GB2590146A

GB2590146A - Apparatus and process for moulding large products

Info

Publication number: GB2590146A
Application number: GB2015469.6A
Authority: GB
Inventors: John Thomas Steven
Original assignee: Individual
Current assignee: Individual
Priority date: 2019-10-14
Filing date: 2020-09-28
Publication date: 2021-06-23

Abstract

An apparatus 2 for moulding large products 4 where the apparatus comprises: a male mould 6; a female mould 8 for use with the male mould; and the separating means (figure 3, 10) for separating the male mould and the female mould when a product has been moulded. The separating means comprises conduit means 12 for introducing water between the male mould and the female mould, the water separating the male mould and the female mould. Also claimed is a process for moulding large products. Preferably, the male and female moulds are of a size for producing products which are at least sixteen feet long, five feet wide and three feet deep and/ or where the products are hulls of boats (e.g. yachts, coastal inshore vessels, warships, mine sweepers and motor torpedo boats), aircraft, road vehicles or trains. The male mould may be flexible and either mould may be made of glass reinforced plastics, carbon reinforced plastics (possibly carbon fibre reinforced plastics), or Kevlar plastics.

Description

APPARATUS AND A PROCESS FOR

MOULDING LARGE PRODUCTS

This invention relates to apparatus and a process for moulding large products.

Large products such for example as the hulls of boats may be made using a male mould and a female mould. The hulls of the boats may be moulded from glass reinforced plastics material, glass reinforced carbon material such as carbon fibre, or Kevlar plastics. When the product has been moulded, the two moulds are typically separated using gravity. Often the moulds will not separate under gravity, and it is necessary to use force to operate them. The force employed can damage the moulds and/or the product.

It is an aim of the present invention to avoid or reduce the above mentioned problem.

Accordingly, in one non-limiting embodiment of the present invention there is provided apparatus for moulding large products, which apparatus comprises: (i) a male mould; (ii) a female mould for use with the male mould; and (iii) separating means for separating the male mould and the female mould when one of the products has been moulded, and the apparatus being such that the separating means comprises: conduit means for introducing water between the male mould and the female mould, the water being for separating the male mould and the female mould.

The apparatus may be one in which the male mould and the female mould are of a size for producing products which are at least 16 feet long, 5 feet wide and 3 feet deep. Typically such products will be the hulls of boats, for example the hulls of yachts, coastal in-shore vessels, war ships, mine sweepers and motor torpedo boats. Other products may however be produced using the apparatus of the present invention including, for example, aircraft, road vehicles and trains.

The apparatus may be one in which at least the male mould is flexible. If desired, the apparatus may be one in which at least the female mould is flexible, Both the male mould and the female mould may be flexible.

The apparatus may be one in which the male mould and/or the female mould are made of glass reinforced plastics, carbon reinforced plastics, or Kevlar plastics. The carbon reinforced plastics may be carbon fibre reinforced plastics.

According to another non-limiting embodiment of the invention, there is provided a process for moulding large products, which process comprises: (i) providing a male mould: (ii) providing a female mould for use with the male mould and (iii) providing separating means for separating the male mould and the female mould when one of the products has been moulded, and the process being such that the separating means comprises: (iv) conduit means which is used to introduce water between the male mould and the female mould, the water being for separating the male mould and the female mould.

The process of the invention may be one in which the male mould and the female mould are of a size for products which are at least 16 feet long, 5 feet wide and 3 feet deep. Typically the process of the invention will be used for producing the hulls of boats. The hulls may be of any suitable and desired boats including, for example, the hulls of yachts, coastal in-shore vessels, war ships, mine sweepers and motor torpedo boats. The process of the invention may be used for producing other products including, for example, aircraft, road vehicles and trains.

In the process of the invention, the male mould and/or the female mould may be flexible as mentioned above in connection with the apparatus of the present invention. Similarly, in the process of the present invention, the male mould and/or the female mould may be made of the materials mentioned above in connection with the apparatus of the invention.

The apparatus and process of the invention are such that the male and female moulds are easily separated from each other. The water is able to avoid the use of the force currently often required to separate the male and female moulds. After use, the water can be drained away, for example to the environment or for reuse.

Embodiments of the invention will now be described solely by way of example and with reference to the accompanying drawings in which: Figure 1 is a side elevation of part of a large product in the form of a hull of a boat; Figure 2 is a top view of the part of the hull of the boat shown in Figure Figure 3 is an enlarged sectional view through part of the hull of the boat shown in Figure 1; Figure 4 is a top plan view of the part of the hull of the boat as shown in Figure 3; Figure 5 is an end elevation of another large product in the form of a boat; Figure 6 is an enlarged sectional view through part of the hull of a boat and illustrates a first process step in a first process for introducing water between a male mould and a female mould; Figure 7 is a view like Figure 6 and illustrates a second process step; Figure 8 is a view like Figure 6 and illustrates a third process step; Figure 9 is an enlarged sectional view through part of the hull of a boat and illustrates a first process step in a second process for introducing water between a male mould and a female mould; Figure 10 is a view like Figure 9 and illustrates a second process step: Figure 11 is a view like Figure 9 and illustrates a third process step; Figure 12 is a view like Figure 9 and illustrates a fourth process step; and Figure 13 is a top view of the conduit means as shown in Figure 12.

Referring to Figures 1 -4, there is shown apparatus 2 for moulding a large product in the form of a hull 4 of a boat. The apparatus 2 comprises a male mould 6 and a female mould 8 for use with the male mould 6. The apparatus 2 also comprises separating means 10 for separating the male mould 6 and the female mould 8 when the hull 4 has been moulded. The separating means 10 comprises conduit means 12 for introducing water between the male mould 6 and the female mould 8, the water being for separating of the male mould 6 and the female mould 8.

In use of the apparatus 2 and the process of the present invention, the male mould 6 is lifted, for example by a crane. This lifting of the male mould 6 may cause the female mould 8 to separate under gravity from the male mould 6. If the female mould 8 does not separate under gravity from the male mould 6, then water is able to be injected between the male mould 6 and the female mould 8 via the conduit means 12. As shown in Figures 1 and 2, the conduit means 12 is provided along the length of the female mould 8, and also along both sides of the female mould 8. The injection of the water causes the required separation of the female mould 8 from the male mould 6.

The use of the water does not cause damage. This is because the male mould 6 is flexible. The male mould 6 is able to flex away from the female mould 8. Because the male mould 6 is flexible, it is able to flex back to its original shape for required use. The use of water is better than air because air may cause a fire risk.

Figure 3 shows one of the conduit means 12 in the female mould 8. The conduit means 12 comprises a bore 14 for the water. As shown in Figure 4, the bore 14 is surrounded by a steel bush 16. The steel bush 16 has at its bottom an aluminium disc 18. The aluminium disc 18 has radial extending fins 20. The steel bush 16 is threaded to receive a pipe 22 which defines the bore 14 for the water. The pipe may be made of steel, a plastics material, copper, or any other suitable and desired material. The fins 20 stably locate the conduit means 12 in the hull 4 as can best be appreciated from Figure 4.

The separating means 10 also comprises a pad 24. The pad 24 closes the bore 14 during the moulding and prior to the water being used to separate the male and female moulds 6, 8. The pad 24 is held in place by holding means 26. The holding means 26 may be glass reinforced plastics putty or carbon reinforced putty. The pad 24 is forced open by water 28. The water 28 is under pressure. The pressurised water 28 causes the male mould 6 to separate from the female mould 8. The water flows downwardly to the keel 30 of the hull 4. The male mould 6 is able to float on the water.

In the apparatus 2. the aluminium discs 18 may be one third of the way up the convex side of the hull 4. For convenience of installation, bearing in mind that the aluminium discs are being positioned relatively high up the convex sides of the hull 4, the aluminium discs 18 may be secured in position, for example by any suitable securing means. Thus, for example, the aluminium discs 18 may be secured in position with an impact adhesive provided at position 31 shown in Figure 3. The impact adhesive can be placed on opposite surfaces to be stuck together and then after an appropriate time period, for example 10 minutes, the two surfaces can be pushed together. The impact adhesive can then hold the aluminium discs 18 in position whilst they are buried in glass reinforced plastics, carbon reinforced plastics, or Kevlar.

As can be appreciated from Figure 3, the pad 24 will shear along the impact adhesive 31 if a cutting tool is used to cut out the pad 24.

In Figures 5 -8, similar parts as in previous Figures have been given the same reference numerals for ease of comparison and understanding.

Figure 5 shows how the male mould 6 may be stood on one end as compared with the position of the male mould 6 in Figure 1.

Figures 6 -8 illustrate a first process for introducing water between a male mould and a female mould using a conduit means 12. Figure 6 shows a first step in the process. More specifically, Figure 6 shows a bolt 32 screwed into the steel bush 16. The bolt 32 acts as a bung. The bolt 32 is not covered by the female mould 8, as can be best be appreciated from Figure 6. More specifically, the bolt 32 has a head 34 which extends out of the top of the female mould 8 as shown in Figure 6.

Referring to Figures 6 and 7, when the moulding material between the male mould 6 and the female mould 8 dries out and becomes hard, the bolt 32 shown in Figure 6 is removed and is replaced by a drilled housing bolt 36 as shown in Figure 7. The drilled housing bolt 36 has a head 38 for enabling it to be screwed in and out of position. The drilled housing bolt 36 also has a central bore 40 for receiving a drill 42. The drill 42 is able to drill through the female mould 8. Then the drilled housing bolt 36 is removed as shown in Figure 8.

Figure 8 shows how the bore 14 is then able to receive a pipe 44 for introducing the pressurised water 28 through the female mould 8 so that the pressurised water gets between the male mould 6 and the female mould 8 and is thus able to separate the male and female moulds 6, 8. The pipe 44 may be connected to a tool 46 as shown. The tool 46 is able to act as a locating device for locating the pipe 44 in position against the female mould 8. The tool 46 has a pair of screw fasteners 48 for tightening against the pipe 44 and holding the pipe 44 in position in the tool 46.

Figure 5 shows how the conduit means 12 are able to be positioned one third up the female mould 8 for medium sized large products, and how the conduit means 12 may be positioned two thirds up the female mould 8 for larger products. The exact positioning of the conduit means 12 may be varied to ensure that adequate pressurised water 28 is forced between the male mould 6 and the female mould 8 in order to cause separation of the male mould 6 and the female mould 8. The pressurised water 28 travels downwardly when the female mould 8 is in the position shown in Figure 5.

As also shown in Figure 5, there is conduit means 50 which is like the conduit means 12. The conduit means 501s located at the base of the stern of the female mould 8 as shown in Figure 5. The housing and location of the conduit means 50 is the same as the housing and location of the conduit means 12, except that the conduit means 50 is such that its closure means in the form of its pad 24 remains closed until the time comes to drain the water 28 from the female mould 8. In order to open the pad 24 in the conduit means 50, a slight pressurised flow of water is applied to the pad 24 in the conduit means 50. Reversed pressure is then applied in order to pump the water 28 out of the female mould 8.

The apparatus of the present invention may be produced in various sizes in dependence upon the size of the product being moulded.

During the operation of the process of the invention carried out using Figures 1 -4 or 5 -8, the male mould 6 is flexible and it does not have any stiffening in it. Thus the pressurised water 28 is able to force the male and female moulds 6, 8 apart. One or both of the two moulds 6, 8 may be provided with a thin layer of wax or other release material, in order to facilitate the separation of the moulds 6, 8.

The pads 24 may be cut out by the tool 46 which can then act as a cutting tool in addition to, or as an alternative to, being a holding tool. The tool 46 operates on the waxed side 54 of the female mould 8. The pads 24 have holes through them as shown. The holes may be filled in using body filler such for example as glass reinforced plastics body filler. The body filler may be placed on the rough side face 52 and also on the aluminium disc 18. A number could be put on the rough side face 52 and the aluminium disc 18, and on the face 53 facing the rough side face 52 of the pad 24. The number may facilitate the matching of the required parts. The body filler does not go all the way through the hole but stops short because the waxed surface is hard and remains in the hole. The hole may alternatively be filled with glass reinforced plastics putty or carbon reinforced plastics putty. A chamfer on the leading waxed edges of the pads 24 may be provided if desired. The chamfer may facilitate assembly of the apparatus 2. The chamfer may be provided by means of a steel file.

In Figure 3, the surface 54 of the female mould 8 is waxed as stated above. The surface 55 of the female mould 8 is not waxed.

Figures 9 -13 illustrate various process steps in a second process for introducing water between a male mould and a female mould. Similar parts as in previous Figures have been given the same reference numerals for ease of comparison and understanding.

Figure 9 is the same as Figure 6 and illustrates a first step in the second process. Thus Figure 9 shows a bolt 32 screwed into the steel bush 16. The bolt 32 acts as a bung. The bolt 32 is not covered by the female mould 8. The bolt 32 has a head 34 which extends out of the top of the female mould 8.

Figure 10 is the same as Figure 7. Figure 10 illustrates a second step in the second process. Thus, referring to Figure 7, when the moulding material between the male mould 6 and the female mould 8 dries out and become hard, the bolt 32 shown in Figure 6 is removed and is replaced by a drilled housing bolt 36. The drilled housing bolt 36 has a head 38 for enabling it to be screwed in and out of position. The drilled housing bolt 36 also has a central bore 40 for receiving a drill 42. The drill 42 is able to drill through the female mould 8. Thus the drill 42 acts as a pilot drill for drilling a hole in the female mould 8. The drill housing bolt 36 is then removed.

Figure 11 shows a third step in the second process. In this third step, it will be seen that a drill 56 is inserted into the pilot hole formed by the drill 42.

The drill 56 provides a hole of a required diameter. By way of example only, the pilot hole may be 0.25 inches. The finished hole may be for example 3/8 inches or 7/8 inches in diameter.

Figure 12 shows a fourth step in the second process. In Figure 12, it will be seen that the bore 14 has been packed with a packing material 58. An example of the packing material 58 is cotton wool. Other packing materials may be used. The packing material 58 is behind filler material 60. The filler material 60 may be a putty such for example as glass reinforced plastics putty or carbon reinforced plastics putty. Other filler materials may be employed.

Figure 13 is a plan view of the conduit means 12 as shown in Figure 13 and illustrates the positioning of the packing material 58 and the filler material 60.

The process illustrated in Figures 9 -13 avoids the use of a pad as is required by the process illustrated with reference to Figures 6 -8. The process illustrated with respect to Figures 9 -13 also avoids the need to cut out the pad. and it further avoids possible loss of the pad, for example by a trades person. In addition, packing the bore with the packing material 58 behind the filler material 60 gives the filler material strength and ensures that the filler material does not sag. Also, the filler material 6 is able to be flush and level with the surrounding surface of the female mould 8. Thus the filler material 60 will not catch on component parts during the release of the male mould 6 from the female mould 8. There should be no holes in the male mould 6 because this is the finished product.

It is to be appreciated that the embodiments of the invention described above with reference to the accompanying drawings have been given by way of example only and that modifications may be effected. Thus, for example, the apparatus and the process of the present invention may be used to produce any large products and they are not restricted to the hulls of boats. Preferably, the products will be of a size which are at least 16 feet long, 5 feet wide, and 3 feet deep. Moulding materials other than glass reinforced plastics, carbon reinforced plastics and Kevlar plastics may be employed. Closure means other than the pads 24 may be employed. Individual components shown in the drawings are not limited to use in their drawings and they may be used in other drawings and in all aspects of the invention. The invention also extends to the individual components mentioned and/or shown above, taken singly or in any combination.

Claims

CLAIMSApparatus for moulding large products, which apparatus comprises: (i) a male mould: a female mould for use with the male mould: and (iii) separating means for separating the male mould and the female mould when one of the products has been moulded, and the apparatus being such that the separating means comprises: (iv) conduit means for introducing water between the male mould and the female mould, the water being for separating the male mould and the female mould.
2. Apparatus according to claim 1 in which the male mould and the female mould are of a size for producing products which are at least 16 feet long, 5 feet wide and 3 feet deep.
3. Apparatus according to claim 1 or claim 2 in which the products are hulls of boats, aircraft, road vehicles or trains.
Apparatus according to any one of the preceding claims in which at least the male mould is flexible.
5. Apparatus according to any one of the preceding claims in which the male mould and/or the female mould are made of glass reinforced plastics, carbon reinforced plastics, or Kevlar plastics.
6. A process for moulding large products, which process comprises: providing a male mould; (ii) providing a female mould for use with the male mould; and providing separating means for separating the male mould and the female mould when one of the products has been moulded, and the process being such that the separating means comprises: (iv) conduit means which is used to introduce water between the male mould and the female mould, the water being for separating the male mould and the female mould.
7. A process according to claim 6 in which the male mould and the female mould are of a size for producing products which are at least 16 feet long, 5 feet wide and 3 feet deep.

A process according to claim 6 or claim 7 in which the products are hulls of boats, aircraft, road vehicles or trains.

A process according to any one of claims 6 -8 in which at least the male mould is flexible.

10, A process according to any one of claims 6 -9 in which the male mould and/or the female mould are made of glass reinforced plastics, carbon reinforced plastics or Keylar plastics.