Apparatus for molding articles

• US 6,338,618 B1
• Filed: 04/18/2000
• Issued: 01/15/2002
• Est. Priority Date: 10/09/1997
• Status: Expired due to Term

• Current Assignee: International Automotive Components Group North America (Lear Corporation)
• Original Assignee: Lear Corporation
• Inventors: Van Ert, Jack M., Byma, George B.
• Primary Examiner(s): DAVIS, ROBERT B
• Application Number:
  US09/551,789
• Time in Patent Office: 637 Days
• Field of Search: 425/389, 425/390, 425/405.1, 425/520, 425/3, 425/171, 425/521, 249/170
• US Class Current: 425/3
• CPC Class Codes: B29C 2791/006 Using vacuum
• CPC Class Codes: B29C 33/20 Opening, closing or clamping
• CPC Class Codes: B29C 33/28 using hydraulic or pneumatic means
• CPC Class Codes: B29C 35/0227 using pressure vessels, e.g. autoclaves, vulcanising pans B29C35/065 takes precedence
• CPC Class Codes: B29C 43/36 Moulds for making articles of definite length, i.e. discrete articles
• CPC Class Codes: B29C 51/082 by shaping between complementary mould parts
• CPC Class Codes: B29C 51/18 Thermoforming apparatus
• CPC Class Codes: B29C 51/30 Moulds
• CPC Class Codes: B29C 51/428 of moulds or mould parts
• CPC Class Codes: B29L 2031/3011 Roof linings
• CPC Class Codes: B32B 37/1018 using only vacuum
• CPC Class Codes: B32B 38/12 Deep-drawing
• CPC Class Codes: B60R 13/0225 self supporting head liners

Abstract

An apparatus for forming an article from at least one layer of formable material includes a mold for receiving the at least one layer of formable material. The mold has first and second thin mold sections and a seal associated with at least one of the mold sections for effecting a sufficiently sealed relationship between the mold sections. Each mold section has a non-planar configuration, and one mold section has at least one aperture. A vacuum source is in fluid communication with the at least one aperture for applying a vacuum pressure to the at least one aperture when the mold sections are sufficiently sealed together in order to reduce air pressure within the mold. As a result, ambient air pressure is used to forcefully bias the mold sections sufficiently together so as to form the at least one layer of formable material to a contour corresponding to the non-planar configurations of the mold sections. Furthermore, each mold section is sufficiently rigid such that the mold sections do not substantially flex when the mold sections are forcefully biased together.

Claims

1. An apparatus for forming an article from at least one layer of formable material, the apparatus comprising:

a mold for receiving the at least one layer of formable material, the mold having first and second thin mold sections and a seal associated with at least one of the mold sections for effecting a sufficiently sealed relationship between the mold sections, each mold section having a non-planar configuration, one mold section having at least one aperture; and

a vacuum source in fluid communication with the at least one aperture for applying a vacuum pressure to the at least one aperture when the mold sections are sufficiently sealed together in order to reduce air pressure within the mold to thereby cause ambient air pressure to forcefully bias the mold sections sufficiently together so as to form the at least one layer of formable material to a contour corresponding to the non-planar configurations of the mold sections;

wherein each mold section is sufficiently rigid such that the mold sections do not substantially flex when the mold sections are forcefully biased together.

2. The apparatus of claim 1 wherein the seal comprises a flange portion formed as part of one of the mold sections, the flange portion being configured to overlap the other mold section when the mold sections are moved sufficiently close together.

3. The apparatus of claim 1 wherein the seal comprises a compressible seal.

4. The apparatus of claim 1 wherein the seal comprises a blade seal.

5. The apparatus of claim 1 wherein one mold section has a peripheral channel in communication with the at least one aperture.

6. The apparatus of claim 1 wherein a portion of at least one of the mold sections comprises a flexible material.

7. The apparatus of claim 1 wherein the mold sections are pivotally connected together such that at least one mold section is pivotable toward the other mold section.

8. The apparatus of claim 7 wherein the mold includes at least one locator for aligning the mold sections as the at least one mold section is pivoted toward the other mold section, the locator including a locating pin assembly connected to the first mold section, and a receptacle connected to the second mold section, the locating pin assembly including a bullet-shaped locating pin that is engageable with the receptacle.

9. The apparatus of claim 8 wherein the locating pin assembly further includes a housing into which the locating pin extends, wherein the locating pin is moveable with respect to the housing to allow the at least one mold section to pivot toward the other mold section after the locating pin has engaged the receptacle.

10. The apparatus of claim 9 wherein the housing has a first engaging surface, and the receptacle has a second engaging surface engageable with the first engaging surface, wherein when the engaging surfaces are engaged with each other, pivotal movement of the at least one mold section toward the other mold section is inhibited.

11. The apparatus of claim 1 wherein the mold further includes a mold gap measurement device for determining gap thickness between the mold sections.

12. The apparatus of claim 11 wherein the mold gap measurement device includes a magnet connected to one mold section, and a magnetic force detection device connected to the other mold section.

13. The apparatus of claim 11 further comprising a controller in communication with the mold gap measurement device and the vacuum source, the controller being operable to control the vacuum pressure applied by the vacuum source based on the gap thickness between the mold sections.

14. The apparatus of claim 1 further including a heating device for heating the at least one layer of formable material, wherein one of the mold sections includes at least one temperature measurement device in communication with the heating device for determining temperature of a portion of the at least one layer of formable material.

15. The apparatus of claim 14 wherein the heating device includes a plurality of heating elements arranged in a first array, and the one mold section includes a plurality of temperature measurement devices in communication with the heating device and arranged in a second array corresponding to the first array.

16. An apparatus for forming an article from at least one layer of formable material, the apparatus comprising:

a mold for receiving the at least one layer of formable material, the mold having first and second mold sections pivotally connected together, and a compressible seal disposed between the mold sections, each mold section having a non-planar configuration, one mold section having at least one aperture and a peripheral channel in communication with the at least one aperture; and

a vacuum source in fluid communication with the at least one aperture and the channel for reducing air pressure within the mold to thereby cause ambient air pressure to forcefully bias the mold sections sufficiently together and compress the seal, so as to form the at least one layer of formable material to a contour corresponding to the non-planar configurations of the mold sections;

wherein each mold section is sufficiently rigid such that the mold sections do not substantially flex when the mold sections are forcefully biased together.

17. An apparatus for forming an article from at least one layer of formable material, the apparatus comprising:

a frame assembly having first and second frame portions pivotally connected together such that at least one of the frame portions is pivotable with respect to the other frame portion between an open position and a closed position, the frame assembly further including an inflatable device connected to the first frame portion;

a mold for receiving the at least one layer of formable material, the mold including first and second mold sections and a seal associated with at least one of the mold sections, the first mold section being cooperable with the inflatable device such that the first mold section is moveable with respect to the first frame portion upon inflation of the inflatable device, the second mold section being connected to the second frame portion, each mold section having a non-planar configuration, one mold section having at least one aperture; and

a vacuum source in fluid communication with the at least one aperture;

wherein when the at least one frame portion is in the closed position, the inflatable device is operable for moving the first mold section toward the second mold section to effect a sufficiently sealed relationship between the mold sections, and the vacuum source is operable for reducing air pressure within the mold to thereby cause ambient air pressure to forcefully bias the mold sections sufficiently together so as to form the at least one layer of formable material to a contour corresponding to the non-planar configurations of the mold sections, each mold section being sufficiently rigid such that the mold sections do not substantially flex when the mold sections are forcefully biased together.

18. The apparatus of claim 17 wherein the seal comprises a flange portion formed as part of one of the mold sections, the flange portion being configured to overlap the other mold section when the mold sections are moved sufficiently close together.

19. The apparatus of claim 17 wherein the seal comprises a compressible seal.

20. The apparatus of claim 17 wherein the seal comprises a blade seal.

21. The apparatus of claim 17 wherein the seal comprises a fibrous material.