With Mechanical Means Forming Or Expanding Pores (e.g., Foaming, Etc.) Patents (Class 425/4R)
  • Patent number: 4783295
    Abstract: An improved process for producing a molded microcellular elastomer with a reduced number of voids from at least two liquid reactants and a gas, which process comprises introducing into at least one reactant a gas to form an admixture; passing the admixture through a static mixer at superatmospheric pressure; then immediately mixing the admixture with the other reactant at superatmospheric pressure to form a reaction mixture; introducing the reaction mixture into a mold in which the pressure is substantially below the superatmospheric pressures used above; and curing the reaction mixture in the mold to produce a molded microcellular elastomer with a reduced number of large voids.
    Type: Grant
    Filed: December 17, 1985
    Date of Patent: November 8, 1988
    Assignee: Union Carbide Corporation
    Inventors: James D. Kearns, Ronald J. Stapleton
  • Patent number: 4783292
    Abstract: A method of forming a foamed plastic article, comprising the steps of: injecting pressurized gaseous bubbles into a stream of heated liquid plastic; feeding the heated liquid, with entrained gas bubbles, into a mold cavity without expanding the bubbles; slowly expanding the mold cavity to permit the gas bubbles to expand and thereby produce a foamed plastic article; controlling the temperature of the mold cavity surfaces so that the plastic material is in a viscous liquid state during at least the major part of the bubble expansion process; and cooling the mold cavity surfaces to a temperature less than the melt point of the plastic.
    Type: Grant
    Filed: June 15, 1987
    Date of Patent: November 8, 1988
    Inventor: Roy K. Rogers
  • Patent number: 4781555
    Abstract: A mold has mold walls defining a cavity and a plurality of heated fluid inlets communicating with the cavity. An enclosed frame for storing a heated fluid is positioned about the mold. Valves are positioned completely within the enclosed frame and each of the valves is coupled to one of the heated fluid mold inlets.
    Type: Grant
    Filed: January 7, 1987
    Date of Patent: November 1, 1988
    Assignee: EFP Corp.
    Inventor: Charles A. Cook
  • Patent number: 4781554
    Abstract: A nozzle for the injection molding of thermoplastic materials includes a nozzle body having a first bore for establishing a flow path for a molten thermoplastic. A first end of the nozzle body is adapted for fluid connection with a sprue of an associated mold body, and a second end thereof is adapted for fluid connection with an end of an associated injection molding machine. The nozzle body also includes a second bore. A first valve assembly, which is adapted for reciprocating movement in the nozzle body second bore, is provided to control the flow of plastic through the nozzle body. The first valve member includes a body having a tip portion and a fluid passage formed in the body and open at one end through the tip portion. A connection member is provided for communicating the valve body fluid passage with an associated source of pressurized fluid.
    Type: Grant
    Filed: July 9, 1987
    Date of Patent: November 1, 1988
    Assignee: Michael Ladney
    Inventor: James W. Hendry
  • Patent number: 4778364
    Abstract: In the manufacture of a foamed confection such as foamed chocolate, a confection in liquid form is mixed with carbon dioxide under pressure. The mixture is discharged from the depositor through annular outlet orifices which are opened and closed in turn by associated valves so that at any one time some of the orifices are discharging the mixture, and the number of orifices which are closed does not vary. Each annular orifice has a length which is not greater than its diameter. Each valve has an annular valve seat and a valve member movable into and out of engagement with the valve seat.
    Type: Grant
    Filed: September 30, 1986
    Date of Patent: October 18, 1988
    Assignee: Cadbury Limited
    Inventor: Brian T. Richards
  • Patent number: 4778631
    Abstract: Polymer materials having viscosities ranging from about 50,000 up to above 1,000,000 centipoises are mixed with a gaseous foaming agent to provide a polymer/gas solution under pressure such that when the polymer/gas solution is subsequently dispensed at atmospheric pressure the gas is released from the solution and becomes entrapped in the polymeric material to form a homogeneous polymer foam. Mixing is accomplished by force feeding the gas and polymeric material into and through a low energy input disk mixer with a low pressure drop across the mixer such that premature foaming or reaction of the polymeric material is avoided. The disk mixer includes a tubular housing, one or more driven shafts extending along the length of the housing, and a series of disks spaced along the shafts. The foaming gas enters into solution in the polymer in the compartments between the rotating disks.
    Type: Grant
    Filed: April 9, 1987
    Date of Patent: October 18, 1988
    Assignee: Nordson Corporation
    Inventors: Walter H. Cobbs, Jr., Robert J. Huddleston, Chan I. Chung, Laurence B. Saidman
  • Patent number: 4759700
    Abstract: The present invention is directed to an apparatus for the production of back-foamed cushions from cover materials and foam comprising:(i) a mold comprising an upper mold half and a lower mold half, said lower mold half defining a cavity, the inside surface of which is capable of being covered by said cover material,(ii) a mix head associated with said mold, said mix head capable of introducing foam materials and/or reactants into said mold cavity, and(iii) at least one pressing element for pressing said cover material into said mold cavity, said pressing element having a pressing edge which consists of at least one balanced spring.
    Type: Grant
    Filed: September 24, 1987
    Date of Patent: July 26, 1988
    Assignees: Fritsche-Mollmann GmbH & Co., Bayer Aktiengesellschaft
    Inventors: Volker Onnenberg, Gunter Mollmann
  • Patent number: 4758394
    Abstract: Forming method of producing thin-walled finished articles such as cups of expanded resin including steps of: heating beads of expandable thermoplastic resin in a mold cavity of a preforming mold, causing the beads to be expanded and fused together to produce a preformed article; transferring the preformed article as pressurized in an atmosphere under pressure to a finish-forming mold; and compressively forming the preformed article with the finish-forming mold.
    Type: Grant
    Filed: October 3, 1986
    Date of Patent: July 19, 1988
    Assignee: Sekisui Kaseihin Kogyo Kabushiki Kaisha
    Inventors: Masato Yaita, Toshikazu Omori, Takao Suzuki, Hiroshi Hasegawa
  • Patent number: 4756859
    Abstract: A method for obtaining expanded polystyrene products comprising portions of comparatively very different densities and thus of different mechanical strengths, in which a first mass of pre-expanded polystyrene beads of greater density is caused to partially cohere by means of steam, the resultant mass is placed in a mould of greater dimensions, said mould is completely filled with polystyrene beads of density less than the preceding, and cohesion is completed therein.
    Type: Grant
    Filed: May 28, 1986
    Date of Patent: July 12, 1988
    Assignee: Plastbau A.G.
    Inventor: Piero Cretti
  • Patent number: 4755117
    Abstract: The present invention is directed to an apparatus for the production of back-foamed cushions from cover materials and foam, comprising:(i) a mold comprising an upper mold half and a lower mold half, said lower mold half defining a cavity, the inside surface of which is capable of being covered by said cover material,(ii) a mix head associated with said mold, said mix head capable of introducing foam materials and/or reactants into said mold cavity,(iii) an upper ram provided above the lower mold half, and comprising several segments with contact pressure surfaces, which segments are mounted to be displaceable in guide bores of a supporting frame and wherein springs are associated with said segments, said springs acting on said segments in the direction of said mold cavity, and wherein when said upper ram is in the position of rest, the various contact pressure surfaces are located at different distances from the bottom of said mold cavity, and(iv) wherein said lower mold half is movable towards and away from
    Type: Grant
    Filed: September 24, 1987
    Date of Patent: July 5, 1988
    Assignees: Fritsche-Mollmann GmbH & Co., Bayer Aktiengesellschaft
    Inventors: Volker Onnenberg, Gunter Mollmann
  • Patent number: 4755120
    Abstract: The present invention is directed to an apparatus for the production of back-foamed covers from cover materials and foam comprising(i) a mold comprising an upper mold half and a lower mold half, the lower mold half having a cavity therein, the inside surface of which is capable of being covered by the cover material,(ii) a mixhead associated with the mold, the mixhead capable of introducing foam materials and/or reactants into the mold cavity,(iii) a pusher bar arranged on a mount for pushing the cover material into the mold cavity and being arranged above the lower mold half, the pusher bar being constructed such that when the bar is pushing the cover material into the mold cavity, a gap is formed between the edge of the mold cavity and the edge of the pusher bar, the gap being less than the thickness of the cover material,(iv) the lower mold half being movable towards and/or away from the pusher bar, and(v) the surface of the pusher bar facing the mold cavity edge being a frictional surface.
    Type: Grant
    Filed: September 24, 1987
    Date of Patent: July 5, 1988
    Assignees: Fritsche-Mollmann GmbH & Co., Bayer Aktiengesellschaft
    Inventors: Volker Onnenberg, Gunter Mollmann
  • Patent number: 4737091
    Abstract: A plant for molding articles in polyurethane material; the plant comprises a plurality of motorized mold supporting carriages independently movable along a suspended monorail running along a production line. Each carriage comprises a mold supporting press for opening and closing a mold provided with independent pneumatic control means supported by the same carriage; the control means are connectable to a source of fluid under pressure in pre-established working positions along the production line; each carriage also comprises a drive unit connected to electrical power supply bus bar along the monorail and a peripheral control unit operatively connected to a central logic unit by dialogue conductors provided on the monorail.
    Type: Grant
    Filed: April 21, 1987
    Date of Patent: April 12, 1988
    Assignee: Afros, S.p.A
    Inventor: Carlo Fiorentini
  • Patent number: 4732181
    Abstract: A vehicle carried system for camouflage with foam includes a plant for generating water-based foam. The foam generating plant includes a reservoir for foaming liquid or a water tank with a reservoir for a foaming agent, which are connected to produce foaming liquid. The foaming liquid is pumped, or delivered in another way, under pressure to the foam generator for generating camouflage to be applied to the ground or to be filled into containers. Containers and free foam are preferably colored to give the protected object a good visual camouflage.
    Type: Grant
    Filed: February 21, 1986
    Date of Patent: March 22, 1988
    Inventors: Stefan Sollander, Rainer Trubenbach, Per Wigren
  • Patent number: 4731211
    Abstract: Thermosetting fluorodiepoxide polymer foams are made by mixing fluid form thermosetting fluorodiepoxide polymer components having a substantial fluorine content, placing the mixture in a pressure tight chamber, filling the chamber with a gas, at relatively low pressure, that is unreactive with the fluorodiepoxide polymer components, allowing the mixture to gel, removing the gelled fluorodiepoxide polymer from the chamber and thereafter heating the fluorodiepoxide polymer at a relatively low temperature to simultaneously cure and foam the fluorodiepoxide polymer. The resulting fluorodiepoxide polymer product is closed celled with the cells storing the gas employed for foaming.
    Type: Grant
    Filed: May 29, 1986
    Date of Patent: March 15, 1988
    Assignee: The United States of America as represented by the Administrator of the National Aeronautics and Space Administration
    Inventor: Sheng Y. Lee
  • Patent number: 4726933
    Abstract: A high pressure mixing head for mixing reactive components in reaction injection molding includes a mixing chamber discharging into a quieting chamber and an injection valve for injecting reactive component into the mixing chamber. Recirculation passages for the reactive component are provided in the mixing chamber and internally of the injection valve. The recirculation passage internally of the injection valve is selectably opened and closed as is the outlet from the injection valve into the mixing chamber. Both the injection valve outlet and the recirculation passage internally of the injection valve are selectably throttleable.
    Type: Grant
    Filed: October 8, 1985
    Date of Patent: February 23, 1988
    Assignee: Admiral Equipment Company
    Inventors: Hubert Mayr, Shirley Leidal
  • Patent number: 4721391
    Abstract: An impingement mixing device for preparation of plastic parts or objects including cellular foam from at least two reactive synthetic components and an auxiliary component such as liquid foaming agent and including at least two injection ports and a third port for input of the auxiliary component. Inert gas optionally and a foaming agent and further additives are mixed at a point in the cylindrical wall of the component mixing chamber located in or near the vicinity of the radial plane passing through the component openings. The introduction of the inert gas, foaming agent, coloring agent, or further additives is controlled by a cleaning piston which also simultaneously cleans the mixed plastic material penetrated therein from the opening area of the inert gas feeder line. The cleaning piston is part of a control piston, which with its rear segment is located in a metering chamber for the inert gas and optionally also for the foaming agent and the additives.
    Type: Grant
    Filed: April 1, 1986
    Date of Patent: January 26, 1988
    Assignee: Krauss-Maffei A.G.
    Inventor: Adolf Bauer
  • Patent number: 4704239
    Abstract: A process is disclosed for the production of expanded particles of polymeric material wherein unexpanded particles of the material are contacted with a nitrogen-containing inorganic gas under a first pressure condition to impregnate the particles with the gas. The gas impregnated particles are heated to a temperature higher than the softening point of the material, and dispersed into a liquid medium. The resulting dispersion is subjected to a lower pressure to expand the particles. The expanded particles may be used as prefoamed particles for the molding of foamed articles.
    Type: Grant
    Filed: April 24, 1985
    Date of Patent: November 3, 1987
    Assignee: Japan Styrene Paper Corp.
    Inventors: Shohei Yoshimura, Toru Yamaguchi, Masato Kanbe, Hideki Kuwabara
  • Patent number: 4698191
    Abstract: A method of producing a polypropylene resin molded product from foamed polypropylene particles is disclosed, which comprises introducing a pressurizing gas into foamed polypropylene particles having closed cells so that the particles have an internal gas pressure of from 0.3 to 2.5 Kg/cm.sup.2 G, charging the particles in a mold cavity while compressing the particles with a pressurizing inorganic gas until the initial apparent volume of the particles is reduced to 50 to 99%, removing the gas from the mold cavity while keeping the foamed particles in a compressed state, and introducing steam in the cavity to cause adhesion of the compressed foamed particles. The method produces a molded product having satisfactory appearance and excellent adhesion among particles in a shortened molding cycle.
    Type: Grant
    Filed: January 29, 1986
    Date of Patent: October 6, 1987
    Assignee: Mitsubishi Yuka Badische Co., Ltd.
    Inventors: Hiroshi Endo, Masakazu Arai, Shigeo Nishikawa, Masanori Saito, Masahiro Tanaka, Kunikazu Nagasaki, Shigeki Mathuno
  • Patent number: 4698001
    Abstract: A machine for the manufacturing of moulded articles of plastic material, in particular of helmets for motor cyclists, includes at least two moulds and at least a counter-mould for the forming of the articles, the moulds and counter-mould(s) defining between themselves moulding cavities of different shapes. The moulds and the counter-moulds, excepting the first one, are each connected with a feeder of a different plastic material, and the moulds can be moved into alignment with the counter-moulds, for the moulding of respective superimposed layers of different plastic materials by sintering with steam.One mould is suitable to be positioned in correspondence of a zone of unloading of the article produced while at least another mould is in its forming position.
    Type: Grant
    Filed: June 14, 1985
    Date of Patent: October 6, 1987
    Assignee: Devi S.p.A.
    Inventor: Mario Vismara
  • Patent number: 4695416
    Abstract: A method of making an expanded plastics foam block section and uniting it with a prior made, or partly made, section comprising the steps of charging a mould space of which one end is defined by a surface of the prior section with expandable plastics beads, initiating the expansion and fusion of the beads to create a cohesive but largely unexpanded mass of beads, obtruding the prior section into the mould space to compress a zone of the cohesive mass adjacent to the said one end, increasing the temperature and pressure in the mould space to complete the expansion and fusion process and to compress the end zone of the prior section to bring its end substantially to its unobtruded position, lowering said pressure and temperature, and ejecting the newly made block section from the mould space.Apparatus for performing the method is also disclosed.
    Type: Grant
    Filed: October 1, 1985
    Date of Patent: September 22, 1987
    Inventors: Peter Treffner, Charles Treffner
  • Patent number: 4693856
    Abstract: Expandible synthetic resinous particles are molded by injecting heated air generally centrally into the mold cavity by means of a probe, withdrawing the probe and heating the surface of the mold. Low densities and rapid cycle times are obtained.
    Type: Grant
    Filed: April 22, 1985
    Date of Patent: September 15, 1987
    Assignee: The Dow Chemical Company
    Inventors: Louis C. Rubens, Willard E. Alexander, Carl A. Raeck
  • Patent number: 4689004
    Abstract: Apparatus for adhering thermally-softenable particles to one another to form a plastic body has a molding tool reciprocable in a chamber for double piston action on a heated gas in the chamber. The molding tool defines a mold with opposite, gas-permeable walls in the directions of the reciprocation for receiving the particles. The double piston action of the reciprocation of the molding tool then forces the heated gas through the mold and particles therein to thermally soften the particles for adhering into the body.
    Type: Grant
    Filed: March 14, 1986
    Date of Patent: August 25, 1987
    Assignee: Firma Carl Freudenberg
    Inventor: Hans-Achim Kunkel
  • Patent number: 4685872
    Abstract: An improved machine for the production of foamed plastic molded parts, including soft foam plastics, i.e. for processing particles without foaming capacity, and including the processing of greatly frothed plastic foam particles, i.e. particles with but little foaming capacity, is obtained in that a pressure equalization system is provided which creates virtually equal pressure conditions while the mold cavity is being filled, i.e. the same overpressure in the material supply line as in the mold cavity. This makes it possible to introduce the foam particles, already compressed in the material supply system, into the mold cavity in a continuous flow by means of an injector, with excess foam particles being blown back into a tank provided in the material supply system by the injector after the mold cavity is filled.
    Type: Grant
    Filed: June 17, 1986
    Date of Patent: August 11, 1987
    Inventor: Hans Erlenbach
  • Patent number: 4680003
    Abstract: Apparatus for producing moldings from flowable reactive components comprising(a) a mold assembly having two halves surrounding a mold cavity,(b) a mixing device for combining said reactive components mounted on said mold assembly, said mixing device having a mixing chamber,(c) a supply channel in said assembly for supplying said components from said mixing chamber to said mold cavity,(d) a throttle device located between said mixing chamber and said mold cavity, said throttle device capable of moving into and out of said supply channel in a direction transverse to the orientation of said supply channel, thereby forming a throttle zone in said supply channel,(e) a relaxation chamber located in said supply channel between said throttle device and said mold cavity, said apparatus further characterized in that the dividing plane which separates the mold assembly into halves extends through said supply channel, said throttle zone and said relaxation chamber.
    Type: Grant
    Filed: December 20, 1985
    Date of Patent: July 14, 1987
    Assignee: Bayer Aktiengesellschaft
    Inventors: Klaus Schulte, Heinrich Ersfeld
  • Patent number: 4671753
    Abstract: Rotational molding apparatus includes a chemical supplying portion, a chemical mixing portion, a mold portion, a mold supporting portion, a mixture delivery portion and a control portion. The chemical mixing portion includes a tubular member disposed in a substantially horizontal orientation with a plurality of spaced angled deflector sections. The mold portion includes a pair of spacially connected substantially parallel frame sections. The mold supporting portion includes spaced upstanding sections with rotating clamping members selectively engageable with opposite edges of the mold portion. The mixture delivery portion includes a translatable elongated hollow probe member that is selectively connected with the tubular member.
    Type: Grant
    Filed: August 19, 1985
    Date of Patent: June 9, 1987
    Inventor: LeRoy Payne
  • Patent number: 4637788
    Abstract: In the manufacture of a foamed confection such as foamed chocolate, a confection in liquid form is mixed with carbon dioxide under pressure and passed still under pressure to a depositor. The mixture is discharged from the depositor through annular outlet orifices which are opened and closed in turn by associated valves so that at any one time some of the orifices are discharging the mixture, and the number of orifices which are closed does not vary. Each annular orifice has a length which is not greater than its diameter. Each valve has an annular valve seat and a valve member movable into and out of engagement with the valve seat.
    Type: Grant
    Filed: October 5, 1983
    Date of Patent: January 20, 1987
    Assignee: Cadbury Limited
    Inventor: Brian T. Richards
  • Patent number: 4627946
    Abstract: A mold for use in heat expanding prefoamed polystyrene beads to form a part of a predetermined shape is disclosed. The mold comprises a cavity defined by separable mold wall portions. Each mold wall portion has on its exterior a chamber into which a heating medium is introduced to heat the mold walls and also into which cooling medium is introduced to cool the walls. A plurality of nozzles are provided in the mold walls and a corresponding plurality of tubes interconnect the nozzles to a manifold located in the corresponding chamber. A pressurized heating medium is introduced to the manifold whereby the heating medium is injected into the cavity to expand prefoamed polystyrene beads in the cavity. A device is provided on the manifold for the selective removal of condensate from the manifold. The mold construction provides for an economical, readily manufactured unit.
    Type: Grant
    Filed: November 1, 1984
    Date of Patent: December 9, 1986
    Assignee: Morval-Durofoam Ltd.
    Inventor: Larry V. Crabtree
  • Patent number: 4615849
    Abstract: A method of molding foaming plastics in consecutive process cycles. The method includes directing foaming plastics to molding means for molding and sintering. The molding means are appropriate to form different molded items. The molding means communicates via an installation means with a supplying means. The supplying means serves to supply under the control of a control means, steam for heating, cold water for cooling, vacuum for providing suction and compressed air as needed to the molding means. The molding means has at least one pressure sensor means and/or temperature sensor means. The pressure sensor means and/or the temperature sensor means are connected to the control means.
    Type: Grant
    Filed: November 28, 1983
    Date of Patent: October 7, 1986
    Assignee: Sodemape Holding AG
    Inventor: Ortwin Hahn
  • Patent number: 4579701
    Abstract: Low density expanded polystyrene is obtained by extended exposure of particles to atmospheric steam and aging the particles in air. Particles have wrinkled cell walls.
    Type: Grant
    Filed: September 24, 1984
    Date of Patent: April 1, 1986
    Assignee: The Dow Chemical Company
    Inventors: Chung P. Park, James T. Grimes
  • Patent number: 4557881
    Abstract: A machine for molding sheets of foamed material includes an upright stationary steam chest having opposing perforated external faces, and a pair of movable assemblies abuttable with the opposite faces of the steam chest to define mold cavities therewith. Each cavity forming assembly includes a mold frame extending normal to a face of the steam chest, and a platen positioned within and coupled to the mold frame. Jackscrews move each mold frame into and out of abutment with the steam chest, and also move each platen relative to its respective mold frame toward and away from the steam chest. A method of molding sheets of foamed material is also disclosed wherein heated polystyrene beads are squeezed by the movable platens to a predetermined thickness to provide a board having the desired dimensions and density.
    Type: Grant
    Filed: April 6, 1984
    Date of Patent: December 10, 1985
    Assignee: Design Engineering Service, Inc.
    Inventor: John Rabotski
  • Patent number: 4555225
    Abstract: A method and apparatus for making a twin-wall internally corrugated plastic structural part provided with a smooth, dense, solid, thin walled, non-cellular skin comprising injecting a thermoplastic or resin material into a pair of closed mold members which define a sealed cavity. A small amount of plastic material is initially injected into the cavity with the material impinging upon and being dispersed over the mold members thereby forming a generally continuous thin skin substantially the mold surfaces. Thereafter, successively and intermittently injecting an inert gas under pressure through one mold member during continued injection of the plastic material into the cavity thereby pressurizing the skin against the walls of the mold cavity and progressively commingling the inert gas under pressure and the inwardly flowing plastic material as both enter the cavity until the cavity is filled with an internal corrugated body integral with and bonded to the skin.
    Type: Grant
    Filed: September 26, 1984
    Date of Patent: November 26, 1985
    Assignee: Lang Fastener Corporation
    Inventor: James W. Hendry
  • Patent number: 4555087
    Abstract: A split mold for multi-component plastics, especially polyurethanes, with venting channels has heating devices in the zone of the said channels to prevent plastic from entering the channels and thus forming flash on the moldings.
    Type: Grant
    Filed: March 23, 1984
    Date of Patent: November 26, 1985
    Assignee: Elastogran Maschinenbau GmbH
    Inventors: Josef Wallner, Manfred Kelterbaum
  • Patent number: 4550003
    Abstract: This invention discloses a vinylidene chloride resin type in-mold foam molding having a broad cross-sectional area and a free shape, useful as thermal insulating plate materials or anti-shock molded vessels, and foam particles or expandable particles convenient for preparation thereof, and also a series of advantageous foaming techniques for completion of such a molding. The above foam molding can be prepared by bringing fine particles of a non-crystalline vinylidene chloride type resin obtained generally by suspension polymerization into contact with a volatile organic blowing agent thereby impregnating the resins with the blowing agent to form expandable resin particles, which are in turn subjected to expansion as such, or after forming into pre-expanded foam particles including expandable gas therein, by filling in a mold cavity which can be closed but not sealed, under heating to form a molding through fusion mutually between the expanded particles.
    Type: Grant
    Filed: December 5, 1984
    Date of Patent: October 29, 1985
    Assignee: Asahi Kasei Kogyo Kabushiki Kaisha
    Inventors: Norihiko Sakata, Nobuo Miura
  • Patent number: 4548776
    Abstract: An apparatus and method are disclosed which greatly facilitate molding of plastic material in the form of structural foam. The invention contemplates the provision of a valve-like mixing nozzle assembly which is selectively operable to control the flow of plastic material into an injection mold. Significantly, the nozzle assembly includes a mixing turbine rotatably mounted in the flow path of the plastic material. Notably, the turbine is driven by the plastic material itself as the material is driven into the mold assembly, and thus desirably provides intense mixing of the material during injection. This mixing action can be advantageously employed for effecting dispersion and/or expansion of the blowing agent carried by the plastic material for greatly enhanced control and flexibility in molding structural foam articles.
    Type: Grant
    Filed: November 23, 1983
    Date of Patent: October 22, 1985
    Assignee: Techplastics, Inc.
    Inventor: Ernest C. Holdredge, Jr.
  • Patent number: 4539167
    Abstract: This invention relates to a method of and apparatus for moulding from an expandable plastics material such as expandable polystyrene beads, an elongate article which has a length greater than the length of the mould. The method includes the steps of introducing the unexpanded plastic material into a mould, expanding the material in such a manner that the material at one end of the article is not fully expanded, moving the article along the mould partially through an opening in its end, introducing fresh material into the mould to be in contact with the partially expanded material at one end of the article and fully expanding and bonding the fresh and partially expanded material in the contact zone between the two.
    Type: Grant
    Filed: April 5, 1983
    Date of Patent: September 3, 1985
    Inventor: Wolfgang E. Schedel
  • Patent number: 4532263
    Abstract: A method for forming a molded polymer foam structure comprising expanding solvent imbibed polymer particles selected from the group consisting of a polyetherimide, a polycarbonate and a polyphenylene oxide-polystyrene blend and fusing the expanded particles together in a mold.
    Type: Grant
    Filed: December 12, 1983
    Date of Patent: July 30, 1985
    Assignee: Mobil Oil Corporation
    Inventors: Charles M. Krutchen, Wen-Pao Wu
  • Patent number: 4532094
    Abstract: A method for forming a molded thermoplastic foam structure comprising partially filling a mold with solvent imbibed particles of a thermoplastic resin, pressurizing said mold under conditions such as to prevent vaporization of said blowing agent during subsequent polymer melting, heating said polymer to a flowable state, releasing the mold pressure to permit foaming of the melt and expansion of the foamed polymer within the mold.
    Type: Grant
    Filed: December 12, 1983
    Date of Patent: July 30, 1985
    Assignee: Mobil Oil Corporation
    Inventors: Wen-Pao Wu, Charles M. Krutchen
  • Patent number: 4492663
    Abstract: A package forming apparatus which produces containers by means of molding thermoplastic material. A mold having a fixed cross-section but a variable length mold cavity is provided by a mold core having a bottom ring means outer shell unit in operative association with the mold core but which is movable axially of the mold core to vary the operative length of the mold and a removable top end plate is provided for the mold cavity.
    Type: Grant
    Filed: January 10, 1983
    Date of Patent: January 8, 1985
    Inventors: Nyles V. Reinfeld, Michael J. Valentine
  • Patent number: 4485520
    Abstract: Uniformly porous foamed erasers and process for the production thereof, the process comprising continuously mixing air or other gas into a flowable plasticized mixture and gelling the mixture by introducing the same continuously to a heating mean.
    Type: Grant
    Filed: November 3, 1980
    Date of Patent: December 4, 1984
    Assignee: Firma J. S. Staedtler
    Inventors: Werner Handl, Rupert Englbrecht
  • Patent number: 4482306
    Abstract: The disclosure relates to a process and device for the production of moldings from foamed thermoplastic plastic, e.g., polystyrol, in a mold, the mold wall enclosing a mold cavity, into which a filling injector discharges, and which is surrounded by an agent chamber and in which there runs an agent channel which is formed by drillings which are sealed at their ends against the outside and the agent chest by means of seals, and are connected to the mold cavity through nozzles. The drillings of the agent channel preferably run in ribs of the mold wall. The agent chest and the agent channel are connected through time-overlapping-controlled valves to an agent supply and removal system for the heating, cooling, inflation, curing, ejection of the mold walls and the molding respectively. A fast cycle sequence is achieved with a small consumption of energy and a high molding quality.
    Type: Grant
    Filed: December 3, 1982
    Date of Patent: November 13, 1984
    Assignee: FLEWU AG
    Inventor: Ortwin Hahn
  • Patent number: 4474717
    Abstract: A method and apparatus for making a twin-wall internally corrugated plastic structural part provided with a smooth, dense, solid, thin walled, non-cellular skin comprising injecting a thermoplastic or resin material into a pair of closed mold members which define a sealed cavity. A small amount of plastic material is initially injected into the cavity with the material impinging upon and being dispersed over the mold members thereby forming a generally continuous thin skin substantially the mold surfaces. Thereafter, successively and intermittently injecting an inert gas under pressure through one mold member during continued injection of the plastic material into the cavity thereby pressurizing the skin against the walls of the mold cavity and progressively commingling the inert gas under pressure and the inwardly flowing plastic material as both enter the cavity until the cavity is filled with an internal corrugated body integral with and bonded to the skin.
    Type: Grant
    Filed: May 24, 1982
    Date of Patent: October 2, 1984
    Assignee: Lang Fastener Corporation
    Inventor: James W. Hendry
  • Patent number: 4456573
    Abstract: A process for manufacturing expanded polystyrene panels includes the following stages:(a) Preparation of pre-expanded panels of polystyrene by extrusion and simultaneous injection of propellent agent into an extruder fitted with an extrusion die of suitable type and in particular fitted with means allowing for good mixing of the molten polymer with the propellent agent and means allowing for uniform cooling to the best value of the temperature of the expandable plastic mass before exit from the die.(b) Conditioning of said panels at room temperature or at whatever temperature higher than room temperature, provided it is such to prevent the panels from undergoing either dimensional variation or deformation due to internal stress or true expansion.
    Type: Grant
    Filed: July 2, 1982
    Date of Patent: June 26, 1984
    Assignee: Lavorazione Materie Plastiche L.M.P. S.p.A.
    Inventors: Franco Ragazzini, Roberto Colombo
  • Patent number: 4456443
    Abstract: A machine for molding sheets of foamed material includes an upright stationary steam chest having opposing perforated external faces, and a pair of movable assemblies abuttable with the opposite faces of the steam chest to define mold cavities therewith. Each cavity forming assembly includes a mold frame extending normal to a face of the steam chest, and a platen positioned within and coupled to the mold frame. Jackscrews move each mold frame into and out of abutment with the steam chest, and also move each platen relative to its respective mold frame toward and away from the steam chest. A method of molding sheets of foamed material is also disclosed wherein heated polystyrene beads are squeezed by the movable platens to a predetermined thickness to provide a board having the desired dimensions and density.
    Type: Grant
    Filed: November 26, 1982
    Date of Patent: June 26, 1984
    Assignee: Design Engineering Service Inc.
    Inventor: John Rabotski
  • Patent number: 4439122
    Abstract: The installation comprises a rectangular, parallelepipedal, leaktight steam chamber (1) provided with a gate (2) on one of the short sides, inside which a tubular fixed mold (4) of perforated steel plate is attached at a distance from the walls of the chamber, the shape of the mold corresponding to the external shape of the panel to be obtained. A first set of fixed, parallel, perforated metal tubes (5), inside the mold (4), possesses lateral holes (9) for the passage of a second set of perforated or non-perforated metal tubes (10) firmly fixed to a movable external support (11), passing through one of the short walls of the steam chamber (1) and capable of moving perpendicular to the tubes (5) of the first set, passing through the latter. The chamber (1) is provided with inlet valves (13) for the partially expanded synthetic material, an inlet (14) for steam and an inlet (15) for a cooling fluid.
    Type: Grant
    Filed: November 17, 1982
    Date of Patent: March 27, 1984
    Assignee: Fresse S.A.
    Inventors: Maurice Besse, Jacques Grisoni
  • Patent number: 4424177
    Abstract: An article having a relatively lower density polystyrene core and a relatively higher density polystyrene skin is prepared by a method in which a mold is supplied, simultaneously and/or sequentially with electrostatically charged prepuffs of a relatively higher density polystyrene and relatively uncharged low density prepuffs. The walls of the metal mold preferentially attract the electrostatically charged particles. The uncharged lower density prepuffs concentrate at the core. The thus filled mold is subjected to the heating and cooling cycle to provide a molded article having a core with a lower density than the skin.
    Type: Grant
    Filed: October 16, 1981
    Date of Patent: January 3, 1984
    Assignee: Atlantic Richfield Company
    Inventor: Richard H. Immel
  • Patent number: 4424180
    Abstract: According to the process, the shape of the mold cavity is at least partly modified at the point where it is desired to modify the physical characteristics of the molding during production. After the synthetic material is injected into the mold and hot expanded to fill the mold, the mold cavity is expanded at the point where the physical characteristics are to be modified and the molding is allowed to expand in a complementary manner in order that the material completely fills the expanded cavity. Then there is a compression of the molding and the molding is cooled to fix its shape.
    Type: Grant
    Filed: August 9, 1982
    Date of Patent: January 3, 1984
    Assignee: Saplest S.A.
    Inventors: Guy Lalloz, Gabriel Joly
  • Patent number: 4415513
    Abstract: A capstan for use on a tape transport, including a hub, a tubular outer rim supported co-axially about the hub, and a body portion of foam plastic between the hub and rim.
    Type: Grant
    Filed: January 15, 1981
    Date of Patent: November 15, 1983
    Assignee: Telex Computer Products, Inc.
    Inventor: Ivo T. Plachy
  • Patent number: 4412962
    Abstract: Improved mold structure and method of molding for mechanically frothed urethane foams is presented. The mold is filled from the bottom via an annular runner which communicates with the mold cavity. The connection between the annular runner and the mold cavity is restricted to create a back pressure in the circumferential runner.
    Type: Grant
    Filed: August 30, 1982
    Date of Patent: November 1, 1983
    Assignee: Rogers Corporation
    Inventors: Michael D. Bessette, Robert B. Jerard
  • Patent number: 4399105
    Abstract: Progammable computer controlled reaction injection mixing of selectively variable reactive fluid polymerizable components is disclosed, embodying an improved reactive injection mixing head construction which facilitates rapid changes in mix formulations between successive pour or molding operations in a continuing succession of such operations, while maintaining consistently uniform results in the finished products.
    Type: Grant
    Filed: March 30, 1981
    Date of Patent: August 16, 1983
    Assignee: The Upjohn Company
    Inventors: Peter Tilgner, Robert D. Wingard, Shirley M. Leida, Kenneth L. Erwin, Jr.
  • Patent number: 4390332
    Abstract: The apparatus molds during each cycle homogeneous plastic material and foam plastic material. It includes a barrel member, a main passageway therein in which is located the screw member. A pair of injecting means for filling molds are provided, one having a homogeneous plastic injection chamber and the other having a foam plastic injection chamber. The first injection means is connected to the screw and barrel member upstream of the place where the inert fluid is introduced into the main passageway whereby homogeneous plastic material is discharged from the main passageway into the first injection means. The apparatus includes means for introducing an inert fluid into the main passageway whereby the rotating screw member mixes the gas with the molten plastic as it moves towards the discharge port which is connected to the second injection means whereby foam plastic material is injected into the foam plastic injection chamber. Each injection means has one or more nozzles connected to a mold located in a press.
    Type: Grant
    Filed: July 6, 1981
    Date of Patent: June 28, 1983
    Assignee: KMMCO Structural Foam, Inc.
    Inventor: James W. Hendry