Method for molding a laminated molded article using a vented mold

• US 5,281,383 A
• Filed: 10/21/1991
• Issued: 01/25/1994
• Est. Priority Date: 03/13/1991
• Status: Expired due to Fees

• Current Assignee: Kasai Kogyo Company Limited
• Original Assignee: Kasai Kogyo Company Limited
• Inventors: Sakai, Tetsuo, Ueki, Katsuji
• Primary Examiner(s): Kuhns, Allan R.
• Application Number:
  US07/779,984
• Time in Patent Office: 827 Days
• Field of Search: 264/102, 264/511, 264/259, 156/244.24, 425/812
• US Class Current: 264/259
• CPC Class Codes: B29C 2043/3613 applying pressure locally
• CPC Class Codes: B29C 33/10 with incorporated venting means
• CPC Class Codes: B29C 37/006 Degassing moulding material or draining off gas during moulding venting means in moulds B29C33/10
• CPC Class Codes: B29C 43/184 shaped by the compression of the material during moulding
• CPC Class Codes: B29C 43/36 Moulds for making articles of definite length, i.e. discrete articles
• CPC Class Codes: B29C 44/588 with means for venting, e.g. releasing foaming gas
• CPC Class Codes: B29K 2105/04 cellular or porous
• CPC Class Codes: B29K 2105/043 Skinned foam
• CPC Class Codes: B29L 2031/3005 Body finishings
• CPC Class Codes: B29L 2031/3014 Door linings
• CPC Class Codes: B29L 2031/3041 Trim panels
• CPC Class Codes: Y10S 425/812 Venting

Abstract

In a method and device for combining a resin core member and a surface skin member at the same time as molding the resin core member into a desired shape, air and reaction gas trapped in the die cavity is removed through air vent pieces embedded in the die surfaces of the upper and lower dies so that a laminated molded article with a favorable appearance free from creases can be obtained. The air vent pieces may be either porous or provided with minute slits so that air and gas may be removed but the resin material may not seep through.

Claims

1. A method for fabricating a laminated molded article by using a die set including upper and lower dies for mold press forming, comprising the steps of:

placing a surface skin member between said upper and lower dies;

closing said upper and lower dies one upon the other;

distributing semi-molten resin material over a die surface of said lower die to mold said resin material into a resin core member having a desired contour and integrally attaching said surface skin member to a surface of said resin core member at the same time; and

expelling air and as produced from said resin material from air vent means, said air vent means comprising a porous block made of sintered metal or alloy which is embedded in the surface of at least one of said upper and lower dies, said porous block providing small passages for communicating a die cavity defined between said upper and lower dies to an external part of said die set.

2. A method according to claim 1, wherein said air vent means is embedded in the surface of each of said upper and lower dies.

3. A method for fabricating a laminated molded article by using a die set including upper and lower dies for mold press forming, comprising the steps of:

placing a surface skin member between said upper and lower dies;

closing said upper and lower dies one upon the other;

distributing semi-molten resin material over a die surface of said lower die to mold said resin material into a resin core member having a desired contour and integrally attaching said surface skin member to a surface of said resin core member at the same time; and

expelling air and gas produced from said resin material from air vent means, said air vent means comprising a metallic block having minute slits which is embedded in the surface of at least one of said upper and lower dies.

4. A method according to claim 3, wherein said air vent means is embedded in the surface of each of said upper and lower dies.