WO1992006834A1 - Systeme de demoulage a jet d'air - Google Patents

Systeme de demoulage a jet d'air Download PDF

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Publication number
WO1992006834A1
WO1992006834A1 PCT/US1991/006909 US9106909W WO9206834A1 WO 1992006834 A1 WO1992006834 A1 WO 1992006834A1 US 9106909 W US9106909 W US 9106909W WO 9206834 A1 WO9206834 A1 WO 9206834A1
Authority
WO
WIPO (PCT)
Prior art keywords
mold
shell
molded
molding
fluid
Prior art date
Application number
PCT/US1991/006909
Other languages
English (en)
Inventor
Robert M. Jensen
Gregory M. Gatarz
Original Assignee
American Standard Inc.
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 American Standard Inc. filed Critical American Standard Inc.
Publication of WO1992006834A1 publication Critical patent/WO1992006834A1/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
    • B29C33/00—Moulds or cores; Details thereof or accessories therefor
    • B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
    • B29C33/46—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles using fluid pressure
    • 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
    • B29C67/00—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00
    • B29C67/24—Shaping techniques not covered by groups B29C39/00 - B29C65/00, B29C70/00 or B29C73/00 characterised by the choice of material
    • B29C67/246—Moulding high reactive monomers or prepolymers, e.g. by reaction injection moulding [RIM], liquid injection moulding [LIM]
    • 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
    • B29C70/78—Moulding material on one side only of the preformed part
    • 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
    • B29L2031/769—Sanitary equipment

Definitions

  • This invention relates to a system for de olding articles, more particularly to an apparatus for separating and lifting molded sanitary fixtures such as bathtubs and sinks by using air pressure to separate and facilitate removal of the molded sanitary fixture from the female portion of a mold.
  • porcelain cast-iron bathtubs and smallware such as sinks have begun to be replaced by composite enamel steel structures of substantially less weight than the older fixtures but having the look and feel of the earlier porcelain cast-iron fixtures.
  • the composite structures are much lighter, have high structural strength and resist cracking, chipping, delamination, when subjected to impact, thermal shock or the weight of a typical bather.
  • the patent discloses fixtures having the look and feel of earlier porcelain cast-iron fixtures with high structural strength, resistance to delamination, chipping and denting due to impact or thermal shock.
  • the c ⁇ osite enamel steel fixture is formed from a steel shell which is used as a part of a mold to form a layer of reinforced foam plastic by Reaction Injection Molding ("RIM”) or by Reinforced Reaction Injection Molding (“RRIM”) processing on the non-finish side (i.e., underside) of the shell.
  • RIM Reaction Injection Molding
  • RRIM Reinforced Reaction Injection Molding
  • Genovese, et al. and U.S. Patent Application Serial No. 07/400,280 to Kuszaj, et al., both of which are incorporated by reference herein, describe polymeric foam-backed enameled carbon steel or stainless steel sanitary fixtures that are resistant to chipping, cracking, grazing, delamination or deformation when subjected to impact on either the finish or the non-finish side.
  • These composite structures also possess excellent physical and mechanical properties due largely to the chemical bonding of the reinforced polymeric layer to the enamel steel or stainless steel shell.
  • a shell having a finish and a non-finish side is inserted into a female mold receptacle forming a cavity between the molding receptacle surface and a non-finish portion of the shell.
  • a male molding portion having a surface which substantially conforms to finish surface contour of the shell, is urged against the finished side of the shell.
  • the cavity formed between the molding receptacle and the non-finish side of the shell must be sealed around the periphery of the shell to prevent leakage of injected polymeric material from the cavity. After injecting the polymeric material into the cavity, the polymeric material is allowed to harden and bond to the non- finish side of the shell.
  • the molded articles are then removed from the female mold portion.
  • one of the difficulties incurred during such molding processes is the removal of the molded product from the female mold portion.
  • the production of molded bathtubs using prior art techniques was time consuming and inefficient. Before demolding, it was necessary for the mold operator to wait for sufficient green-strength to develop or cure before removing the molded article from the female portion of the mold to avoid damage due to insufficient support of the molded article.
  • a further problem was that a vacuum often formed between the molded articles and the mold, making demolding more difficult. Often, the newly molded article would stick to and pull the mold seal used in forming the sealed cavity described above out of its groove during demolding. The frequent delays incurred to reinsert the seal increased the costs of manufacture and was an inefficient use of labor.
  • Another feature of the present invention is to provide a method and apparatus for separating and lifting molded sanitary fixtures from a rigid mold receptor of a mold using air pressure.
  • Yet another feature of the present invention is to provide a method and apparatus useful in separating and lifting molded sanitary fixtures from a rigid mold receptor of a mold without having * to wait for sufficient green strength of the polymeric material to develop.
  • the present invention provides a method and apparatus for removing molded sanitary fixtures from a mold.
  • the method includes directing a stream of fluid between a rigid mold surface and a molded sanitary fixture so that the molded sanitary fixture is urged away from the mold surface and ejected from the mold.
  • the mold of the present invention is adapted for receiving a sanitary fixture shell having a non-finish side and a finish side.
  • the shell is placed in the mold so that the rigid mold surface may receive the shell so as to define a void between the non-finish side of the shell and the rigid mold surface.
  • the sanitary fixture shell is sealably retained in the mold, for example, by hydraulic pressure and lowering a male molding member which engages the finish side of the sanitary fixture shell to form a sealed continuous injection molding cavity.
  • a hardenable polymeric material is introduced under pressure through an aperture in the mold and fills the void between the non- finish side of the shell and the rigid mold surface.
  • the pressure used to engage the male molding member is released before the mold is opened.
  • the male molding member then supports the molded workpiece which is separated and ejected from the mold receptacle by a fluid ejection means.
  • the fluid ejection means is preferably realized as a fluid directed from a pressurized source via a conduit and a r ⁇ l ⁇ asable valve.
  • the releasable valve is preferably placed on the molding surface and is capable of releasing a fluid under a pressure of from about 30 to about 60 psi between the molding surface and the molded sanitary fixture to urge the molded fixture away from the rigid mold surface and ejects the fixture from the mold.
  • the releasable valve is activated by the mold operator upon demand to urge the sanitary fixture away from the mold surface and eject the fixture from the mold.
  • the method and apparatus of the present invention provide shortened mold cycle times.
  • the molded sanitary fixture may be separated and urged away from the rigid mold surface prior to the polymeric molding material completely hardening without blemishing the molded sanitary fixture. This advantageous feature is realized by supporting the molded article against deflection by the male molding member in combination with the fluid ejection means.
  • the molded sanitary fixtures made in the mold of the present invention and removed therefrom according to the method of the present invention are preferably formed in the shape of a sink.
  • the molded sanitary fixture may be selected from bathtubs, spas, shower receptors, whirlpools, toilets and the like.
  • a mold for molding sanitary fixtures and a method for removing molded sanitary fixtures from the mold are disclosed. Neither the mold nor the method rely upon expensive hydraulic or mechanical piston ejectors to lift and separate the fixture from the mold receptor.
  • the fixture By directing a stream of pressurized fluid between the mold surface and the molded sanitary fixture, the fixture can be urged away and ejected from the mold without blemishing the polymeric molding material which has been affixed to the non-finish side of the sanitary fixture.
  • no physical object comes in contact with the polymeric molding material during removal of the fixture from the mold, it is now possible to demold the fixtures prior to the polymeric molding material completely hardening.
  • the mold used in molding the sanitary fixtures and the method of removal thus provide improved efficiency during molding without sacrificing the quality of molded sanitary fixture.
  • Fig. 1 is a bottom perspective view of a sink made in a mold designed in accordance with the present invention showing the polymeric molded non-finish side.
  • Fig. 2 is a top perspective view of the sink illustrated in Fig. 1 showing the finish side of the sink.
  • Fig. 3 is a top perspective view of a sink shell used in the present invention showing the finish and non- finish sides.
  • Fig. 4 is a schematic front elevational view of a sanitary fixture molding apparatus in accordance with the present invention.
  • Fig. 5 is a top perspective view of a mold receptor in accordance with the present invention illustrating the fluid ejection means.
  • Fig. 6 is a top plan view of a mold receptor made in accordance with the present invention illustrating the fluid ejection means.
  • Fig. 7 is a bottom view of the mold illustrated in Fig. 6.
  • FIG. 1-7 a preferred air ejection system constructed in accordance with the present invention is described.
  • the present invention may be used in a wide variety of apparatus for applying a reinforced polymeric material to the non-finish surface of a shell, such as those used in forming sanitary fixtures including bathtubs, sinks, whirlpools, tubs, spas, and the like.
  • sanitary fixture shall be understood to include all such sanitary fixtures, as well as other types of liquid-containing molded vessels.
  • Fig. 4 shows a molding apparatus used in applying a polymeric foam material to the non-finish surface 48 of a shell 1.
  • Copending U.S. Patent Application Serial No. 07/458,598 to Marsilio, et al. filed on December 29, 1989 describes a molding apparatus which is suitable for molding a layer of polymeric foam material to the non-finish side of a shell.
  • the molding, apparatus described in this application can be used with any of the shells and polymeric materials which are described in U.S. Patent Nos. 4,664,982, 4,844,944, 4,844,955 and 4,644,092, and Application Nos. 07/400,280 and 07/458,598.
  • the molding apparatus __0 containing the fluid ejection system of the present invention is shown in Fig. 4.
  • the molding apparatus includes a platform 13 onto which a molding receptacle 6 is mounted.
  • the molding receptacle is rigid in structure and has a molding surface 8 which generally corresponds to surface contour of the shell 1.
  • the molding receptacle 6 is provided with at least one aperture 39 formed in the molding surface which communicates with a- mix head 38 for introducing a polymeric material into the molding cavity.
  • the molding cavity formed defines a void created between the molding surface 8 and the non- finish side 48 of the shell 1.
  • the male molding member 7 includes a surface having a shape which conforms to the sanitary fixture to be molded.
  • a particular shell for a sink is illustrated in Fig. 3.
  • the shell 1 has a first reservoir 20 and a second reservoir 22.
  • the male molding member 7 has a shape corresponding to the finish side 51 of shell 1 with surface contours which allow it to be received in the respective reservoirs 20, 22.
  • a first male mold reservoir portion 21 is received in the first reservoir 20 and the second male mold reservoir portion 23 is received in the second reservoir 22.
  • the male molding member may also include a protective coating 12.
  • the protective coating may be made from materials such as urethane and provides a soft resilient surface which supports the shell during molding and demolding operations without damaging the finish side 51 of the sanitary fixture.
  • the finish side of the shell and molded article are typically coated with a ceramic material.
  • TEFLONS strips or other non-abrasive materials may also be included around the periphery of the protective coating 12 for contacting and urging the deck portion 55 of the shell 1 toward the molding receptacle 6 during the molding process without causing damage to the finish side 51 of the shell 1.
  • the molding apparatus of the present invention also may include a hydraulically operated press 16 which lowers and retains the male molding member 7 against the finish side 51 of the sink shell 1.
  • the non-finish side 48 of the shell is received in the mold receptacle 6 adjacent the molding surface 8.
  • a molding cavity is formed between the non-finish side 48 of the shell 1 and the molding surface 8 of the molding receptacle 6.
  • a molding press suitable for molding sanitary fixtures and which can be adapted to include the fluid ejection system of the present invention is manufactured by Linden Industries, Inc.
  • the fluid ejection means preferably utilizes an air poppet valve supplied, for example, by National Tool and Manufacturing of Mountainside, New Jersey.
  • the air poppet valve includes a spring loaded releasable air valve capable of delivering a stream of pressurized air to separate and eject the newly molded fixture. For example, a pressure of from about 30 to about 60 lbs. per square inch (psi) has been found to be sufficient to separate and eject molded sinks. Higher pressures, however, may be used depending upon the sanitary fixture being ejected.
  • the fluid ejection means of the present invention also includes means for receiving fluid 58 from a fluid source 60 and directing the fluid between the molding surface 8 and the molded sanitary fixture 50 formed on the molding surface.
  • Means for receiving the fluid may include a conduit such as a suitable hose in fluid communication with the releasa'rle valve 32 and a fluid source 60 such as air, whose pressure is regulated by a valve 62.
  • the molding surface 8 may also be coated with a non ⁇ stick material to assist in demolding.
  • non-stick materials include TEFLON®, a wax coating, silicone coatings and the like.
  • the present invention includes a method of removing a molded sanitary fixture such as a sink 50 having a finish side 51 and hardened polymeric material 66 applied to the non-finish side 48 from a mold.
  • the method includes directing a stream of fluid from a source of fluid between the mold surface 8 and the molded sanitary fixture 50, such as the sink, urging the sink away from the mold surface and ejecting it from the mold.
  • Examples of molded sanitary fixtures and molds which can be adapted to utilize the present invention are disclosed in U.S. Patent Application Serial Nos. 07/458,598, 07/467,771 and 07/516,284.
  • the molded sanitary fixture is coated in the mold by a hardenable polymeric material 66 introduced from a mix head 38 through aperture 39 in the bottom of the mold receptor 6.
  • the polymeric material fills the molding cavity formed between the mold receptor surface 8 and the non- finish side 48 of the shell.
  • the cavity is sealed by the male molding member 7 which fully engages the finish side 51 of the sink 50 when in the molding apparatus .10..
  • the cavity is then filled with the hardenable polymeric material which is injected through the aperture 39 under suitable molding pressure.
  • suitable polymeric materials include, for example, cross-linkable isocyante-modified thermo- setting unsaturated polyester or polyether foams, pastes and liquids. These materials, as well as other useful polymeric molding materials are set forth in U.S. Patent No. 4,844,944 and U.S. Patent Application Serial No. 07/400,289, the disclosures of which are accordingly incorporated by reference herein.
  • a steel shell is molded in the molding apparatus. Under these circumstances, it is preferred to maintain hardenable polymeric material at a temperature in the range of from about 85 * F to 105*F, and most preferably at about 95'F.
  • the low pressure molding process and polymeric shell disclosed in commonly assigned and copending U.S. Patent Application Serial No. 07/516,284 may be adapted to include the fluid ejection means of the present invention.
  • These non-isocyanate polymeric materials include cross-linked reinforcing resins such as epoxy, acrylic, vinyl esters and blends thereof.
  • the disclosure of U.S. Patent Application Serial No. 07/516,284 is also incorporated herein by reference.
  • Such heating may be accomplished by a fluid system 70 which serves to warm the mold receptor by circulating heated fluid through the mold.
  • the mold receptor 6 should be made from a suitable heat conducting material, such as aluminum.
  • the mold receptor surface 8 may be optionally coated with a layer of a non-stick material, such as TEFLOI® which does not retard its heat conducting properties.
  • the molded sanitary fixture After the molded polymeric material has sufficiently hardened, the molded sanitary fixture needs to be removed from mold.
  • the molded sanitary fixture is removed from the mold by directing a stream of fluid from a source of fluid 60 between the rigid mold surface 8 and the molded fixture.
  • the stream of fluid urges the molded sanitary fixture away from the mold surface and ejects it from the mold.
  • any hydraulic pressure, if used, or locking of the male molding member to engage the male molding member against the finish side is released prior to initiating the stream of fluid.
  • the method includes directing the stream of fluid from the source 60 via a conduit 58 to a releasable valve 32 located on the mold surface 8.
  • the fluid may be regulated by a valve 62.
  • a stream of fluid for example, pressurized air, at from about 30 to about 60 psi, is released by the releasable valve 32 located on the mold surface 8 and directed between the mold surface and the molded sink 50 for a time period of from about 3 to about 5 seconds before the mold is opened.
  • the stream of fluid urges the molded article away from the mold surface 8.
  • male molding member 7 supports the molded sanitary fixture against deflection upon demolding.
  • Deflection of the molded article inverts the concavity of the reservoirs and can be a significant concern especially when acrylic type fixtures such as those disclosed in U.S. Patent Application No. 07/516,284 are being ejected.
  • the molded sink is ejected from the mold receptacle prior in the manner described above, but prior to polymeric molding material hardening completely on the non-finish side 48 of the sink 50.
  • This preferred embodiment allows more efficient use of the molding apparatus by shortening mold cycle time.
  • a complete mold cycle for a molded sink, including sufficient hardening of the polymeric material and ejection is typically about 220 seconds.
  • the molding cycle can be reduced by about 100 seconds due to the ability to separate and eject the molded fixtures prior to complete hardening of the polymeric material without blemishing the molded article.
  • the present invention provides improved, blemishless removal of molded articles by fluid ejection. Moreover, in a preferred embodiment, it is no longer necessary to wait for complete hardening of the polymeric material before ejecting the molded fixture. By directing a source of fluid between the mold surface and the molded fixture, the present invention allows for early removal of the molded article without blemishing the prehardened material or waiting for the sufficient green strength to develop.

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  • Physics & Mathematics (AREA)
  • Fluid Mechanics (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

L'invention se rapporte à un moule et à un procédé qui servent à mouler des appareils sanitaires (50) et qui utilisent à cet effet un logement de moule rigide (6), une surface de moulage rigide (8) et un organe de démoulage à jet de fluide. Le moule comporte un organe (32) destiné à recevoir un fluide sous pression et à diriger ce fluide entre la surface de moulage (8) et l'appareil sanitaire moulé fabriqué dans le moule. L'organe de démoulage à jet de fluide comprend de préférence une source de fluide pressurisé (60), qui dirige le fluide entre la surface de moulage et l'appareil sanitaire moulé, afin de détacher l'appareil sanitaire moulé de la surface du moule et permettre ainsi son éjection du moule.
PCT/US1991/006909 1990-10-18 1991-09-25 Systeme de demoulage a jet d'air WO1992006834A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US59948590A 1990-10-18 1990-10-18
US599,485 1990-10-18

Publications (1)

Publication Number Publication Date
WO1992006834A1 true WO1992006834A1 (fr) 1992-04-30

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ID=24399806

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1991/006909 WO1992006834A1 (fr) 1990-10-18 1991-09-25 Systeme de demoulage a jet d'air

Country Status (2)

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AU (1) AU8727691A (fr)
WO (1) WO1992006834A1 (fr)

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB997277A (en) * 1963-07-01 1965-07-07 Peter Derek John Dicks Method of moulding plastic containers
JPS61121915A (ja) * 1984-11-19 1986-06-09 Matsushita Electric Ind Co Ltd 金型装置
FR2580218A1 (fr) * 1985-04-12 1986-10-17 Stradour Sa Procede et machine pour le moulage par compression a chaud de pieces d'aspect pourvues d'un revetement sur une face
GB2232920A (en) * 1989-02-23 1991-01-02 Carter Holt Harvey Roofing Alu Gas pressure ejection of a moulded article

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB997277A (en) * 1963-07-01 1965-07-07 Peter Derek John Dicks Method of moulding plastic containers
JPS61121915A (ja) * 1984-11-19 1986-06-09 Matsushita Electric Ind Co Ltd 金型装置
FR2580218A1 (fr) * 1985-04-12 1986-10-17 Stradour Sa Procede et machine pour le moulage par compression a chaud de pieces d'aspect pourvues d'un revetement sur une face
GB2232920A (en) * 1989-02-23 1991-01-02 Carter Holt Harvey Roofing Alu Gas pressure ejection of a moulded article

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN vol. 10, no. 311 (M-528)(2367) 23 October 1986 & JP,A,61 121 915 ( MATSUSHITA ELECTRICAL IND CO LTD ) 9 June 1986 see abstract *

Also Published As

Publication number Publication date
AU8727691A (en) 1992-05-20

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