WO1984003251A1 - Systeme de moulage de produits mousses de polyurethane - Google Patents

Systeme de moulage de produits mousses de polyurethane Download PDF

Info

Publication number
WO1984003251A1
WO1984003251A1 PCT/AU1984/000022 AU8400022W WO8403251A1 WO 1984003251 A1 WO1984003251 A1 WO 1984003251A1 AU 8400022 W AU8400022 W AU 8400022W WO 8403251 A1 WO8403251 A1 WO 8403251A1
Authority
WO
WIPO (PCT)
Prior art keywords
core
mould
skin
density
poiyurethane
Prior art date
Application number
PCT/AU1984/000022
Other languages
English (en)
Inventor
Bruce Philip Cresswell
Original Assignee
Barup Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Barup Pty Ltd filed Critical Barup Pty Ltd
Publication of WO1984003251A1 publication Critical patent/WO1984003251A1/fr

Links

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
    • 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
    • B29C44/1285—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being foamed
    • 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
    • B29C44/04—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 consisting of at least two parts of chemically or physically different materials, e.g. having different densities
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle

Definitions

  • THIS * INVENTION relates to the moulding of articles from poiyurethane foam. It is particularly applicable to arti ⁇ cles in which the weight is extremely critical, consistent with an acceptable strength, such as in the surfboard and allied industries. It is equally applicable in other fields demanding similar criteria.
  • fibreglass coated poiyurethane The disadvantages of fibreglass coated poiyurethane are that it is extremely labour intensive, it is extremely rigid and hence has less ability to absorb impact. It tends to fracture easily, and separates, and it is a fairly unpleasant and hazardous material to handle.
  • the present invention involves the manufacture of the core first, with a very low density, lightweight material, then covering it with a thin medium density poiyurethane skin.
  • core material including poiyurethane and styrene.
  • the present invention resides in a method of produc ⁇ ing articles from poiyurethane foam which comprises form ⁇ ing «-a core of low density material, placing the core within a mould so that at least part of the core is spaced apart from the wall of the mould and injecting materials to form a skin of poiyurethane foam into the space between the core and the wall of the mould, the skin having a density greater than the density of the core.
  • Buoyancy is a major significant factor in that it relates directly to performance. The more buoyant a surfboard is, the less energy that is required to utilize it.
  • a surfboard constructed with this method may be significan ⁇ tly reduced in size compared with a similar surfboard constructed with conventional methods, resulting in in ⁇ creased performance, yet carrying the same person.
  • a major factor of this invention is the high volume pro ⁇ duction that can be achieved with relatively few rejects, resulting in extremely low cost per unit.
  • This invention preferably uses the R.I.M. method (Reaction Injection Moulding) of poiyurethane construction for the formation of both the core and skin.
  • Moulds may be constructed from several types of material, however, aluminium moulds were found to be the most suc ⁇ cessful.
  • the mould described in this document was highly polished on the surface to be reproduced, with a minimum of 25 mm. aluminium thickness.
  • the mould was made in two halves, a top and bottom, joining mid way around the edge, or rail, of the surfboard.
  • a skin thickness of between 6mm. and 10 mm. with an average density of between 200-400 kilograms per cubic metre, moulded around a lightweight core of density between 28-50 kilograms per cubic metre gives the most satisfactory balance between weight and strength.
  • the density of the skin may be increased to obtain more surface hardness and strength.
  • An alternative method is to increase the density of the core, to increase the strength, and corres ⁇ pondingly reduce the skin thickness, thus realising the same overall weight, and strength. With strict control, skin thickness may be reduced to 2 mm., however, at this thickness, a minimum density of 250 kg./c . was most satisfactory.
  • OMPI skin thickness is 8 mm. with a density of 250 kg./cm. moulded around a core of density 30 kg./cm.
  • Two inserts are constructed, in this case of fibreglass, however any material that can be moulded to the shape of the mould may be used. These inserts are 8 mm. in thick ⁇ ness, and made so that they fit exactly inside both the top and bottom of the mould (halves). When the mould is closed, the void inside with the inserts is 8 mm. thinner all over than the closed mould without the inserts.
  • the poiyurethane When the poiyurethane has cured, it may be removed from the mould.
  • the core is now 8 mm. thinner all over than the finished article is to be.
  • the cores must be stored to minimise distortion and to cure properly.
  • another mould may be made up that is exactly 8 mm. thinner all over than the master mould, and the cores may be manufactured separately.
  • the demould time of the cores is dependent upon the thick ⁇ ness.
  • Moulding a skin around the core may be done by either of two methods?
  • Method 1 The aluminium mould is prepared in the usual manner. Spacers are either glued or placed on both sides of the core so that when it is placed inside the mould and it is closed, an even void of 8 mm. exists all around the core. It is into this void that the higher density skin ⁇ ning poiyurethane is to be injected and react. The spacers are positioned so that when the mould is closed, they hold the core tightly and evenly, not allowing any movement of the core when the skin material is reacting. The length of the spacers is 9 mm. so that when the mould is closed, they push into the core slightly, holding it tightly.
  • the spacers maybe of any suitable configuration.
  • a pre ⁇ ferred form of spacers is formed of nylon or other suit ⁇ able plastic and comprises a disc having a central pig projecting from each face. One peg is pushed into the core until the disc bears against the surface of the core. This leaves the other pig projecting outwardly so that in position the outer end bears against the wall of the mould to hold the core spaced therefrom.
  • a predetermined amount of poiyurethane is injected into the void so that the required density is reached.
  • the entry gates where the poiyurethane enters the mould must be constructed carefully to enable it to react evenly along both sides of the core. Bad design will result in more material forcing its way to one side of the core, with little or none of the other side.
  • Each item to be moulded requires its own gating system. This method becomes extremely difficult where one side of the core is shaped in such a way as to allow for easier flow of the skinning material than the other. In such a case, Method 2 may be used.
  • Method 2 The mould is prepared as usual, and the bottom insert is positioned in the bottom of the mould.
  • the core is then placed into the insert, fitting exactly as it was moulded in it beforehand. Spacers are then placed on the top of the core, so that when the mould is closed, there will'be a void of exactly 8 mm. around the top of the core only. The closure of the mould will force the spacers into the core, pushing it hard against the bottom insert, so that no material can find its way around the bottom half of the core.
  • a predetermined amount of poiyurethane is injected into the mould, which finds its way into the only void i.e. the top of the core.
  • the demould time which is rela ⁇ tively short
  • the mould is opened.
  • the skin around the top of the core adheres to the aluminium, and the whole thing comes away from the bottom of the mould.
  • the bottom insert can now be removed.
  • Poiyurethane may now be injected into the mould, filling the only void, the bottom half. Adhesion to the top half that has already been skinned is excel ⁇ lent.
  • the mould may be opened and the product removed.
  • Method 2 involves extra time, for more complicated mouldings, it is preferable to Method 1.
  • the amounts of material to be injected into the mould can be calculated from test shots by trial and error.
  • Strengthening of the product may be carried out by the insertion of various strengthening rods or by cutting grooves in the core prior to inserting it in the mould, these grooves are filled during the skinning process. These grooves are an ideal method of reinforcing specific sections of the product with little effort. While spacers are specifically mentioned in this description, it was found that plastic straps, equidistant from each other. and fastened each side of the bottom of the mould so that they span the cavity, were satisfactory. When the mould ⁇ was closed the edges of the upper part of the mould bear against the ends of the stoop so that they tightened across the core and hold it sufficiently for the skinning process.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

Un procédé de production d'articles en mousse de polyuréthane consiste à former un noyau d'un matériau de faible densité, à placer le noyau dans un moule de sorte qu'au moins une partie du noyau soit espacée par rapport à la paroi du moule et à injecter des matériaux pour former une pellicule de mousse de polyuréthane dans l'espace entre le noyau et la paroi du moule, la pellicule ayant une densité supérieure à celle du noyau.
PCT/AU1984/000022 1983-02-21 1984-02-21 Systeme de moulage de produits mousses de polyurethane WO1984003251A1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
AUPF810383 1983-02-21

Publications (1)

Publication Number Publication Date
WO1984003251A1 true WO1984003251A1 (fr) 1984-08-30

Family

ID=3769996

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU1984/000022 WO1984003251A1 (fr) 1983-02-21 1984-02-21 Systeme de moulage de produits mousses de polyurethane

Country Status (2)

Country Link
EP (1) EP0138842A4 (fr)
WO (1) WO1984003251A1 (fr)

Cited By (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3438602A1 (de) * 1984-10-20 1986-04-24 Robbe Modellsport Gmbh, 6424 Grebenhain Verfahren zur herstellung eines modellteiles sowie nach diesem verfahren hergestelltes modellteil
FR2593011A1 (fr) * 1986-01-14 1987-07-17 Guillou Marc Procede de fabrication d'une structure creuse, incorporant une feuille de plomb, et enceinte acoustique realisee selon ce procede
EP0386818A1 (fr) * 1989-03-03 1990-09-12 Recticel Procédé pour la fabrication d'un objet avec une surface extérieure en élastomère et un noyau en mousse synthétique
EP0533018A1 (fr) * 1991-09-19 1993-03-24 Bayer Ag Procédé de préparation d'articles composites
DE4214744C1 (en) * 1992-05-04 1993-05-13 Correcta Gmbh, 3590 Bad Wildungen, De Prodn. of spoiler sections for motor vehicle - comprises fixing feet sections in moulding unit and filling with epoxy] resin at specified temp.
US5580501A (en) * 1994-11-07 1996-12-03 Gallagher; Michael J. Method of manufacturing an interior trim panel using polyurethane powder
US6033616A (en) * 1994-12-22 2000-03-07 Maruwa Plastics Ind. Co., Ltd. Process for the production of molded synthetic resin article with finished surface
EP1022105A1 (fr) * 1999-01-22 2000-07-26 Bernard Gonsette Article à noyau mousseux et avec une couche de couverture et son procédé de fabrication
EP2743535A1 (fr) * 2011-08-11 2014-06-18 Bridgestone Corporation Absorbeurs d'impact et procédé de production d'un absorbeur d'impact
WO2017032360A1 (fr) * 2015-08-21 2017-03-02 Wolfgang Staude Flotteur pour faire flotter un liquide

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1982004023A1 (fr) * 1981-05-11 1982-11-25 Frank Wolfgang Procede de fabrication de planches a voile et de surf
DE3225259A1 (de) * 1981-07-06 1983-02-03 Société Anonyme Block (Sand Sales) ( Proprietary) Ltd., Alberton, Transvaal Verfahren zur umhuellung von gegenstaenden und vorrichtung zur durchfuehrung des verfahrens
FR2523035A1 (fr) * 1982-03-15 1983-09-16 Plastimo Sa Procede de fabrication d'articles autoporteurs, alleges, en matiere plastique et planche a voile realisable par ce procede

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR1293628A (fr) * 1961-04-06 1962-05-18 Dunlop Sa Perfectionnements à la préparation d'articles cellulaires synthétiques
NL6617353A (fr) * 1965-12-16 1967-06-19
GB1182104A (en) * 1966-12-29 1970-02-25 Aldo Maria Andrea Emilo Eggers Production of Moulded Articles from Polyurethane
BE712171A (fr) * 1967-03-18 1968-09-16
US3543315A (en) * 1967-10-09 1970-12-01 William L Hoffman Soft board fabrication
US3520769A (en) * 1968-04-09 1970-07-14 Pacific Foam Packaging Packaging material and method of making same
SE335795B (fr) * 1969-08-27 1971-06-07 Ici Svenska Ab
CH538351A (it) * 1970-03-06 1973-06-30 Tornielli Giannina Procedimento per la fabbricazione di cuscini, materassi, imbottiture di schienali e simili, in gomma schuima da lattice o resina sintetica espansa
ATE14284T1 (de) * 1981-06-30 1985-08-15 Ciba Geigy Ag Verfahren zur herstellung eines verbundkoerpers mit einem kunststoff-hartschaumkern und einer tragschicht aus hartem kunststoffschaum hoeherer dichte.

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1982004023A1 (fr) * 1981-05-11 1982-11-25 Frank Wolfgang Procede de fabrication de planches a voile et de surf
DE3225259A1 (de) * 1981-07-06 1983-02-03 Société Anonyme Block (Sand Sales) ( Proprietary) Ltd., Alberton, Transvaal Verfahren zur umhuellung von gegenstaenden und vorrichtung zur durchfuehrung des verfahrens
FR2523035A1 (fr) * 1982-03-15 1983-09-16 Plastimo Sa Procede de fabrication d'articles autoporteurs, alleges, en matiere plastique et planche a voile realisable par ce procede

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of EP0138842A4 *

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE3438602A1 (de) * 1984-10-20 1986-04-24 Robbe Modellsport Gmbh, 6424 Grebenhain Verfahren zur herstellung eines modellteiles sowie nach diesem verfahren hergestelltes modellteil
FR2593011A1 (fr) * 1986-01-14 1987-07-17 Guillou Marc Procede de fabrication d'une structure creuse, incorporant une feuille de plomb, et enceinte acoustique realisee selon ce procede
EP0386818A1 (fr) * 1989-03-03 1990-09-12 Recticel Procédé pour la fabrication d'un objet avec une surface extérieure en élastomère et un noyau en mousse synthétique
EP0533018A1 (fr) * 1991-09-19 1993-03-24 Bayer Ag Procédé de préparation d'articles composites
US5300264A (en) * 1991-09-19 1994-04-05 Bayer Aktiengesellschaft Process for the production of composite bodies
DE4214744C1 (en) * 1992-05-04 1993-05-13 Correcta Gmbh, 3590 Bad Wildungen, De Prodn. of spoiler sections for motor vehicle - comprises fixing feet sections in moulding unit and filling with epoxy] resin at specified temp.
US5580501A (en) * 1994-11-07 1996-12-03 Gallagher; Michael J. Method of manufacturing an interior trim panel using polyurethane powder
US6033616A (en) * 1994-12-22 2000-03-07 Maruwa Plastics Ind. Co., Ltd. Process for the production of molded synthetic resin article with finished surface
EP1022105A1 (fr) * 1999-01-22 2000-07-26 Bernard Gonsette Article à noyau mousseux et avec une couche de couverture et son procédé de fabrication
EP2743535A1 (fr) * 2011-08-11 2014-06-18 Bridgestone Corporation Absorbeurs d'impact et procédé de production d'un absorbeur d'impact
EP2743535A4 (fr) * 2011-08-11 2015-03-25 Bridgestone Corp Absorbeurs d'impact et procédé de production d'un absorbeur d'impact
WO2017032360A1 (fr) * 2015-08-21 2017-03-02 Wolfgang Staude Flotteur pour faire flotter un liquide

Also Published As

Publication number Publication date
EP0138842A4 (fr) 1987-06-25
EP0138842A1 (fr) 1985-05-02

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