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
  • B29C33/30—Mounting, exchanging or centering
• • 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
  • B29C31/00—Handling, e.g. feeding of the material to be shaped, storage of plastics material before moulding; Automation, i.e. automated handling lines in plastics processing plants, e.g. using manipulators or robots
  • B29C31/04—Feeding of the material to be moulded, e.g. into a mould cavity
• • 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

• the present invention is directed generally to molding presses used for applying a coating of plastic material on the underside of sanitary fixtures such as tubs, sinks, lavatories and the like and, in particular, to a molding press insert table which is placed in the clamp of the press on top of the original lower platen to enable the molding of smaller sanitary fixtures such as sinks, lavatories and the like.
• composite enamel steel structures of substantially less weight than the prior fixtures but having the look and feel of such earlier fixtures.
• the composite structures are lighter, have a high structural strength and resist cracking and delamination when subjected to impact, thermal shock or the weight of a user.
• 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 the non-finish portion of the shell.
• the platen on which the female mold is placed is generally at floor level, with the operative components of the press including the mix head system and ejector system being found below floor level.
• a male molding portion is supported on an upper moveable platen and includes a surface which substantially conforms to the finish surface contour of the shell.
• the upper platen is urged downwardly against the finish side of the shell to hold the shell in the female mold portion.
• the desired polymeric material is injected from the mix head through a bushing into the mold to coat the non-finish side of the shell.
• the upper platen is then moved away thereby releasing the male mold member from the shell to permit removal of the shell from the female mold portion.
• a manufacturing insert for a molding press having an upper movable platen adapted to support a male mold member and a fixed lower platen adapted to support a female mold member, is provided.
• the molding press includes a mix head system and a hydraulic ejector system supported below the fixed lower platen.
• the manufacturing insert includes a table having a platen surface with legs depending downwardly therefrom with the legs being removably securable to the fixed lower platen of the molding press.
• the platen surface includes an enlarged opening therethrough.
• a mix head assembly is supported below the platen surface intermediate the legs of the table.
• the mix head assembly includes a mix head support for supporting a mix head and a slide system for permitting three dimensional movement of the mix head support to permit movement of the mix head from a first position where the mix head support extends through the enlarged opening in the platen surface and a second position where the mix head support extends outwardly beyond the legs of the table.
• the slide system includes slide rods supported intermediate the legs of the table to permit two dimensional X-Y movement of the mix head support and a vertical slide mechanism to permit up and down movement of the mix head support.
• the mix head support with mix head can be readily coupled to the mix head system of the molding press.
• the platen surface may include a plurality of openings for receiving hydraulic ejector cylinders which can be readily coupled to the hydraulic ejector system of the molding press.
• the manufacturing insert raises the level of the female mold member to a convenient working height and permits a large molding press to be used to mold smaller sanitary fixtures.
• Another object of the present invention is to provide a RIM flexible manufacturing insert for a molding press which raises the level of the female mold to a convenient working height.
• a further object of the present invention is to provide a manufacturing insert for a molding press which includes a movable mix head support system which can be coupled to the mix head system of the press in which it is used.
• Yet another object of the present invention is to provide a manufacturing insert for a large molding press used to mold large sanitary fixtures such as tubs or the like to permit the molding of small sanitary fixtures such as sinks, lavatories and the like.
• Still another object of the present invention is to provide a manufacturing insert for a molding press which is readily moved into and out of position in the molding press to provide flexibility to the molding press.
• Fig. 1 is a front elevational view of a molding press using a flexible manufacturing insert constructed in accordance with a preferred embodiment of the present invention
• Fig. 2 is an enlarged sectional view taken along line 2-2 of Fig. l;
• Fig. 3 is a sectional view taken along line 3-3 of Fig. 2;
• Fig. 4 is a sectional view taken along line 4-4 of Fig. 2;
• Fig. 5 is an enlarged sectional view taken along line 5-5 of Fig. 2;
• Fig. 6 is a top plan view of the platen surface viewed along line 6-6 of Fig. 1;
• Fig. 7 is a sectional view taken along line 7-7 of Fig. 2;
• Fig. 8 is a sectional view taken along line 8-8 of Fig. 2;
• Fig. 9 is a sectional view taken along line 9-9 of Fig. 6; and
• Fig. 10 is a partial sectional view of a molded sanitary fixture formed using the manufacturing insert of the present invention.
• FIG. 1 depicts a molding press, generally indicated at 20, including a manufacturing insert, generally indicated at 40, constructed in accordance with a preferred embodiment of the present invention.
• Molding press 20 is a conventional large molding press used generally for molding large articles such as bathtubs or the like. As described in commonly assigned U.S. Patent No. 4,664,982, mold 20 may be used to apply a plastic layer to the underside non-finish surface of a bathtub.
• molding press 20 When used conventionally for molding large items, molding press 20 includes an upper platen 22 slidably supported on guide rods 24a and 24b operated by an arm 25 to which a male mold member is secured. A lower fixed platen 26 at floor level supports a female mold member. The male and female mold members conform generally to the shape of the respective finish and underside non-finish surfaces of the tub to be molded.
• the operative molding components of molding press 20, such as mix head 28, are housed below lower platen 26 and hence below floor level.
• the tub to be molded is placed in the female mold member supported on lower platen 26, and upper platen 22 is moved downwardly to insert the male mold member within the concavity of the bathtub.
• Mix head 28 then injects the appropriate plastic material into the mold to coat the underside surface of the tub.
• upper platen 22 is moved upwardly and the finished bathtub is then removed from the mold using a hydraulically operated ejector system, the operative components of which are also housed below floor level of platen 26.
• molding press 20 While such large molding presses such as molding press 20 are suitable for molding large articles, they have proven unsuitable for molding smaller articles such as sinks, lavatories and the like since upper platen 22 cannot be moved downwardly far enough to properly insert the male mold member against the sanitary fixture to be molded.
• a spacer was placed on the undersurface of the upper platen to accommodate smaller molds. The use of such a spacer has proven less than completely satisfactory in actual manufacturing operations. Accordingly, the present invention provides a manufacturing insert 40, the construction and use of which is described below in detail.
• manufacturing insert 40 is in the form of a table 42 having a raised platen surface 44 supported by first and second legs 46 and 48.
• the height of legs 46 and 48 is such as to place platen surface 42 at a convenient working height.
• Feet 50 and 52 are provided at the bottom of legs 46 and 48, respectively, to provide stability thereto, to secure table 42 to the platen and to support various components housed under platen surface 44.
• platen 44 includes an enlarged central opening 60 through which a mix head is inserted. Platen 44 also includes four smaller circular openings 62a through 62d through which hydraulic cylinders 64a through 64d respectively extend. Additionally, a plurality of small openings 66 are provided to permit proper mounting of various female mold members on platen 44.
• a female mold member 70 is supported and secured on platen surface 44.
• Sink 80 includes a finish surface 82 and a non-finish surface 84 on its underside.
• Female mold member 70 includes a receptacle 72 shaped to conform to the shape of sink 80 which is received therein.
• a male mold member 76 is supported on upper platen 22 and is shaped to be received in sink 80 during the molding process.
• Female mold 70 includes an opening 76 in the bottom thereof through which the mix head is inserted to inject the plastic material which will coat non-finish surface 84 of sink 80.
• a mix head assembly 90 including mix head 92 is supported by a carriage 100.
• Mix head assembly 90 is slidably supported on carriage 100 for up and down movement with respect thereto. Such movement can be done manually or with an automatic system.
• Figs. 3 and 4 show mix head assembly 90 extending through enlarged opening 60 in platen 44 in its mold position.
• Fig. 5 shows mix head assembly 90 in its lower retracted position below platen surface 44.
• carriage 100 is slidably supported on a guide rail 110 which itself is slidably supported on opposing cross rails 112 and 114. Accordingly, in addition to be movable upwardly and downwardly with respect to platen surface 44, mix head assembly 90 can be moved both longitudinally and laterally to permit proper positioning thereof through opening 60 as well as to permit movement of mix head assembly 90 outside of manufacturing insert 40 to permit maintenance to be performed thereon.
• Various toggle clamps and locking arms 130, 132, 134 and 136 are provided for locking mix head assembly 90 in any desired position.
• Fig. 9 depicts the four hydraulic cylinders 64a through 64d which are utilized in connection with ejector pins provided in female mold member 70 to assist in ejecting the finished product from the mold.
• the hydraulic cylinders are used in pairs on opposite sides of mix head assembly 90 so that one of hydraulic cylinders 64a or 64b are used with one of hydraulic cylinders 64c or 64d.
• Mix head assembly 90 can be coupled through appropriate hoses and couplings to the mix head system contained as part of molding press 20.
• hydraulic cylinders 64a through 64d can be appropriately coupled to the conventional ejector system included as a part of molding press 20.
• manufacturing insert 40 is positioned on regular lower platen 26 and then bolted or otherwise secured thereto through feet 50 and 52.
• Female mold member 70 is placed on platen surface 44 at the convenient height provided and is affixed thereto through the appropriate openings 66.
• the appropriate two of hydraulic cylinders 62a through 62d are coupled to the pin ejector system of the female mold and mix head assembly 90 is moved into position.
• the various electrical, fluid and hydraulic couplings can then be made to the corresponding couplings provided by molding press 20.
• the molding procedure can then proceed as discussed above.
• assembly 90 can be moved downwardly and out from under platen surface 44 to the position depicted in phantom in Fig. 4.
• Fig. 10 shows a cross-sectional portion of sink 80 including its finish surface 82 and non-finish surface 84 which has now been coated with a plastic material 86 after the molding process.
• the manufacturing insert of the present invention provides manufacturing flexibility for molding large or small products on the same molding equipment including, for example, molding presses of 50, 75 or 100 tons. Molds of all sizes can then be utilized in connection with a single large molding press.
• the manufacturing insert provides a positive mold locator system using the appropriate opening 66, a ready ejector system attachment and selectable ejector cylinder locations to accommodate non-symmetrical mold mounting.
• the mix head assembly permits automatic or manual vertical movement and horizontal manual movement.
• the vertical movement is used to engage and disengage the mix head from the mold.
• the horizontal movement is used for convenient access to the mix head assembly for adjustment and/or repair.
• the manufacturing insert also places small molds at a convenient working height to assist in the loading of the molds and the unloading of the molded units. Mold servicing is also facilitated.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Robotics (AREA)
• Casting Or Compression Moulding Of Plastics Or The Like (AREA)
• Moulds For Moulding Plastics Or The Like (AREA)

Applications Claiming Priority (2)

Publications (1)

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Family Applications (1)

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Citations (3)

Family Cites Families (9)

• 1991
  • 1991-04-23 US US07/689,424 patent/US5118380A/en not_active Expired - Lifetime
  • 1991-04-30 TW TW080103363A patent/TW218368B/zh active
• 1992
  • 1992-04-22 AU AU20244/92A patent/AU2024492A/en not_active Abandoned
  • 1992-04-22 WO PCT/US1992/003367 patent/WO1992018315A1/en not_active Ceased

Patent Citations (3)

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