letters or designs, and allowing the layer or layers to set before applying to said base assembly sufficient transparent liquid plastics to form said solid body.
The invention also provides a method of forming from settable liquid plastics a base assembly for use in an article of the kind first referred to above. The method comprises the steps of using a mould corresponding in shape to the desired final shape of the base assembly, partly filling the mould with a removable filler, pouring settable liquid plastics of a first colour into the unfilled part of the mould, allowing the liquid plastics to set, removing the filler, pouring settable liquid plastics of a second colour into the part of the mould previously occupied by the filler, allowing the liquid plastics to set, and removing the base assembly from the mould.
Before pouring the settable liquid plastics of the second colour into the mould, the mould may again be partly filled with a removable filler, this process being repeated as many times as desired to produce a multi-coloured base assembly.
The following is a more detailed description of methods and apparatus in accordance with the invention, reference being made to the accompanying drawings in which: Figure 1 is a perspective view of an article made in accordance with the invention, Figure 2 is a vertical section through a mould during one stage in the formation of the article, and Figure 3 is a side elevation of another mould during a further stage in the formation of the article.
Fig. 1 shows a typical article of the basic kind produced by the methods and apparatus according to the invention. The illustrated article is a paperweight comprising a base assembly 10 in the form of a circular plastics disc having a red sector 11 separated by a white strip 12 from a blue sector 13. A Royal Air Force Squadron badge 14 is secured to the upper surface of the disc 10 and the whole is embedded in a hemispherical body 15 of transparent plastics material. A circle of baize (not shown) is glued to the underside of the paperweight to protect any surface on which it is placed.
The article shown in Fig. 1 is by way of example only, and it will be appreciated that the methods and apparatus to be described are equally applicable to articles of different shapes and configurations. The settable liquid plastics employed to make the paperweight is of the kind widely available from commercial sources and comprises a clear resin to which a hardener is added in predetermined proportions to set the resin. Colour pigments, either opaque or translucent, can be mixed with the resin before setting.
In making the paperweight of Fig. 1, the disc 10 is first formed. Although the multicoloured disc shown in Fig. 1 is preferred a disc of a single colour may be used if required. In the latter case the disc is simply formed by pouring the required quantity of resin, mixed with hardener and appropriate colour pigment, into a circular mould to the required depth. When set, the cast disc is removed from the mould. It will be found that a cusp has formed around the periphery of the upper surface of the casting due to sur face tension. This may be removed by rubbing the upper surface of the disc flat using "wet and dry" abrasive paper.
Alternatively, a cylindrical circular cross-section block of plastics may be formed in a suitably shaped mould, the block then being sawn into slices and the resulting discs polished.
To form the multi-coloured disc 10 shown in Fig. 1, the circular mould is partly packed with plasticine or other suitable filler so as to leave unfilled a sector of the mould corresponding in size to the required size of the red sector 11. Red coloured plastics is then poured into this sector of the mould and is allowed to set. When set the casting is removed from the mould and its straight edge rubbed down with an abrasive to give a smooth edge and to give the required width to the sector. The sector is then returned to the mould and the re~maining free portion of the mould is again partly packed with plasticine or other filler to leave between the filler and the red sector an unfilled strip corresponding generally to the width of the strip 12. This strip is then filled with white coloured plastics which is allowed to set.The casting is then again removed from the mould and the free edge of the white strip rubbed down with abrasive to bring the white strip to the required width. The casting is then returned to the mould and finally blue coloured plastics is poured into the remaining free area to form the blue sector. It will be appreciated that many variations of colour and arrangement of portions of the disc may be provided by suitably packing different portions of the mould with filler at each stage of the casting operation.
In an alternative method of construction the outer two sectors of the disc 10 may be cut respectively from separate preformed red and blue discs. The sectors are then placed in the mould and white plastics is poured between them to complete the three colour disc.
In each case when the base disc has been cast its upper and lower surfaces are rubbed flat with suitable abrasive, such as "wet and dry" paper.
The next stage is to bond the badge, or any other object which it is required to embed in the paperweight, to the centre of the base disc 10 with a suitable adhesive.
Following this step, the base, bearing the badge or other object to be embedded, is placed in a mould 16 as shown in Fig. 2. The mould 16 comprises an open-bottomed hemispherical dome having a maximum internal diameter corresponding to the diameter of the disc 10. The dome 16 is formed with an upper circular pouring hole 17.
The disc 10 is first placed on a bed 18 of plasticine or similar material, and the dome 16 is then placed over the disc 10, as shown in Fig. 2. The lower peripheral edge of the dome is bedded into the plasticine to provide a seal to prevent leakage of the liquid plastics from the mould. The liquid plastics is then poured into the mould through the hole 17 to cover the disc 10 and fill the mould so as to embed the badge 14.
Hitherto it has been the practice to form solid bodies of transparent plastics by casting them a layer at a time. The reason for this is that, using the proportion of hardener to resin recommended by the manufacturers of the plastics, the amount of heat generated by the plastics while setting would cause it to crack if an attempt were made to form the casting in one piece. It has been found, however, that by reducing the proportion of hardener to significantly less than that normally recommended, it is possible to form large castings in one pouring. This is due to the consequent lengthening of the setting time which provides sufficient time for the heat generated during setting to be dissipated.
When the casting has set and is removed from the mould 16, it will be found that the domed surface of the casting is rough and irregular due to shrinkage of the plastics while setting. The surface of the dome is therefore rubbed down with "wet and dry" abrasive paper to provide a smooth opaque surface in preparation for the next stage of the process.
In the next stage, the casting is inverted and lowered into an open-topped hemispherical mould partly filled with liquid plastics as shown in Fig. 3. As shown in that figure, the mould 19 has around its upper open mouth an outwardly projecting peripheral flange 20 and the mould is supported within an annular stand 21 of greater depth than the mould by the flange 20 resting on the upper edge of the stand 21. Triangular apertures 22 are provided at each side of the stand 21 so that the level of plastics in the mould, and the position of the casting in the mould, can be seen. For this purpose also the stand 21 may rest upon a flat mirror 23.
To suspend the casting in the required position within the mould 19 there is screwed into the base disc 10 a screw eye 24, so that the casting can be suspended from a suitable support by a thread 25.
The mould 19 is one quarter to one third filled with liquid plastics and the casting is lowered into the mould to a position where the layer of plastics between the casting and the interior surface of the mould covers the entire domed surface of the casting. The casting remains suspended in this position until the layer has set, and the casting is then removed from the mould. It will be found that the surface of the casting has a comparatively good surface which can be rubbed down with progressively finer grades of "wet and dry" paper and then with metal polish to give a highly polished finish. The final stage is the gluing of the baize to the underside of the base disc 10.
If it is required to embed lettering within the article, the appropriate preformed letters are adhered to the base disc 10 before the main body of transparent plastics is applied to it. The lettering may be disposed around the peripheral edge of the disc 10, or may be disposed on the upper surface of the disc 10.
The lettering may be of the "dry rub" kind sold under the trade name "LETRASET", or may be any other form of adhesive lettering.
Before the main body of transparent plastics is applied to the base, a small quantity of the liquid plastics is painted over the lettering in a thin layer. The thin layer is allowed to set and the process then repeated a number of times, preferably at least six to eight times. The plastics used for this procedure should incorporate only a small quantity of hardener so that the curing of the layers is slow enough to prevent wrinkling of the lettering.
Lettering may also be applied to the casting after the first stage of casting shown in Fig. 2 and before the second stage shown in Fig. 3.
It will be appreciated that the same procedure may be adopted for embedding all types of preformed designs, other than lettering, within the article.
Although only hemispherical moulds are described above, other shapes of mould may also, of course, be used, depending on the required shape of the finished article.

Claims (14)

1. A method of forming from settable liquid plastics an article of the kind comprising a base assembly and a solid body of transparent plastics material formed onto the base assembly, covering the surface thereof and embedding any parts projecting from that surface, the method comprising disposing the base assembly with said surface thereof facing upwardly, placing over the base assembly an openbottomed mould having a filling aperture in the uppermost part thereof, sealing the mould around the lower peripheral edge thereof, pouring settable transparent liquid plastics into the mould through said upper filling aperture so as to cover the base assembly and at least partly fill the mould, allowing the liquid plastics to set, and removing the mould from the article.
2. A method according to claim 1, comprising the further step of forming a finishing layer of transparent plastics on the surface of the article.
3. A method according to claim 2, wherein said finishing layer is formed on the surface of the article by inverting the article so that the base assembly is uppermost, and lowering the article into an open-topped mould containing sufficient transparent liquid plastics to form a layer between the outer surface of the article and the interior surface of the mould, allowing the liquid plastics to set, and removing the article from the mould.
4. A method according to any of claims 1 to 3, including the steps of applying to a part of the base assembly, before the solid body of transparent plastics material is formed thereon, one or more preformed letters or designs, painting one or more thin layers of the transparent liquid plastics over the letters or designs, and allowing the layer or layers to set before applying to said base assembly sufficient transparent liquid plastics to form said solid body.
5. A method according to any of claims 1 to 5, wherein the base assembly is preformed from plastics material of at least two colours.
6. A method according to claim 5, wherein the base assembly is preformed by using a mould corresponding in shape to the desired final shape of the base assembly, partly filling the mould with a removable filler, pouring settable liquid plastics of a first colour into the unfilled part of the mould, allowing the liquid plastics to set, removing the filler, pouring settable liquid plastics of a second colour into the part of the mould previously occupied by the filler, allowing the liquid plastics to set, and removing the base assembly from the mould.
7. A method according to claim 6, wherein, before pouring the settable liquid plastics of the second colour into the mould, the mould is again partly filled with a removable filler, this process being repeated as many times as desired to produce a multi-coloured base assembly.
8. A method of forming an article from settable liquid plastics material substantially as hereinbefore described with reference to the accompanying drawings.
9. An article, when formed from settable liquid plastics by the method according to any of the preceding claims.
10. Apparatus for forming an article from settable liquid plastics by the method according to claim 1, comprising an open-bottomed mould having a filling aperture in the uppermost part thereof, and means for sealing the mould around the lower peripheral edge thereof
11. Apparatus according to claim 1 O and further comprising an open-topped mould the interior shape of which is similar to the interior shape of said open-bottomed mould, but the internal dimensions of which are greater than the corresponding internal dimensions of said open-bottomed mould, whereby an article formed in said open-bottomed mould may be inverted in said open-topped mould to permit casting of a surface layer on the article.
12. Apparatus according to claim 11, including a stand for supporting said opentopped mould.
13. Apparatus according to claim 12, wherein the open-topped mould is formed from translucent material and there is pro vided a mirror spaced beneath said mould to permit viewing of the underside thereof.
14. Apparatus for forming an article from settable liquid plastics substantially as hereinbefore described with reference to the accompanying drawings.
GB7919043A 1979-05-31 1979-05-31 Methods and apparatus for forming articles from settable liquid plastics Expired GB2050231B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB7919043A GB2050231B (en) 1979-05-31 1979-05-31 Methods and apparatus for forming articles from settable liquid plastics

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB7919043A GB2050231B (en) 1979-05-31 1979-05-31 Methods and apparatus for forming articles from settable liquid plastics

Publications (2)

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GB2050231A true GB2050231A (en) 1981-01-07
GB2050231B GB2050231B (en) 1983-05-25

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* Cited by examiner, † Cited by third party
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US20170125909A1 (en) * 2015-10-28 2017-05-04 Rogers Corporation Broadband multiple layer dielectric resonator antenna and method of making the same
US11283189B2 (en) 2017-05-02 2022-03-22 Rogers Corporation Connected dielectric resonator antenna array and method of making the same
US11367960B2 (en) 2015-10-28 2022-06-21 Rogers Corporation Dielectric resonator antenna and method of making the same
US11367959B2 (en) * 2015-10-28 2022-06-21 Rogers Corporation Broadband multiple layer dielectric resonator antenna and method of making the same
US11482790B2 (en) 2020-04-08 2022-10-25 Rogers Corporation Dielectric lens and electromagnetic device with same
US11552390B2 (en) 2018-09-11 2023-01-10 Rogers Corporation Dielectric resonator antenna system
US11616302B2 (en) 2018-01-15 2023-03-28 Rogers Corporation Dielectric resonator antenna having first and second dielectric portions
US11637377B2 (en) 2018-12-04 2023-04-25 Rogers Corporation Dielectric electromagnetic structure and method of making the same
US11876295B2 (en) 2017-05-02 2024-01-16 Rogers Corporation Electromagnetic reflector for use in a dielectric resonator antenna system

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20170125909A1 (en) * 2015-10-28 2017-05-04 Rogers Corporation Broadband multiple layer dielectric resonator antenna and method of making the same
US10601137B2 (en) * 2015-10-28 2020-03-24 Rogers Corporation Broadband multiple layer dielectric resonator antenna and method of making the same
US11367960B2 (en) 2015-10-28 2022-06-21 Rogers Corporation Dielectric resonator antenna and method of making the same
US11367959B2 (en) * 2015-10-28 2022-06-21 Rogers Corporation Broadband multiple layer dielectric resonator antenna and method of making the same
US11283189B2 (en) 2017-05-02 2022-03-22 Rogers Corporation Connected dielectric resonator antenna array and method of making the same
US11876295B2 (en) 2017-05-02 2024-01-16 Rogers Corporation Electromagnetic reflector for use in a dielectric resonator antenna system
US11616302B2 (en) 2018-01-15 2023-03-28 Rogers Corporation Dielectric resonator antenna having first and second dielectric portions
US11552390B2 (en) 2018-09-11 2023-01-10 Rogers Corporation Dielectric resonator antenna system
US11637377B2 (en) 2018-12-04 2023-04-25 Rogers Corporation Dielectric electromagnetic structure and method of making the same
US11482790B2 (en) 2020-04-08 2022-10-25 Rogers Corporation Dielectric lens and electromagnetic device with same

Also Published As

Publication number Publication date
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