U.S. patent number 3,700,368 [Application Number 04/814,868] was granted by the patent office on 1972-10-24 for continuous molding apparatus.
Invention is credited to Howard E. Wells.
United States Patent |
3,700,368 |
Wells |
October 24, 1972 |
CONTINUOUS MOLDING APPARATUS
Abstract
A continuous foamed strip molding method and apparatus uses two
continuous lengths of mold halves that snap-fit together to hold
the foamed strip and are flexible enough to be driven in a curved
path with one mole half inside the other for high speed and
adequate cure time in relatively small space.
Inventors: |
Wells; Howard E. (Rochester,
NY) |
Family
ID: |
25216208 |
Appl.
No.: |
04/814,868 |
Filed: |
January 22, 1969 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
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460404 |
Jun 1, 1965 |
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Current U.S.
Class: |
425/115; 425/363;
425/4C; 425/817C; 425/4R; 425/817R |
Current CPC
Class: |
B29C
44/302 (20130101) |
Current International
Class: |
B29C
44/30 (20060101); B29C 44/00 (20060101); B29c
003/02 (); B29g 007/02 () |
Field of
Search: |
;18/4B,4M,15M,15S,14M,5P,35,DIG.44,12TB |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
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426,203 |
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Mar 1935 |
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GB |
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574,977 |
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Apr 1959 |
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CA |
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Primary Examiner: Spicer, Jr.; Robert L.
Parent Case Text
RELATED U.S. APPLICATION
Continuation-in-part of Ser. No. 460,404 filed June 1, 1965, now
abandoned.
Claims
I claim:
1. In an apparatus for continuous molding of a foamed product, said
apparatus including first and second endless strip mold portions
relatively configured to snap-fit together in interlocking relation
to form an elongate mold cavity for said foamed product, and means
for advancing said mold portions respectively through a path having
an open portion where said mold portions are separated and a closed
portion where said mold portions are interlocked, the improvement
comprising:
a. said interlocked mold portions being capable of containing said
foamed product without external support;
b. said closed portion of said path including a curve of at least
substantially 180.degree.;
c. one of said mold portions being disposed radially inside the
other throughout said closed portion of said path; and
d. said closed portion of said path being longer than one half the
length of either said first or second mold portions.
2. The apparatus of claim 1 wherein said first and second mold
portions are each formed of flexible synthetic plastic material
flexible enough to be bendable in at least one plane.
3. The apparatus of claim 2 wherein said first and second mold
portions are formed of extrusions joined in continuous respective
lengths.
4. The apparatus of claim 1 wherein said closed portion of said
path comprises a helix.
5. The apparatus of claim 1 wherein heating means is arranged along
said closed portion of said path for curing said foamed
product.
6. The apparatus of claim 1 wherein said closed portion of said
path includes regions in which said interlocked mold portions are
unsupported by external means.
7. The apparatus of claim 1 wherein said first mold portion is
configured to define a long trough having side flanges extending
outward adjacent its edges, and said second mold portion is
configured to define a cover for said trough having side walls
adapted to engage said flanges.
8. The apparatus of claim 7 wherein said side walls are configured
in cross section to define inwardly directed hooks adapted for
engaging said flanges.
9. The apparatus of claim 8 wherein said side walls are tapered
from their hook portions to their free extremities.
10. The apparatus of claim 9 including means for spreading apart
said side walls to receive said flanges therebetween, and means for
pressing said mold portions together as said side walls are spread
apart for closing said mold portions in said interlocking relation
at the beginning of said closed portion of said path.
11. The apparatus of claim 1 including means located at said open
portion of said path for depositing foamable material in one of
said mold portions.
12. The apparatus of claim 11 including means for guiding a
continuous strand into said foamable material so that said strand
is embodied in said foamed product.
13. The apparatus of claim 1 wherein said closed portion of said
path includes a downwardly inclined reach approaching said
curve.
14. In an apparatus for continuous molding of a foamed product,
said apparatus including first and second endless strip mold
portions relatively configured to snap-fit together in interlocking
relation to form an elongate mold cavity for said foamed product,
and means for advancing said mold portions respectively through a
path having an open portion where said mold portions are separated
and a closed portion where said mold portions are interlocked, the
improvement comprising:
a. said first and second mold portions being formed of respective
extrusions of flexible, synthetic material joined in continuous
lengths;
b. said interlocked mold portions being capable of containing said
foamed product without external support;
c. said closed portion of said path including a curve of at least
substantially 180.degree.;
d. one of said mold portions being disposed radially inside the
other throughout said closed portion of said path;
e. said closed portion of said path being longer than one half the
length of either said first or second mold portions;
f. means located at said open portion of said path for depositing
foamable material on one of said mold portions; and
g. heating means arranged along said closed portion of said path
for curing said foamed product.
15. The apparatus of claim 14 wherein closed portion of said path
includes a helix.
16. The apparatus of claim 14 wherein said first mold portion is
configured to define a long trough having side flanges extending
outward adjacent its edges, and said second mold portion is
configured to define a cover for said trough having side walls
adapted to engage said flanges.
17. The apparatus of claim 16 wherein said side walls are
configured in cross section to define inwardly directed hooks
adapted for engaging said flanges.
18. The apparatus of claim 17 wherein said side walls are tapered
from their hook portions to their free extremities, and including
means for spreading apart said side walls to receive said flanges
therebetween, and means for pressing said mold portions together as
said side walls are spread apart for closing said mold portions in
said interlocking relation at the beginning of said closed portion
of said path.
19. The apparatus of claim 14 including means for guiding a
continuous strand into said foamable material so that said strand
is embodied in said foamed product.
20. The apparatus of claim 14 wherein said closed portion of said
path includes a downwardly inclined reach approaching said curve.
Description
This invention relates to improved molding of foamable materials
such as foamed plastics or synthetic resins and the like, and
especially to continuous molding of such materials at speeds higher
than any previously achieved by using a mold formed of continuous
strips of relatively long lengths which are driven through a curved
path for curing of the foamed product.
Continuous molding of foamed materials such as foamed polyurethane
has been accomplished by prior art devices using molds formed of
continuous strips, but the foaming and curing of the molded product
has been accomplished only along a linear path, and continuous
strip mold sections have required external support to contain and
support the foamed product during its formation and curing. Also,
foamed synthetic resins such as polyurethane presently require a
minimum curing time during which they are heated to a desired
temperature before they can be safely removed from the mold in
which they were foamed. The curing time-temperature requirement has
limited prior art devices to relatively slow molding speeds. Since
lengths of foam-molded material are useful in large quantities for
purposes such as weatherstripping in places such as around windows,
doors, and in automobile bodies, and for uses such as windlaces,
gaskets, seals, etc., it is important to be able to manufacture
various configurations of continuous strips of foamed material in
large quantities and at economical cost.
Accordingly, it is an object of this invention to mold foamed
materials continuously in strip form at high speeds to provide
economical molded products of high quality.
Another object of the invention is to mold foamed products
continuously at high speeds in a relatively simple and inexpensive
apparatus that is easily serviced and dependable and is reliable
and economical of materials and space.
Another object of the invention is to mold continuous lengths of
foamed strips in large quantities relatively quickly and
cheaply.
Another object of the invention is to make maximum use of materials
and space in molding continuous lengths of foamed plastic strips in
large quantities at high speeds.
Another object of the invention is to mold foamed plastic strips
continuously at high speeds in apparatus that is automatic and
easily operated and serviced.
Other objects of the invention will be apparent hereinafter from
the specification and from the recital of the appended claims. To
these and other ends, the invention resides in certain improvements
all as will be hereinafter more fully described, the novel features
being pointed out in the claims at the end of this
specification.
SUMMARY OF THE INVENTION
Generally, the invention comprises continuous molding of a length
of foamed product such as polyurethane strip by use of relatively
long continuous strip mold portions that are snap-fitted together
to contain the foamed product and that are driven in interlocking
relation through a path longer than one half the length of either
of the mold halves and including a curve of at least about
180.degree.. Such a path is preferably arranged by disposing one
mold half inside the other, and the path is preferably made
relatively long by including several turns or loops. By such an
arrangement, the mold can be filled and driven at a relatively high
rate of speed, and the closed path extends for a sufficient length
to provide the necessary curing time for the molded product.
The mold portions according to the invention are arranged to
interlock with sufficient tenacity to maintain the foamed product
within a closed cavity without requiring external support for the
mold portions. Also, the mold according to the invention is
preferably rigid enough when interlocked to bridge unsupported
reaches of travel and is preferably flexible enough to be bent
through a curve without stressing the foaming product so as to
impair its development. Mold portions having such desirable
characteristics are preferably extruded of synthetic plastic
materials and bonded to form the necessary continuous lengths.
THE DRAWINGS
FIG. 1 shows a side elevation of continuous molding apparatus
according to the invention;
FIG. 2 shows a plan view of the apparatus of FIG. 1;
FIG. 3 shows a partial end elevation of the left end of the
apparatus of FIG. 1;
FIG. 4 shows a cross-section of mold portions according to the
invention;
FIG. 5 shows the mold portions of FIG. 4 in the process of being
closed together;
FIG. 6 shows a partial side elevation of the apparatus of FIG. 1 on
an enlarged scale;
FIG. 7 shows an enlarged view partially in section of the mold
filling station of the apparatus according to the invention;
FIG. 8 is a partial plan view showing a mold closing device
according to the invention;
FIG. 9 shows a side elevation of a curing oven according to the
invention with its side removed;
FIG. 10 shows a partial end elevation of mold guide rolls located
in the oven of FIG. 9;
FIG. 11 shows a partial end elevation of mold drive rolls located
in the oven of FIG. 9;
FIG. 12 shows a partial cross-sectional view of mold filling
apparatus according to the invention taken along the line 12-12 of
FIG. 7;
FIG. 13 shows a partial cross-sectional view of mold closing
apparatus according to the invention taken along the line 13--13 of
FIG. 8;
FIG. 14 shows a partial cross-sectional view of mold driving and
guiding apparatus within an oven according to the invention taken
along the line 14--14 of FIG. 6;
FIG. 15 shows a partial cross-sectional view of the mold guiding
and driving apparatus of FIG. 14 taken along the line 15--15;
FIG. 16 shows a side elevation of a curing oven according to the
invention;
FIG. 17 shows a partial side elevation of mold opening and cleaning
apparatus and molded product processing apparatus according to the
invention;
FIG. 18 shows a cut-away end elevation of the oven of FIGS. 9 and
16; its
FIG. 19 shows a partial cross-sectional view of a flashing trimmer
according to the invention and taken along the line 19--19 of FIG.
17;
FIG. 20 shows a partial cross-sectional view of squeeze rolls
according to the invention and taken along the line 20--20 of FIG.
17; and
FIGS. 21-25 are schematic side elevational views of various mold
paths, curves and oven arrangements within the spirit of the
invention.
DETAILED DESCRIPTION
The inventive apparatus is suited for continuous molding of a
variety of materials in endless strip forms of many cross-sectional
configurations. Such strips have many applications in
weatherstripping, beading, trimming, gaskets, seals, and the like,
and are demanded in quantity. Molding according to the invention
can be applied to a variety of foamable materials including, but
not limited to, synthetic resins such as polyurethane. In forming
foamed products of such materials, a foamable mixture is deposited
in a mold and expands to fill the mold by forming gaseous bubbles
in the foamed material. To be self-sustaining and useful for
practical applications, such foamed material is set or cured by
heating such as at temperatures of from 170.degree. to 180.degree.
F. for 10 to 15 minutes. Of course, the invention is not limited to
any particular foamable material or curing time or temperature.
Throughout the drawings, corresponding parts are indicated by the
same reference numeral. The apparatus illustrated in FIGS. 1-20
shows one preferred embodiment of the invention as applied to the
molding of half-round polyurethane foam strips in continuous
lengths. However, it is to be understood that the particular
apparatus illustrated is only one of a great number of embodiments
of the invention and that apparatus and method may take many other
forms and steps, and products other than a half-round strip can be
manufactured within the spirit of the invention.
THE MOLD
The inventive apparatus and method require a continuous mold, and a
preferred embodiment of the mold itself, as best shown in FIGS. 4
and 5, will be described before the apparatus and method are taken
up.
The illustrated mold 25 is formed of two sections or portions 26
and 27, one of which, such as mold portion 27, is preferably formed
as a trough for continuously receiving a bead of foamable material.
It is preferred that mold portions 26 and 27 be configured to snap
fit together in an interlocking relation, and to this end, mold
portion 27 is provided with side flanges 28 extending outward
adjacent its edges, and mold portion 26, a section 32 of which
forms a cover for the trough of mold portion 27, is provided with
side walls 29 extending downward over flanges 28. Side walls 29 are
preferably provided with hook portions 30 extending inward under
flanges 28 when the mold portions are interlocked together. Raised
ribs or ridges 31 on mold portion 26 strengthen the juncture of
side walls 29 with cover portion 32 and provide bearing surfaces
for various drive and guide means in the inventive apparatus.
From the lower extremities 33 of side walls 29, a preferably
tapered surface 34 leads to hook portion 30 to provide a surface by
which the side walls 29 of mold portion 26 can be spread apart for
opening or closing the mold 25. The spreading apart of side walls
29 and hook portions 30 is best shown in FIG. 5 where a central
portion 35 of wheel 36 supports the trough portion of mold portion
27, while the rim portions 37 of wheel 36 force apart the side
walls 29 of mold portion 26 as it is pressed downward by roller 38.
Mold portions 26 and 27 can be separated merely by being forced
apart by rollers at an appropriate point in their travel, and it is
possible within the spirit of the invention to snap fit these mold
portions together without the aid of spreading wheel 36. Also,
other interlocking configurations are possible within the spirit of
the invention.
It is preferred that mold portions 26 and 27 be extruded of a
synthetic plastic resin such as polyolefins including polyethylene,
polypropylene, or mixtures of these or other materials. A
satisfactory mold material is essentially an alloy of propylene and
ethylene and is preferably formed as a smooth-surfaced extrudate.
The preferred material for a mold according to the invention has a
waxy, unctuous surface for ready release of the molded product and
is preferably not only rigid enough for a secure interlock between
the mold portions to retain the foaming material within the mold
cavity but also flexible enough to be driven through the required
curved path. Extruded mold portions 26 and 27 have their ends
welded or bonded together to form continuous lengths according to
the invention.
MOLD-HANDLING METHOD AND APPARATUS
Turning now to mold handling according to the invention, the
illustrated embodiment of the apparatus according to the invention
is shown in its entirety in FIGS. 1 and 2, and the other views show
various details of this apparatus.
Referring to FIGS. 1 and 2, the bead of foamable material is
deposited in the mold at a filling station 40. The mold portions
are closed together and interlocked at a mold closing station 41,
the interlocked mold portions are then driven through a first oven
42 into a main oven 43 where they move through a helical path, and
then into a third oven 44. After emerging from oven 44, the mold
portions are separated at a separating station 45, and the cured
product is removed from the mold. Of course, the arrangement of
ovens and paths can be varied within the spirit of the
invention.
The downward incline or slope of the mold in passing through oven
42 is preferred to assist in allowing gas to escape freely from the
foaming product contained within the mold. The linear traverse of
the mold through oven 42 allows the material to foam to fill the
mold cavity and gives the material a preliminary curing or gel so
that it can bend through the helix in oven 43 without any detriment
to the foamed product. Generally, a foam such as polyurethane must
be handled gently and not stressed or disturbed during curing to
produce the best quality finished product. In this connection, the
helical path through oven 43, as more fully described below, is
preferred in that the mold and the curing product contained within
its cavity are bent about a constant radius during a considerable
length of travel for undisturbed curing.
In considering the details of the illustrated embodiment of
apparatus according to the invention, the sequence of the inventive
method will be followed from the point of filling the mold to the
point of removal of the cured product.
Filling station 40 is located at the open portion of the mold path
where mold portions 26 and 27 are separated, and station 40 is near
the left end of the apparatus illustrated in FIGS. 1 and 2. FIG. 3
shows an end elevation of this end of the apparatus with bottom or
trough mold portion 27 guided over tensioning arc 46 which is urged
outward by weight 47 acting on cable 48 to tighten or remove slack
from mold portion 27. A similar tension arc 49, best shown in FIG.
6, is biased by weight 50 pulling on cable 51 to tension upper mold
portion 26.
As shown in FIG. 6, tanks 52-55 are provided for various compounds,
solvents, or ingredients for providing a foamable mixture to be
molded according to the invention. Of course, such tanks will
contain various materials depending upon the foamed product, and
for the illustrated embodiment of the invention, contain the
materials necessary for a foamable polyurethane. Pumps 56 and 57
force ingredients through lines 58 and 59 to mixing head 60 where
the materials are accurately mixed and metered for delivery to
trough mold portion 27. Also, for many applications of strips
molded according to the invention, it is desirable to embed a
strengthening cord, a wire, or mesh wire in the foamed product, and
to this end, a winding of cord 62 is positioned so that the cord is
fed to the filling station for inclusion within the molded
product.
The depositing of foamable mixture in mold portion 27 is best shown
in FIGS. 7 and 12. Mold portion 27 is moved through the illustrated
filling station with uniform speed, and mixing head 60 is arranged
for accurately metering a bead 63 of material to be delivered to
the trough of mold portion 27. Cord 62 is guided through tube 64,
under roller 65, and under guide wheel 66 for accurate positioning,
guide wheel 66 has a peripheral slot 67 for steering cord 62 and is
preferably adjustable both vertically and horizontally by means of
threaded rod 68 and adjustment bracket 69. Support rollers 70 which
are preferably shaped to conform to the outside of mold portion 27
carry mold portion 27 continuously past mixing head 60 for
receiving bead 63 of mixture and cord 62. Driving means for
advancing the mold are preferably located beyond filling station 40
as will be described below. The bead 63 of foamable material begins
to foam and expand as soon as deposited in mold portion 27, so that
its volume increases as it moves toward mold closing station
41.
As best shown in FIG. 6, upper mold portion 26 is guided to a
position immediately above lower mold portion 27 as the mold
portions approach mold closing station 41. In such a relationship,
mold portions 26 and 27 are disposed for snap-fitting together in
an interlocked relation.
It is preferred according to the invention that the foamable
material be expanded to a volume sufficient for filling the closed
mold at the point at which the mold portions are interlocked
together. This allows the escape of gasses formed during the
foaming process and yet accomplishes mold closure before the volume
of the foamed material exceeds that of the mold cavity, so that the
mold portions are readily snap-fitted together. Thus, for various
molding operations and speeds, it is desirable that the mold
closure station 41 be adjustable longitudinally of the mold path,
and it is possible within the spirit of the invention that mold
closure take place within oven 42 on the downwardly inclined reach
leading to the helical path in the main oven 43 (FIG. 1). Until the
location for optimum mold closure is reached, mold portions 26 and
27 are held apart and guided by guides 71.
The details of mold closure are best shown in FIGS. 5, 8 and 13.
FIG. 8 shows the longitudinally movable closure carriage 72 on
which is mounted a mold closure device according to the invention.
Carriage 72 is moved longitudinally by means of crank wheel 73 and
driven screw 74 while supported by guide rods 75. Such longitudinal
adjustment allows positioning of the mold closure device at
precisely the desired point at which the volume of the foaming
material equals that of the mold cavity.
Mold portions 26 and 27 can be snap-fitted together by forcing them
into engagement with each other, but it is preferred to spread the
side walls of mold portion 26 as the mold portions are pressed
together for smoother snap-fitting. To this end, generally
vertically disposed guide rolls 76 align mold portion 26 with
spreading wheel 36 which operates as described above and as shown
in FIGS. 5, and 13. Simultaneously with the spreading of its side
walls, mold portion 26 is pressed downward by vertically adjustable
roller 38 into engagement with lower mold portion 27 which is
supported by the concave periphery of roller 36 so that as the mold
portions leave rollers 38 and 36, they are in interlocking
engagement with each other. Of course, other mold closure devices
can be used within the spirit of the invention, it merely being
preferred that the mold portions be forced into a snap-fitted,
interlocking relation.
After being snap-fitted into a closed position, the mold containing
the foaming mixture is guided into downwardly inclined oven 42 as
shown in FIGS. 1 and 6. It is preferred that the path of the mold
through oven 42 be downwardly inclined to facilitate the escape of
gas from the foaming product, but the invention can be practiced
without using such an incline.
As best shown in FIGS. 6, 14, and 15, mold 25 and its contents are
driven and guided through oven 42. Guide wheel 77 controls the
entry of mold 25 into oven 42, and chains 78 powered by drive motor
83 through gearing 94 are arranged along the outside of oven 42 for
driving the mold at various contact points throughout oven 42. A
plurality of driven rollers 79 and associated pressure rollers 80
grip mold 25 at spaced locations along oven 42 and guide and drive
it forward. Pulleys 81 spaced along the outside of oven 42 indicate
the points at which driven rollers 79 are located within oven 42
for advancing mold 25. From this and from FIG. 15, it is clear that
mold 25 is self-supporting from one drive roller 79 to the next,
and that mold 25 is sufficiently rigid to span the reach between
rollers 79. Since the foaming material places some separating
pressure on the two portions of mold 25, sufficient interlocking
strength to retain the foamed material is desirable for the linear
run through oven 42.
Preferably, a central forced air heating system 82 (FIGS. 2 and 18)
is arranged for circulating heated air not only to oven 43, but to
ovens 42 and 44 as well. As best shown in FIG. 16, heat from oven
43 can be forced into oven 42 through their open connection with
each other.
After passing through oven 42, mold 25 enters oven 43 best
illustrated in FIGS. 9, 16, and 18. By this time, the foaming
material in mold 25 has preferably completed its expansion and has
achieved a sufficient gel or set so that it can be bent into a
curved path. The foamed product at this point requires several more
minutes of curing at a temperature of about 180.degree. F. before
it is ready to be removed from mold 25. As mentioned above, heating
unit 82 is preferably arranged for forcing heated air in thorough
circulation throughout oven 43 to accomplish curing of the foamed
product.
Because of the flexibility of mold 25, it can be bent through a
closed curve and is preferably driven within oven 43 in a helix
each turn of which is of uniform radius. This allows mold 25 to be
bent upon its entry into oven 43 into a radius of curvature
constantly maintained throughout its travel through the helix in
oven 43. The result is that one gentle bend is applied to mold 25
and its foamed contents for minimum stress and agitation of the
contents, and such bend is maintained undisturbed for several
minutes of travel through oven 43.
Mold 25 is preferably driven through the helix in oven 43 by a
drive motor 83 powering chains 84 which drive rollers 85 extending
through oven 43. As shown in FIG. 16, six driven rollers are
arranged within oven 43, but of course, any suitable number of
drive rollers can be used. As shown in FIGS. 9 and 11, each roller
85 is provided with an associated pressure or counter roller 86
that is preferably spring loaded to urge mold 25 against drive
rollers 85.
In adjusting the lateral spacing of each convolution of the mold in
its helical path in oven 43, mold 25 is first guided into an
initial position by generally vertically disposed guide roller 87
shown in FIG. 9. From guide 87, mold 25 is bent into its radius of
curvature between the lowermost set of idler support rolls 85a and
86a and driven guide rolls 89 and 90 where the mold enters the
first of a plurality of channels 91 in guide roll 89 as best shown
in FIG. 10. Pressure roll 90 urges mold 25 against guide roll 89
and keeps mold 25 within the desired slot or channel in guide roll
89. It is preferred that other sets of channeled guide rolls 89 and
associated pressure rollers 90 be provided about the helix in oven
43, and such other sets are shown at 120.degree. angles from each
other. Of course, additional or fewer guide rolls can be used, and
guide rolls can be idled as well as driven. Also, it is possible
within the spirit of the invention for each turn of the mold 25 in
the helix in oven 43 to bear against each successive turn without
the spacing provided by guide rolls 89. However, heating is
enhanced by the resulting spacing, and deviation from the desired
path is prevented by selective use of guide rolls 89. Turns of the
mold 25 in the helix of oven 43 are best shown in the partially
cut-away view of FIG. 18.
It has been found that extrudate mold portions according to the
invention stretch or elongate in use, and it is desirable to take
up the resulting slack in mold 25. A preferred location for such
take-up is in oven 43, and take-up rolls 92 are provided inside the
helix for urging mold 25 outward toward a slightly larger radius.
Extremely strong bias springs or preferably pneumatic bias means
are preferred for forcing the many turns of the helix outward. Such
bias means 93 for take-up rolls 92 are shown in FIG. 16.
As mold 25 traverses the many turns of the helix in oven 43, it
moves from left to right as illustrated in FIG. 18 and leaves oven
43 at the left side as best shown in FIG. 2 and enters oven 44.
Oven 44 is similar to previously described oven 42 in providing
drive means for advancing mold 25 and in being in communication
with central heating source 82 for continuing the heat curing of
the foamed product in mold 25. The drive means within oven 44 is
preferably powered by drive means 83 previously described for
driving the mold through the helix in oven 43.
After leaving oven 44, mold 25 enters separating station 45 best
shown in FIGS. 6, 17, 19, and 20. As best shown in FIG. 17, trough
mold portion 27 and cover mold portion 26 are separated by being
forced apart by separating rollers 95 and 96. From this point
onward, mold portions 26 and 27 are guided through the foaming and
curing cycle. To this end, guides 97 (FIG. 6) direct each
respective mold portion toward tensioning arcs 46 and 49 where
their paths are separated.
After opening the mold and removing the cured product 100 therefrom
as illustrated in FIG. 17, it is preferred that the mold portions
be cleaned before running through another cycle. For this purpose,
jets 101 and 102 direct air from air line 120 against mold portions
27 and 26 respectively to remove any flashing or scrap material
remaining in the mold. It is also preferred that jets 103 and 104
direct a cleaning fluid from line 105 into the cavities of the
separated mold portions. It is preferred that such cleaning fluid
spray be directed into the corners of mold cover portion 26 to
remove any flashing bits therein, and one preferred cleaning fluid
is an extremely fine spray of a silicone release fluid which not
only cleans the mold, but coats it with a silicone and wax residue
which makes mold opening and release of the molded product easier
on the next molding cycle. Of course, a variety of mold cleaning
and coating operations can be accomplished as desired at the mold
opening station 45, and the invention is not limited to any
particular cleaning fluid or method or coating operation.
In addition to the previously described tension arcs 46 and 49 for
tensioning and taking up slack in mold portions 26 and 27, it is
possible to introduce other or additional such slack take-up
devices conveniently between mold opening station 45 and filling
station 40. Take-up devices biased by weights can conveniently be
arranged immediately beyond mold opening station 45.
As best shown in FIG. 17, cured product 100 is led around pulley
106 for removal from mold portion 27 and is then guided under
tension pulley 107 which is preferably biased downward to place
product 100 under predetermined tension.
Subsequent to its removal from the mold, cured product 100 is
preferably trimmed to remove flashing and squeezed to destroy any
shrinkable intact gas bubbles remaining within it. These operations
can be done in any desired order, and in the illustrated
embodiment, the product is first squeezed, and then trimmed.
Squeezing of the cured product is preferred because occasionally
intact bubbles or relatively hot gas remain in the cured product,
and as such gas bubbles cool, they can produce shrunken spots in
the final product which detract from its appearance and value.
Squeezing can rupture any such bubbles, prevent any such shrinking,
and result in a more attractive and functional product.
In the illustrated embodiment, a pair or flanged squeeze rolls 108
and associated pressure rolls 109 are arranged in series for
successively squeezing the cured product 100. It is preferred that
squeezers and trimmers be driven by a single drive unit 110
transmitting power through chain 111 so that the squeezers and
trimmers are all driven at a uniform speed.
As best shown in FIG. 20, pressure roll 109 is preferably
vertically adjustable for a predetermined tension against flanged
squeeze roll 108 to give the desired squeezing or crushing
treatment to the foamed strip. Such adjustment is preferably
accomplished by adjustment bolts 112.
Trimming is preferably accomplished by a continuous trimming shear
preferably having a boundary wheel 113 and a pair or shearing
wheels 114 best illustrated in FIG. 19. Shearing wheels 114 are
preferably biased apart from each other by springs 115 for urging
the shearing wheels 114 against the inside edges of boundary wheel
113 with predetermined force. As wheel 113 rolls with wheels 114,
the edges of the channel 116 in wheel 113 sever the flashing off
product 100 and leave its edges trimmed to a predetermined uniform
dimension. After trimming, the finished product 100 is preferably
allowed to drop downward into a box 117 or other container, but of
course, product 100 could be wound or spooled after trimming as
desired.
It can be seen that according to the invention a relatively long
length of mold filled with curing product can be driven through
ovens 42-44 so that molding can proceed at a relatively high speed
and the desired curing time can still be obtained. Thus, with 48
turns of mold in a helix of 4 foot radius, in addition to the mold
running through ovens 42 and 44, it has been possible to operate
the illustrated apparatus at molding speeds of 100 feet per minute
with curing times of 12 minutes for the foamed product. Although
such speeds at present require over 1,000 feet of mold, they exceed
by far any speed obtained with prior art apparatus. Furthermore,
with product improvement, and different or improved curing, it may
be possible to reduce the total length of mold required or speed up
the molding rate with the inventive apparatus. Although a
relatively long length of mold is required, according to the
invention, such a mold length is not unreasonably burdensome or
difficult to handle because of the self-supporting and interlocking
and flexing characteristics of the mold, none of which were
available with prior art structures known to the applicant.
The apparatus of FIGS. 1 - 20 uses one of several preferred mold
paths providing a curve in the closed portion of the path. Other
preferred mold paths and oven arrangements are illustrated
schematically in FIGS. 21-25. Variations on these arrangements are
also possible.
Outer mold part 125 follows an oblong continuous loop around inner
mold part 126 as shown in FIG. 21. An oven 127 is arranged to heat
the closed portion of the path of mold parts 125 and 126. The
initial reach of the closed portion of the mold path is downwardly
inclined into oven 127 to allow the gaseous escape from the foam
product as described above. The curves at the ends of the path for
mold parts 125 and 126 are of approximately equal diameter and
extend through substantially 180.degree..
The curve-within-a-curve arrangement shown in FIG. 21 is preferred
to make the closed portion of the mold path a maximum length
relative to the total mold length. This conserves on the required
mold, space and heating equipment.
The mold path illustrated in FIG. 22 is similar, but the curvature
radii differ at opposite ends of the closed loops. Outer mold part
128 forms a continuous oblong loop around inner mold part 129, and
oven 130 is generally horseshoe shaped to enclose the closed
portion of the mold travel. Ovens or heating means along the closed
portion of the mold portion can be unitary, multiple, or arranged
in a variety of ways to cure the foamed product.
In FIG. 23, outer mold part 131 follows an approximately
rectangular path around inner mold part 132. Such an arrangement
requires relatively small radius turns separated by linear lengths
of travel. Instead of approximately 180.degree. turns at the ends
of the oblong as illustrated in FIG. 1, such ends include two
90.degree. turns. Variations on the curvatures in the mold path
according to the invention can range through any curves between
FIGS. 21 and 23, and the pairs of 90.degree. turns at the ends of
the path in FIG. 23 are equivalent to the 180.degree. turns at the
ends of the path of FIG. 21. Oven 133 of FIG. 23 is formed in an
approximate U shape to heat the closed portion of the mold path.
Oven 33 can readily be divided into three linear ovens if
desired.
FIG. 24 shows a multi-loop version of the mold path of FIG. 21.
Outer mold part 135 forms a continuous loop around inner mold part
136, and at least one doubling back of such loop is provided. Oven
137 is arranged in an open-centered rectangle to surround the
closed portion of the mold path. The general path illustrated in
FIG. 24 can save space and increase efficiency over the helical
path version illustrated in FIGS. 1-20. The oblong oval loop of the
closed portion of the mold path can be repeated for any desired
number of turns, and a greater length of mold can be run through
such an oblong path for the overall height and width of the machine
than can be accommodated in the circular helical path previously
described.
FIG. 25 shows a multi-loop closed portion of mold path similar to
the single loop path of FIG. 22. Outer mold part 138 forms a closed
loop around inner mold part 139, and a generally cylindrical oven
140 encloses the closed portion of the mold path. Complete loops of
interlocked travel of the mold can be repeated for as many loops as
desired. The relatively large radius of the closed loop portion of
the mold travel allows gentle bending of the mold while the foamed
product is contained within the mold cavity. The relatively smaller
radii of the curves at the open portion of the path is possible
since the foamed product is not contained within the mold cavity at
that point.
Persons wishing to practice the invention should remember that
other embodiments and variations can be adapted to particular
circumstances. Even though one point of view is necessarily chosen
in describing and claiming the invention, this should not inhibit
broader or related applications within the spirit of the invention.
For example, many different heating arrangements and many mold
paths, mold driving equipment, guides, rollers, tensioning devices,
mold separating and closing equipment, mold and product cross
sections, and mold cleaning gear can be used within the spirit of
the invention.
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