Abstract: A valve assembly for a molding system includes a plurality of sequentially activated valves. The valves suppress the initial surge of each individual fluid material component such that a proper quantity of each component is supplied to the mix head at the beginning of each cycle. Each of the valves includes a respective opening. The feed assembly continues to force fluid material against a first valve until the pressure is above a predetermine value. Once the pressure is above the predetermined value, the controller releases the pressure from an actuator associated with the first valve such that the valve opens. Fluid material can now flow through the valve assembly at a rate suppressed by the first valve. As the feed assembly continues to build toward it operational pressure, each remaining partially closed valve is opened in sequence. The restriction of one valve is thereby replaced by a lesser restriction. By opening the valves at a predetermined pressures the pressure buildup can be readily controlled.

Abstract: A low-pressure mold valve assembly includes a coupler to removably attach a mix head to a mold assembly in an assembly line environment. A first piston which is rectilinear in cross section is movable within the first flow passage along a first axis by an actuator. A second piston is movable along a second axis substantially perpendicular to the first axis by a second actuator. After injection is complete, the second piston seals a mix chamber of the mix head while remnants of the matrix that remain in a flow passage are driven into the first flow passage by the piston. The first piston is then driven toward the mold port such that matrix remnants are further driven into the mold cavity. The coupler is thus cleared of remnants without flushing.

Abstract: A method of manufacturing a molded article from a settable mixture includes the steps of in-taking a plurality of components into a plurality of separate material discharge containers sized relative to each other to provide the required mix ratio of the settable mixture. The components contained in the material discharge containers are discharged to a mold tool through a mixing head that receives each of the components separately and thoroughly mixes them into the settable mixture. The settable mixture flows from the mixing head to fill the mold tool. The mold tool rotates about an axis during the filling step to evacuate air from the mold tool. Pressure of the settable mixture is monitored during the filling step and rate of discharge of the settable component is varied in response to changes in pressure of the settable mixture.

Abstract: A system of manufacturing a molded article includes a mold having first and second parts engagable to one another to form a cavity. A first mold part is fixed to a mold station. The second part of the mold is movable between a spray station adjacent the mold station. An enclosure disposed between the mold station and the spray station contains emissions from the spray station so that the mold station is not contaminated. The molded article is fabricated by applying a surface coating at the spray station into, shuttling the movable part of the mold into alignment with the fixed part of the mold, and filling the mold with a settable mixture. The second part of the mold is released from the first part, and shuttled back to the spray station for demolding of the completed molded article.

Abstract: A lock assembly for a low pressure mold assembly includes a pin which extends from the first mold portion to be received into a female lock member. The female lock member includes a movable lock plate having a key-hole shaped opening. An actuator selectively moves the lock plate relative to the second mold portion between an unlocked and a locked position. In another embodiment, the lock assembly includes a female lock member mounted to the first mold portion and a male lock member mounted to the second mold portion. The female lock member includes a fixed bracket having a pair of parallel plates each having a substantially hook-shaped opening. The male lock member includes a linear actuator to drive an engagement member into and out of the hook-shaped opening to provide a locked and an unlocked position. A swing actuator drives the linear actuator through an arc such that the engagement portion of the linear actuator clears the female lock member to separate the mold portions.

Abstract: An air injection valve assembly includes an actuator and a valve section. The valve section generally includes a valve body and a valve stem movable therein. The valve stem includes a valve head which mates with a valve seat when in the closed position. A valve head facing surface of the valve head is manufactured to be completely flush with a valve seat facing surface of the valve seat. The facing surfaces are preferably contoured to exactly match the interior contour of the mold cavity. When in the closed position the valve head blends into the mold cavity and thus minimizes the chance of a blemish being formed on the molded article.

Abstract: A method of controlling a molding system for fabricating a molded article from a settable mixture includes the steps of priming several discharge containers with different components of the settable mixture and evacuating the discharge containers through a conduit into a mixing head. The mixing head combines the components to form the settable mixture that is then injected into the mold. During the priming step, pressure within each of the discharge containers is monitored to detect air being drawn into the system. Pressure of the settable mixture is monitored at the mixing head and at the mold tool to detect any blockages that can cause damaging pressure fluctuations. To prevent built up of residual settable mixture within the settable mixture, all parts of the system that contact the settable mixture are flushed with a solvent and then air-dried to rid the system of the solvent.

Abstract: A method of manufacturing a molded article from a settable mixture includes the steps of in-taking a plurality of components into a plurality of separate material discharge containers sized relative to each other to provide the required mix ratio of the settable mixture. The components contained in the material discharge containers are discharged to a mold tool through a mixing head that receives each of the components separately and thoroughly mixes them into the settable mixture. The settable mixture flows from the mixing head to fill the mold tool. The mold tool rotates about an axis during the filling step to evacuate air from the mold tool. Pressure of the settable mixture is monitored during the filling step and rate of discharge of the settable component is varied in response to changes in pressure of the settable mixture.

Abstract: The invention is a molded article having a reinforcement structure disposed therein. A settable mixture preferably including a catalyst, a matrix polymer, and a foaming agent introduced into a mold forms the shape of the molded article. The molded article includes a base section having a first thickness and wall sections extending upwardly about a periphery of the base section. The base section is substantially thicker than the wall sections. The reinforcement structure is disposed within the base section to reduce the amount of settable material required to form the base section and maintain the structural strength of the molded article.

Abstract: A system of manufacturing a molded article includes a mold having first and second parts engagable to one another to form a cavity. A first mold part is fixed to a mold station. The second part of the mold is movable between a spray station adjacent the mold station. An enclosure disposed between the mold station and the spray station contains emissions from the spray station so that the mold station is not contaminated. The molded article is fabricated by applying a surface coating at the spray station into, shuttling the movable part of the mold into alignment with the fixed part of the mold, and filling the mold with a settable mixture. The second part of the mold is released from the first part, and shuttled back to the spray station for demolding of the completed molded article.

Abstract: A method of reducing the restrictions of mixing fiber reinforced plastic includes the step of first coating the fiber. The coating is of a sort which will prevent the fiber from beginning to absorb the plastic such that the combined plastic and fiber may be stored for a period of time. Once the combined fiber and plastic are moved towards a mold, a mix station preferably cracks the coating. This allows the fiber to absorb the plastic matrix. The combined fiber and plastic is then delivered into a mold. By allowing the fiber to be pre-mixed with the plastic, the requirement of a “mix room” for mixing fiber into a plastic matrix adjacent to a molding facility is eliminated.

Abstract: This fiber chopper overcomes the disadvantages of the previous cutting rollers for chopping continuous filaments. The apparatus includes a means for feeding continuous fibers to a vibrating cutting blade. The vibrating blades engage the continuous fiber and chops them into discrete fiber lengths. A vibrating head vibrates the cutting blades through a vibrating table.

Abstract: A mix head assembly for a rapid discharge multiple material delivery molding system includes an output chamber assembly having a plurality of impellers, a main body assembly, and a drive assembly. The main body assembly preferably includes a plurality of input ports which correspond to the number of fluid material supplies. In one disclosed embodiment, the mix head assembly include a flush assembly to communicate a flushing fluid from a supply through the gates and into the feed chambers to minimize residual fluid material after each molding cycle. In operation, the fluid materials are directed by their respective input ports to a first impeller. The first impeller is driven by the drive shaft such that the impeller drives the fluid materials back toward the input ports. The pressure in the material builds up and it eventually is driven back past the first impeller.

Abstract: This fiber chopper overcomes the disadvantages of the previous cutting rollers for chopping continuous filaments. The apparatus includes a means for feeding continuous fibers to a chopping roller. A spring holds the cutting blades on the chopping roller. The filaments pass between the chopping roller and a feed roller for chopping.

Abstract: A low-pressure mold valve assembly includes a coupler to removably attach a mix head to a mold assembly in an assembly line environment. A first piston which is rectilinear in cross section is movable within the first flow passage along a first axis by an actuator. A second piston is movable along a second axis substantially perpendicular to the first axis by a second actuator. After injection is complete, the second piston seals a mix chamber of the mix head while remnants of the matrix that remain in a flow passage are driven into the first flow passage by the piston. The first piston is then driven toward the mold port such that matrix remnants are further driven into the mold cavity. The coupler is thus cleared of remnants without flushing.

Abstract: This fiber chopper overcomes the disadvantages of the previous cutting rollers for chopping continuous filaments. The apparatus includes a means for feeding continuous fibers through apertures in a fixed head. Rotating blades engage the continuous fiber and chops them into discrete fiber lengths. In another embodiment, a rotating chopping disc with cutting apertures therethrough replaces the fixed head and rotating blades. The cutting apertures have sharp edges for chopping the continuous fibers.

Abstract: This fiber chopper overcomes the disadvantages of the previous cutting rollers for chopping continuous filaments. The apparatus includes a means for feeding continuous fibers to a vibrating cutting blade. The vibrating blades engage the continuous fiber and chops them into discrete fiber lengths. A vibrating head vibrates the cutting blades through a vibrating table.

Abstract: This fiber chopper overcomes the disadvantages of the previous cutting rollers for chopping continuous filaments. The apparatus includes a means for feeding continuous fibers to a chopping roller. A spring holds the cutting blades on the chopping roller. The filaments pass between the chopping roller and a feed roller for chopping.

Abstract: This fiber chopper overcomes the disadvantages of the previous cutting rollers for chopping continuous filaments. The apparatus includes a means for feeding continuous fibers through apertures in a fixed head. End mills engage the continuous fiber and chops them into discrete fiber lengths.

Abstract: This fiber chopper overcomes the disadvantages of the previous cutting rollers for chopping continuous filaments. The apparatus includes a means for feeding continuous fibers through apertures in a fixed head. End mills engage the continuous fiber and chops them into discrete fiber lengths.