U.S. patent application number 10/816740 was filed with the patent office on 2005-10-06 for methods and molds for producing hot poured cosmetic materials.
Invention is credited to Booth, Alfred E..
Application Number | 20050218560 10/816740 |
Document ID | / |
Family ID | 35053400 |
Filed Date | 2005-10-06 |
United States Patent
Application |
20050218560 |
Kind Code |
A1 |
Booth, Alfred E. |
October 6, 2005 |
Methods and molds for producing hot poured cosmetic materials
Abstract
Generally, the present invention is a mold and a process for
preparing a ready-to-use hot pour material, such as a cosmetic
article and the like, in a mold. The process comprises the steps of
providing a mold for casting hot pour material, the mold having a
top part with a pour space and a base part, applying hot pour
material into the mold through the pour space and allowing the hot
pour material to cool, removing the top part of the mold, wherein
the hot pour material remains in the bottom part of the mold,
placing a first receptacle in contact with the hot pour material,
and introducing fluid pressure through the base part to release the
hot pour material in the first receptacle. The mold may be
customized by including projections, recesses, and combinations
thereof, to provide for a hot pour material that is embossed,
debossed, or both.
Inventors: |
Booth, Alfred E.; (San
Pedro, CA) |
Correspondence
Address: |
GARDERE WYNNE SEWELL LLP
INTELLECTUAL PROPERTY SECTION
3000 THANKSGIVING TOWER
1601 ELM ST
DALLAS
TX
75201-4761
US
|
Family ID: |
35053400 |
Appl. No.: |
10/816740 |
Filed: |
April 2, 2004 |
Current U.S.
Class: |
264/299 ;
264/335; 425/375 |
Current CPC
Class: |
B29L 2031/718 20130101;
B29C 33/301 20130101; A45D 40/16 20130101; B29C 33/46 20130101 |
Class at
Publication: |
264/299 ;
264/335; 425/375 |
International
Class: |
B29C 039/00 |
Claims
What is claimed:
1. A process for preparing a ready-to-use hot pour material
comprising the steps of: providing a mold for casting hot pour
material in a fluid state, the mold having a top part and a base
part and an interior cavity formed thereby with at least one
pressure fluid passage in the base part and at least one pour space
in the top part; applying hot pour material into the mold through
the pour space and allowing the hot pour material to cool in the
mold; removing the top part of the mold, wherein the top part is
removed upward relative to the base part and hot pour material
remains in contact with the base part of the mold; placing a first
receptacle in direct contact with the hot pour material; and
introducing fluid pressure through the base part of the mold to
release hot pour material contacted by a first receptacle, thereby
providing a ready-to-use hot pour material in a first
receptacle.
2. The process of claim 1, wherein the process is automated.
3. The process of claim 1, wherein the top part further comprises a
perimeter wall, a planar surface, and one or more customized mold
portions.
4. The process of claim 3, wherein one or more customized mold
portions is selected from the group consisting of at least one
projection, at least one recess, and combinations thereof.
5. The process of claim 1, wherein the base part further comprises
an outer rim, inner rim, base surface, bottom wall, and one or more
customized mold portions.
6 The process of claim 5, wherein one or more customized mold
portions is selected from the group consisting of at least one
projection, at least one recess, and combinations thereof.
7. The process of claim 1, wherein the first receptacle is selected
from the group consisting of a container, article, case, compact,
godet, and combinations thereof, which may be made of a material
selected from the group consisting of a hardened polymer, polymer
blend, glass, fibrous material, metal and combinations thereof.
8. The process of claim 1, wherein the pressure fluid is compressed
air.
9. The process of claim 1 further comprising the step of placing
the first receptacle in a second receptacle.
10. The process of claim 1, wherein the surface of the ready-to-use
hot pour material is selected from the group consisting of
substantially planar with the side edge of the first receptacle,
extending above the first receptacle side edge, or disposed below
the first receptacle side edge.
11. The process of claim 1, wherein the mold is in a shape selected
from the group consisting of a cylinder, triangle, sphere, polygon,
uniform design, nonuniform design, letter, word, and combinations
thereof.
12. A process for preparing a customized hot pour material
comprising the steps of: providing a mold for casting hot pour
material in the fluid state, the mold having a top part and a base
part and an interior cavity formed thereby, wherein the base part
has at least one pressure fluid passage and at least one customized
mold portion, and the top part has at least one pour space;
applying hot pour material into the mold through the pour space and
allowing the hot pour material to cool in the mold; removing the
top of the mold, wherein the top part is removed upward relative to
the base part and hot pour material remains in contact with the
base part of the mold; placing a first receptacle in direct contact
with the hot pour material; and introducing fluid pressure through
the base part of the mold to release hot pour material contacted by
a first receptacle, thereby providing a customized hot pour
material in a first receptacle.
13. The process of claim 12, wherein the process is automated.
14. The process of claim 12, wherein the top part further comprises
a perimeter wall, a planar surface, at least one pressure fluid
passage, and at least one customized mold portion.
15. The process of claim 14, wherein at least one customized
portion is selected from the group consisting of one or more
projections, one or more recesses, and combinations thereof.
16. The process of claim 12, wherein the base part further
comprises an outer rim, inner rim, base surface, and bottom
wall.
17. The process of claim 12, wherein at least one customized
portion is selected from the group consisting of one or more
projections, one or more recesses, and combinations thereof.
18. The process of claim 12, wherein the mold is in a shape
selected from the group consisting of a cylinder, triangle, sphere,
polygon, uniform design, nonuniform design, letter, word, and
combinations thereof.
19. The process of claim 12, wherein the first receptacle is
selected from the group consisting of a container, article, case,
compact, godet, and combinations thereof, which may be made of a
material selected from the group consisting of a hardened polymer,
polymer blend, glass, fibrous material, metal and combinations
thereof.
20. The process of claim 12 further comprising the step of placing
the first receptacle in a second receptacle.
21. The process of claim 20, wherein the surface of the customized
hot pour material is selected from the group consisting of
substantially planar with the side edge of the first receptacle,
extending above the first receptacle side edge, or disposed below
the first receptacle side edge.
22. A process for preparing a customized hot pour cosmetic article
comprising the steps of: providing a mold for casting hot pour
cosmetic article in the fluid state, the mold having a top part and
a base part and an interior cavity formed thereby, wherein the base
part comprises an outer rim, inner rim, base surface, bottom wall,
at least one pressure fluid passage and at least one customized
mold portion, and the top part comprises a perimeter wall, a planar
surface, and at least one customized mold portion; applying hot
pour cosmetic article into the mold through the pour space and
allowing the hot pour cosmetic article to cool in the mold;
removing the top of the mold, wherein the top part is removed
upward relative to the base part and hot pour cosmetic article
remains in contact with the base part of the mold; placing a first
receptacle in direct contact with the hot pour cosmetic article;
and introducing fluid pressure through the bottom wall of the mold
to release the hot pour cosmetic article contacted by the first
receptacle, thereby producing a customized hot pour cosmetic
article in a first receptacle.
23. The process of claim 22, wherein the process is automated.
24. The process of claim 22, wherein at least one customized mold
portion is selected from the group consisting of one or more
projections, one or more recesses, and combinations thereof.
25. The process of claim 22, wherein the first receptacle is
selected from the group consisting of a container, article, case,
compact, godet, and combinations thereof, which may be made of a
material selected from the group consisting of a hardened polymer,
polymer blend, glass, fibrous material, metal and combinations
thereof.
26. The process of claim 22, wherein fluid pressure is compressed
air applied evenly over the customized mold portions.
27. The process of claim 22, wherein the mold is in a shape
selected from the group consisting of a cylinder, triangle, sphere,
polygon, uniform design, nonuniform design, letter, word, and
combinations thereof.
28. The process of claim 22 further comprising the step of placing
the first receptacle in a second receptacle.
29. The process of claim 22, wherein the surface of the customized
hot pour cosmetic article is selected from the group consisting of
substantially planar with the side edge of the first receptacle,
extending above the first receptacle side edge, or disposed below
the first receptacle side edge..
30. A mold for preparing a customized hot pour cosmetic article,
the mold capable of receiving a hot pour cosmetic article and
comprising: a top part with a pour space providing for a
predominantly open space at the top; and a base part with at least
one pressure fluid passage and at least one customized mold
portion, wherein the customized mold portion is selected from the
group consisting of projection, recess, and combinations thereof,
and wherein the top part and base part are tightly engaged forming
an interior cavity therein capable of receiving a hot pour cosmetic
article.
31. The mold of claim 30, wherein the mold is in a shape selected
from the group consisting of a cylinder, triangle, sphere, polygon,
uniform design, nonuniform design, letter, word, and combinations
thereof.
32. The mold of claim 30, wherein the top part further comprises a
perimeter wall, a planar surface, at least one pressure fluid
passage, and at least one customized mold portion, wherein the
customized mold portion is selected from the group consisting of a
projection, recess, and combinations thereof.
33. The mold of claim 30, wherein the base part further comprises
an outer rim, inner rim, bottom wall, and base surface.
34. A mold for preparing a customized hot pour cosmetic article,
the mold capable of receiving a hot pour cosmetic article and
comprising: a top part with a pour space, a perimeter wall, a
planar surface; and a base part with an outer rim, inner rim, base
surface, bottom wall, at least one pressure fluid passage and at
least one customized mold portion wherein the customized mold
portion is selected from the group consisting of a projection,
recess, and combinations thereof, and wherein the top part and base
part are tightly engaged forming an interior cavity therein capable
of receiving a hot pour cosmetic article.
35. The mold of claim 36, wherein the mold is in a shape selected
from the group consisting of a cylinder, triangle, sphere, polygon,
uniform design, nonuniform design, letter, word, and combinations
thereof.
36. The mold of claim 36, wherein the top further comprises at
least one customized mold portion selected from the group
consisting of a projection, recess, and combinations thereof.
Description
BACKGROUND OF THE INVENTION
[0001] The present invention relates to improvements in hot pour
technology, particularly for cosmetic articles, that provides ready
to use customized materials and products and a method of hot
pouring such materials and products.
[0002] Prior art hot pour technology requires hot pour materials
and products (such as for cosmetics made available in compact form)
to be poured into a first receptacle and then transferred by
gravity of pressure pour into another receptacle, such as a
cosmetic receptacle. As such, the poured material or product for
use in a compact generally has a concave (recessed) viewing surface
without any distinctive or customized features, such as embossed or
debossed surfaces. In addition, such surfaces are often uneven and
inconsistent. Any customization of such materials or products, such
as the creation of designs on the viewing surface of the material
or product requires additional and complicated steps that rely on
computers, lasers, and other equipment. Such customization
techniques are not only complicated and costly (e.g., requiring
costly equipment), they often produce inconsistent results.
Clearly, then, there remains a need to provide a more economical
and efficient method of producing hot pour cosmetic materials and
products with consistent and even surfaces as well as providing hot
pour cosmetic materials and products that may be customized with
ease and efficiency and ready for use.
SUMMARY OF THE INVENTION
[0003] The present invention solves the current problem associated
with current costly and inefficient methods of producing and
customizing hot pour cosmetic materials and products. For example,
the present invention provides improved hot poured materials, such
as cosmetic articles and the like, and a method of providing the
same.
[0004] In one embodiment of the present invention, there is
provided a process for preparing a ready-to-use hot pour material,
such as a hot pour cosmetic article or the like, comprising the
steps of providing at least one mold for casting the hot pour
material in a fluid state, the mold having a top and a base with at
least one pressure fluid passage in the base and at least one pour
space in the top, applying hot pour material into a cavity or
interior chamber of the mold through the pour space and allowing
hot pour material to cool in the mold, removing the top of the
mold, wherein hot pour material remains in contact with the base of
the mold, placing a first receptacle in direct contact with the hot
pour material, and introducing pressure fluid through the base part
of the mold to release the hot pour material in contact with the
first receptacle from the base part of the mold, thereby producing
a read-to-use hot pour material. The introduction of pressure fluid
to release the hot pour material may take advantage of any of a
number of pressure fluid techniques known to one of ordinary skill
in the art. Preferably, the pressure is applied evenly through the
base part of the mold to provide for an even ejection force.
[0005] The process of the present invention includes the provision
of a two part mold with a top part and a base part. The top part
generally comprising all or some of the following, including a
perimeter wall, a planar surface, one or more pressure fluid
passages, and/or one or more customized mold portions that may be
raised as projections, sunken as recesses or combinations thereof
to provide for material or product that is embossed, debossed, or
both. The base part generally comprise all or some of the
following, including an outer rim, inner rim, base surface,
interior base chamber or cavity, bottom wall, one or more pressure
fluid passages and one or more customized mold portions that may be
raised as projections, sunken as recesses or combinations thereof
to provide for material or product that is embossed, debossed, or
both.
[0006] The process of the present invention may use, for example, a
first receptacle to house the article upon its removal from the
mold. The first receptacle may be any receptacle capable of
receiving a hot pour cosmetic article or the like. Here, the hot
pour cosmetic article is any material or product capable of being
formed in a hot pour process. The process may also include a
further step of placing the first receptacle in a second
receptacle. Importantly, the process provides for a ready-to-use
hot pour material or product, such as a cosmetic article or the
like, that may have a substantially planar surface which extends
above the side edge of the first receptacle, is coplanar with the
side edge of the first receptacle, or is disposed below the first
receptacle side edge. As such, the formed hot pour material or
product surface (e.g., cosmetic article) is either contiguous with
a cooperative surface of a first receptacle, above the surface of a
first receptacle or below the surface of a first receptacle.
Similarly, such material or product after being placed in a second
receptacle, may have a surface coplanar with a second receptacle,
above the top edge of a second receptacle or below the top edge of
a second receptacle. First and second receptacles include any case,
compact, godet, or other such container capable of holding a hot
pour material or product, such as a cosmetic article or the like.
First and second receptacles are made of any material capable of
holding a cooled hot pour product, such as plastic, a hardened
polymer or polymer blend, glass, fibrous material, and metal as
examples and may be transparent or opaque.
[0007] The present invention also provides a mold for preparing a
customized hot pour material or product, the mold being capable of
receiving a hot pour material such as a cosmetic article or the
like and comprising a top part with a pour space and a bottom or
base part with at least one pressure fluid passage and at least one
customized mold portion. The bottom or base part further comprises
some or all of the following, including an outer rim, inner rim,
bottom wall, base surface, and an interior base chamber. The mold
top (i.e., top part) may include similar customized mold portions
and/or pressure fluid passages, as well as a perimeter wall, a
planar surface, and one or more pour spaces as needed. In one
embodiment, the pour space is the large enough to encompass a
predominant portion of the top part.
[0008] The customized mold portion is selected from the group
consisting of one or more projections (e.g., raised portions), one
or more recesses (e.g., sunken portions), or combinations thereof
to provide for material or product that is embossed, debossed, or
both. The mold portion may be of any shape with recesses,
projections, or both to provide for an overall design (uniform or
nonuniform), letter(s), or word(s), as examples. Other shapes
include a cylinder, sphere, polygon, palette, as examples. The
shaped material, upon removal from the mold, is transferred to a
receptacle of a similar shape or one that is different than the hot
pour material, itself.
[0009] The present invention may be used with any number of hot
pour materials or products, in particular cosmetic articles for
lips, eyes, face, etc., that include lipsticks, lip glosses,
pomades and their packaging. In the cosmetic industry, examples of
receptacles include pans, godets, tubes, bottles, jars, flasks,
boxes, and compacts. In addition, the cosmetic article may be
placed in one or more sampling devices and may even be used for
product promotion or as handouts. Examples of promotional means or
handouts include magazine inserts, postcards, department store
catalogs, and customer mailings.
[0010] An advantage of the present invention includes its
availability and use with applied technology processes, such as
dispensing and dosing systems and devices. As such, it may be used
with automated or semi-automated systems and/or with
multiprocessing equipment (e.g., equipment for feeding, preheating,
filling, post heating, refrigerating, and collating). The present
invention enables such hot pour material or product to be produced
in a consistent and less costly fashion, and is readily
customizable as needed.
[0011] Those skilled in the art will further appreciate the
above-noted features and advantages of the invention together with
other important aspects thereof upon reading the detailed
description that follows in conjunction with the drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For more complete understanding of the features and
advantages of the present invention, reference is now made to the
detailed description of the invention along with the accompanying
figures, wherein:
[0013] FIG. 1 depicts a top plan view of the bottom or base part of
a mold of the present invention;
[0014] FIG. 2 depicts a bottom plan view of the top part of a mold
of the present invention;
[0015] FIG. 3 depicts a side elevation view of the top and base
parts of a mold of the present invention, wherein the top and base
parts of the mold are separated from each other;
[0016] FIG. 4 is a section view of the top and base parts of a mold
of the present invention, shown separated from each other;
[0017] FIG. 5 is a section view of the top and base parts of a mold
of the present invention, wherein the top and base parts are
connected to show the mold in its closed position and shown with
cutout views showing some of the interior features;
[0018] FIG. 6 is a section view of a mold of the present invention
showing the step of pouring a hot pour material or product through
the top part of the mold;
[0019] FIG. 7 is a section view showing the step of removing the
top part from the base part of a mold of the present invention;
[0020] FIG. 8 depict section views showing placement of a first
receptacle on the hot pour material or product while the material
is still in the mold base or bottom part;
[0021] FIG. 9 is a section showing the step of introducing a fluid
stream through the base part of a mold of the present
invention;
[0022] FIG. 10 is a section view showing the step of removing an
hot pour material or product from a base part of the mold of the
present invention;
[0023] FIG. 11 is a side elevation view of an hot pour material or
product in a first receptacle following its transfer from a mold of
the present invention, wherein the hot pour material extends above
the side edge of the first receptacle;
[0024] FIG. 12 is a side elevation view of an hot pour material or
product in a first receptacle following its transfer from a mold of
the present invention, wherein the hot pour material is disposed
below the side edge of the first receptacle; and
[0025] FIG. 13 is a side elevation view of an hot pour material or
product in a first receptacle following its transfer from a mold of
the present invention, wherein the hot pour material is
substantially planar with the side edge of the first
receptacle.
DETAILED DESCRIPTION OF THE INVENTION
[0026] Although making and using various embodiments of the present
invention are discussed in detail below, it should be appreciated
that the present invention provides many inventive concepts that
may be embodied in a wide variety of contexts. The specific aspects
and embodiments discussed herein are merely illustrative of ways to
make and use the invention, and do not limit the scope of the
invention.
[0027] In the description which follows like parts are marked
throughout the specification and drawing with the same reference
numerals, respectively. The drawing figures are not necessarily to
scale and certain features may be shown exaggerated in scale or in
a somewhat generalized or schematic form in the interest of clarity
and conciseness.
[0028] Now referring to FIGS. 1 and 4, an example of a mold 2 in
accordance with the invention is illustrated with respect to a base
part 4. Generally, the exemplary base part 4 is a shaped block
having a bottom wall 6, an upward facing continuous, planar outer
rim 8, an inner rim 10, at least one interior base chamber or
cavity 12 delimited by a base surface 14. (See FIG. 4) The outer
rim 8 is of a different, often lower, elevation than the inner rim
10. Likewise, the inner rim 10 is generally of a different
elevation than the base surface 14 and delimits the top of the base
part 4. The base surface 14 will generally include one or more
projections 16 (e.g., raised or debossed portions) as well as one
or more recesses 18 (e.g., sunken or embossed portions) with
respect to a baseline 20. (See FIG. 4) Baseline 20 may be coplanar
with outer rim 8. The base surface 14 may include only projections
16 or only recesses 18. The projections 16 and/or recesses 18 may
be of various configurations or combinations of configurations, and
generally provides for a material that is shaped, such as in a
uniform design, nonuniform design, letter(s), and/or word(s) with
viewing surfaces that are embossed, debossed or both. One or more
pressure fluid passages 22 are located at various positions in
bottom wall 6 and extend between bottom wall 6, opening into one or
more interior base chambers or cavities 12. Pressure fluid passages
22 open generally into the interior base chamber or cavity 12 at
projections 16 and recesses 18; however, the pressure fluid
passages may be disposed in other locations opening into interior
base chamber 12.
[0029] FIG. 1 shows a base part 4 that is square in shape.
Similarly, the figure shows a square-shaped outer rim 8,
square-shaped inner rim 10, and square-shaped base surface 14. Any
alternative shape may be used for the base part 4, outer rim 8,
inner rim 10, and base surface 14. In one embodiment of the base
part 4, the outer rim 8, inner rim 10, and base surface 14 are the
same shape. Alternatively, the outer rim 8, inner rim 10, and base
surface 14 may be of different shapes. Shapes include but are not
limited to a rectangle, triangle, sphere, polygon, and combinations
thereof. In addition, the shape may be a design that is uniform or
nonuniform, and may include letters and/or words.
[0030] Now referring to FIG. 2, there is illustrated an example of
a top part 30 of a mold of the present invention. Generally, the
top part 30 comprises a perimeter wall 32 delimited by a planar
surface 34, and at least one pour space 40. A recess 36, as shown
in FIG. 4, is formed in top part 30 between surface 34 and a
perimeter ledge or shoulder 38 and opens to the pour space 40.
Optionally, the top part 30 may also include pressure fluid
passages as needed (not shown). While FIG. 2 shows the top part 30,
perimeter wall 32, and surface 34 to be rectangular in shape, any
alternative shape may be used. Shapes include one or more of the
shapes described above (e.g., rectangle, triangle, sphere, polygon,
uniform design, nonuniform design, letter, word, and combinations
thereof). In the embodiment shown in FIG. 2, the perimeter wall 32,
planar surface 34, and pour space 40 are the same shape.
Alternatively, the perimeter wall 32, planar surface 34, and pour
space 40 may be of different shapes. The perimeter wall 32 of the
top part 30 is often the same shape as the outer rim 8 of the base
part 4; however, the perimeter wall 32 (of the top part 30) and the
outer rim 8 (of the base part 4) may be of different shapes.
Likewise, the planar surface 34 of the top part 30 are often the
same shape as the inner rim 10 of the base part 4, but may be of
different shapes.
[0031] When referring to the top part 30, as shown in FIG. 2, the
perimeter wall 32 and surface 34 may or may not be continuous. When
not continuous, they comprise separate parts that are in close
contact with one another. As shown in FIG. 2, the perimeter wall 32
and surface 34 are of different elevations. Generally, the
perimeter wall 32 of top part 30 fits the outer rim 8 of base part
4. Similarly, surface 34 of top part 30 fits inner rim 10 of the
base part 4. Surface 34 may, however, include a larger surface than
shown (e.g., wider). In such a case, pour space 40 of top part 30
will be dimensionally smaller. In addition, top part 30 may have
more than one pour space 40. Top part 30 may also comprise one or
more recesses, projections and/or pressure fluid passages. The
shape and design of such projections and/or recesses will determine
the number and location of pour spaces.
[0032] FIGS. 3 and 4 illustrate how top part 30 and base part 4 of
a mold engage each other. Arrows 70 in FIGS. 3 and 4 show how the
top part 30 is positioned in order to engage it to base part 4.
Cutout views of FIG. 4 show pour space 40 of top part 30 as well as
projection 16, recess 18, and pressure fluid passages 22 of base
part 4. Top part 30 also shows a shoulder or perimeter ledge 38
that contacts base part 4 of the mold of the present invention,
dimensions of which will vary depending on, for example, the shape
of the mold and on the number and extent of projections and/or
recesses. Consequently, pour space 40 may be narrower or wider than
shown, depending on the dimensions of shoulder or perimeter ledge
38.
[0033] Generally, the method of introducing a hot pour material or
product 50 (HPM 50), such as a cosmetic article or the like, to a
mold of the present invention comprises the steps of setting up a
mold 2 with top part 30 and base part 4 tightly engaged, adding HPM
50 to the mold 2 through one or more pour spaces 40 to a fill level
60, and allowing the HPM 50 to cool to a hot pour consistency using
cooling techniques known to one of ordinary skill in the art. (See
FIGS. 5 and 6). As shown in FIGS. 5 and 6, fill level 60 is
coplanar with perimeter wall 32 of top part 30. Other alternatives
may be equally advantageous depending on the desired end product.
Upon cooling of HPM 50, top part 30 of mold 2 is removed carefully,
generally by moving upward relative to base part 4 (as shown in
FIG. 7). A first receptacle 70 replaces top part 30 of mold 2 (as
shown in FIGS. 8A and 8B). HPM 50 in contact with first receptacle
70 is released from base part 4 by introducing pressure fluid, such
as compressed air, through one or more pressure fluid passages 22
(as shown in FIGS. 9 and 10) providing for HPM 50 in contact with
first receptacle 70, wherein HPM 50 displays one or more
projections 16 and/or one or more recesses 18 (as shown in FIG.
11).
[0034] As shown in FIGS. 5 and 6, the highest elevation for
baseline 20 of base part 4 is higher than projections 16 and
recesses 18 of mold 2. Other embodiments may provide for one or
more projections 16 and/or one or more recesses 18 of base part 4
to be higher than the highest elevation of the baseline 20. In
addition, peak portions of projection 16 may be near or coplanar
with fill level 60. Furthermore, fill level 60 may be coplanar with
the uppermost surface of top part 30, as shown in FIGS. 5 and 6. An
alternative embodiment includes a fill level that is not coplanar
with the uppermost surface of top part 30.
[0035] Removal of top part 30 of mold 2 from base part 4 after HPM
50 has cooled, as shown in FIG. 7, may be performed mechanically or
by hand. In some instances, pressure fluid, such as air, introduced
through pressure fluid passages 22 may used to remove the top part
30 from base part 4. The addition of a first receptacle 70 to the
cooled HPM 50, as shown in FIG. 8, may also be performed
mechanically or by hand. Similarly, the first receptacle 70 may be
introduced into a second receptacle 72. Mechanical techniques, as
used herein and throughout the specification are those known to one
of ordinary skill in the art and may be automated.
[0036] As shown in FIG. 11, the surface of formed HPM 50 is above
the surface of a first receptacle 70. Alternate embodiments include
a surface of formed HPM 50 that is either contiguous with a
cooperative surface of first receptacle 70, as shown in FIG. 12, or
below the surface of first receptacle 70, as shown in FIG. 13.
[0037] While specific alternatives to steps of the invention have
been described herein, additional alternatives not specifically
disclosed but known in the art are intended to fall within the
scope of the invention. Thus, it is understood that other
applications of the present invention will be apparent to those
skilled in the art upon reading the described embodiment and after
consideration of the appended claims and drawing.
* * * * *