NZ280489A - Moulding fibreglass article with a flat insert comprising an insert held in the mould by vacuum - Google Patents

Description

28 0 4 89 PATENTS FORM NO. 5 Fee No. 4: $260.00 PATENTS ACT 1953 COMPLETE SPECIFICATION After Provisional No: 280489 Dated: 17 November 1995 .Tamp* ft. Wells Ref: 22285/1 WE Fibreglass Technologies Limited, a New Zealand company of 15 Norrie Road, Drury, Auckland, New Zealand hereby declare the invention for whicb 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: 280489 MOULDING METHODS Background Art Composite table tops and other furniture items formed from a mouldable material such as fibreglass and a decorative panel such as formica are popular choices for business and personal use.

One form of table top provides a decorative formica panel set in fibreglass the top is sometimes reinforced with timber or metal. The decorative panel is made to be flush with a fibreglass surround. The manufacture of same involves the installation of the decorative panel as an insert, that is, a two-stage process.

It is an object of the present invention to provide a method of manufacturing moulded products such as those described in a one step process.

Further objects and advantages of the present invention will become apparent from the ensuing description which is given by way of example.

DISCLOSURE OF INVENTION According to the present invention there is provided a method of moulding comprising the steps of laying a mould on a supporting service with a cavity in the mould uppermost, placing a panel on the surface of the mould cavity, applying a mouldable material to the panel and mould cavity whilst the panel secured in the desired position by a suction device.

After the mouldable material has been cured to the extent required the panel and moulded material can be removed from the mould.

In accordance with a further aspect of the present invention a stiffening 2 280489 member may be set in the mouldable material.

The mouldable material may consist of any layer or any combination of gel coat, fibreglass resin or other filler materials.

According to yet a further aspect of the present invention there is provided an apparatus for performing the aforesaid method of the apparatus comprising a cavity mould, and air chamber beneath said cavity mould, a plurality of apertures in the base of the cavity mould communicable with the air chamber, and means for inducing a vacuum within the air chamber so that material overlaid on the mould base is secured whilst mouldable material is laid in the mould and over the material. brief description of drawings Further aspects of the present invention will become apparent from the ensuing description which is given by way of example only and with reference to the accompanying drawings in which: Figure 1 is a perspective view of a mould article in accordance with the present invention, and Figure 2 is a diagrammatic cross-sectional drawing of a moulding method in accordance with another aspect of the present invention. best modes for carrying out the invention With respect to the drawings, figure 1 illustrates by way of example a table top in accordance with the present invention generally indicated by arrow 1 comprising an insert panel 2 set in a body of mouldable material 3 280489 3. Purely by way of example, the panel 2 may be a sheet of formica, marble, or another suitable material and the body 3 may be moulded in fibreglass comprising an outer skin of gel coat, a resin layer, a mounting or stiffening member, and finally a fibreglass layer. Such a construction is known, however to manufacture such articles with efficiency and precision an efficient method needs to be found of "setting" the panel in a mould whilst the mouldable material is overlaid.

The present invention provides a novel method of setting the panel 2 in position during the manufacturing process.

With respect to figure 2 a mould 4 is positioned over a support in the form of an air chamber 5. The mould 4 is a cavity mould and the base 6 of the mould is provided with a plurality of apertures 7 which directly communicate with the the air chamber 5 below. The air chamber is communicable with a source of low pressure air such as a vacuum pump 8 via a conduit 9, such that when the pump is operable air is drawn from the region of the mould cavity to the air chamber and exhausted via the pump.

When a decorative panel 2 is placed over the base of the mould cavity and covers all apertures 7 and the vacuum pump is started the panel 2 is set in position by suction and the moulding process can be commenced without fear of the panel being misplaced.

Typically moulding is completed by the laying of a gel coat 10, the optional introduction of a reinforcing panel (not shown), a resin layer 11 and finally a further filler such as fibreglass 12.

It is to be appreciated that the present methodology provides an accurate and efficient method of positioning an insert panel during the moulding 280489 process without involving semi-permanent fastenings or other means to obtain the correct setting of the panel.

Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof. f

Claims (1)

1. WHAT WE CLAIM IS: A method of moulding comprising the steps of; laying a mould on a supporting surface with a cavity in the mould uppermost, placing a single panel on the surface of the cavity in the mould, whilst the panel is secured in a desired position by a suction device, wherein the mould and suction device are configured to contain and secure in a desired position a single panel only. A method of moulding as claimed in claim 1, further characterised by the additional step of removing the mouldable material from the cavity in the mould after the mouldable material has cured to a required extent. A method of moulding as claimed in either of claims 1 or 2, wherein the mouldable material includes a stiffening member. A method of moulding as claimed in any one of claims 1 to 3, wherein the mouldable material consists of any layer or combination of gel coat, fibreglass, or resin. A moulding apparatus comprising; a cavity mould, an air chamber for supporting said cavity mould, a plurality of apertures in the base of the cavity mould communicable with the air chamber, means for inducing a vacuum within the air chamber so that a sheet of material overlaid on the base of the cavity mould is secured whilst mouldable material is laid in the mould over said sheet material, 280489 280 ^89 wherein said cavity mould and said means for inducing a vacuum within the air chamber are adapted to contain and secure a single sheet of material only. A method of moulding substantially as herein described with reference to the accompanying drawings and/or examples. Moulding apparatus substantially as herein described with reference to the accompanying drawings and/or examples. FIBREGLASS TECHNOLOGIES LIMITED by its Attorneys INTELLkUUHAL PROPERTY OFFICE OF N.Z. 2 7 MAR 1998 RECEIVED 7