Carrier transfer molding device

• US 6,796,788 B2
• Filed: 05/30/2001
• Issued: 09/28/2004
• Est. Priority Date: 05/30/2001
• Status: Expired due to Fees

• Current Assignee: Robert M. Gallagher
• Original Assignee: Robert M. Gallagher
• Inventors: Gallagher, Robert M.
• Primary Examiner(s): Drodge, Joseph
• Assistant Examiner(s): Luk, Emmanuel S.
• Application Number:
  US09/867,974
• Publication Number:
  US 20020182283A1
• Time in Patent Office: 1,217 Days
• Field of Search: 141/231, 141/232, 141/233, 198/463.2, 198/463.3, 222/344, 222/355, 425/574, 425/448, 425/449, 425/375, 425/129.1, 425/258, 425/112, 425/117, 425/126.1, 425/377, 425/376.1, 425/404, 425/575, 425/257, 264/308, 264/320, 264/211.12
• US Class Current: 425/574
• CPC Class Codes: B29C 2043/3433 using dispensing heads, e.g. extruders, placed over or apart from the moulds
• CPC Class Codes: B29C 2043/3438 moving during dispensing over the moulds, e.g. laying up
• CPC Class Codes: B29C 31/044 with moving heads for distributing liquid or viscous material into the moulds
• CPC Class Codes: B29C 31/085 combined with positioning the preforms according to predetermined patterns, e.g. positioning extruded preforms on conveyors B29C70/30 takes precedence; for building tyres B29D30/08
• CPC Class Codes: B29C 43/18 incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles B29C43/206 takes precedence
• CPC Class Codes: B29C 43/203 Making multilayered articles
• CPC Class Codes: B29C 43/36 Moulds for making articles of definite length, i.e. discrete articles
• CPC Class Codes: B29K 2105/06 containing reinforcements, fillers or inserts
• CPC Class Codes: B29K 2105/20 Inserts
• CPC Class Codes: B29L 2031/3005 Body finishings

Abstract

A polymer is plasticized in a plasticizing unit and is thereafter fed into a transfer device which is moved into alignment with a clamping press which is remotely located from the plasticizing unit. The polymer from the transfer device is deposited on a carrier which moves into the forming device. An impress preforming device allows the carrier with the deposited polymer to be shaped in the mold or forming device. Alternatively, the transfer device can be connected with a chamber which is capable of coating continuous or chopped fibers which are deposited on a carrier in a continuous or chopped manner. The carrier with the fiber and polymer composite layer are shaped in the forming device.

Claims

1. A polymer transfer and deposition system comprising:

a polymer plasticating machine for providing a flow of a molten polymer;

a discharge device connected to said plasticating machine containing one or more valves to discharge the molten polymer;

a movable non-rotatable hollow first transport and deposition device separate and independent from said plasticating machine;

said first transport and deposition device including top and bottom walls and a pair of end walls;

an entrance port in said top wall and an exit port in said bottom wall;

said first transport and deposition device when said entrance port is aligned with one of said valves of said discharge device accepting the molten polymer from said plasticating machine;

a ram located within said first transport and deposition device for moving the molten polymer toward said exit port;

a forming device;

a conveyor having a carrier of generally planar shape attached thereto;

drive means for operating said conveyor and thereby moving said first transport and deposition device into alignment with said discharge device and then with said forming device;

said drive means capable of moving said conveyor and carrier to a first position beneath the exit port of said first transport and deposition device where said ram discharges through said exit port a first layer of plasticized molten polymer which is deposited on the carrier; and

said drive means thereafter capable of moving said conveyor and carrier with said first layer of plasticized molten polymer into said forming device which produces an article of a desired shape from the combined carrier and the first layer of plasticized polymer.

2. The polymer transfer and deposition system defined in claim 1, said system including a first robotic device wherein, prior to said conveyor moving the carrier into said forming device, said first robotic device is energized to place an insert on the first layer of plasticized polymer on the carrier;

said conveyor again moving the carrier into a position underneath the exit port of said first transport and deposition device where, said ram discharges through said exit port a second layer of plasticized molten polymer which is deposited on the carrier over the insert and the first layer; and

said drive means being effective to operate said conveyor to move the carrier, insert and the first and second layers of plasticized polymer into said forming device to produce an article of a desired shape.

3. The polymer transfer and deposition device defined in claim 2, wherein a second robotic device is located between said first transport and deposition device and said forming device;

an undercarriage provided beneath the carrier to support it during the depositing of the first layer, insert and second layer of plasticized molten polymer on the carrier;

said second robotic device having a vertically mounted robot guide having at the bottom edge thereof a curved surface located in close proximity to said undercarriage and the carrier and the first layer, insert and second layer of plasticized molten polymer;

said robot guide carrying and supporting a surface layer of material;

said drive means being effective to move said undercarriage with the carrier, first layer, insert and second layer of plasticized molten polymer thereon into a position underneath the curved surface of said robot guide where the surface layer of material is placed by said robot guide over the carrier, insert and layers of polymer;

said, robot guide thereafter applying a compressive force between said undercarriage and the surface layer of material, the first layer, insert and second layer and carrier to laminate the layers and carrier together; and

said undercarriage separating from the carrier when the carrier and laminated layers are moved by said conveyor into said forming device.

4. A polymer transfer and deposition system as defined in claim 1, wherein a second transport and deposition device, similar in construction to said first transport and deposition device is provided, said second transport and deposition device containing a plasticized molten polymer, said first transport device being aligned, spaced apart and arranged parallel to said second transport and deposition device;

said drive means being effective to operate said conveyor and to move the carrier with the first layer of plasticized polymer thereon under the exit port of said second transport and deposition device where said ram discharges through said exit port a second layer of plasticized molten, polymer over the first layer of plasticized polymer deposited on the carrier.

5. The polymer transfer and deposition system as defined in claim 4, wherein the system includes a first robotic device which when energized places an insert on the first layer of plasticized molten polymer on the carrier prior to the second layer of plasticized molten polymer being placed on the insert and over the first layer, all prior to moving the combined carrier with the insert and deposited layers of plasticized polymer into said forming device to produce an article of a desired shape.

6. The polymer transfer and deposition device defined in claim 5, wherein a second robotic device is located between said first transport and deposition device and said forming device;

an undercarriage provided beneath the carrier to support it during the depositing of the first layer, insert and second layer of plasticized molten polymer on the carrier;

said second robotic device having a vertically mounted robot guide having at the bottom edge thereof a curved surface located in close proximity to said undercarriage and the carrier and the first layer, insert and second layer of plasticized molten polymer;

said robot guide carrying and supporting a surface layer of material;

said drive means being effective to move said undercarriage with the carrier, first layer, insert and second layer of plasticized molten polymer thereon into a position underneath the curved surface of said robot guide where the surface layer of material is placed by said robot guide over the carrier, insert and layers of polymer;

said robot guide thereafter applying a compressive force between said undercarriage and the surface layer of material, the first layer, insert and second layer and carrier to laminate the layers and carrier together; and

said undercarriage separating from the carrier when the carrier and laminated layers are moved by said conveyor into said forming device.

7. The polymer transfer and deposition system as defined in claim 1, wherein said forming device contains a cavity or concave section on one side and a core or convex section on the opposite side where said forming device compresses the carrier and the layer of plasticized polymer into an article of a desired shape.

8. The polymer transfer and deposition system as defined in claim 7, wherein said forming device has at least two formed shapes having matching edges on the concave side when said matching edges are opposite each other, with each matching edge having the carrier side on the matching edge surface where the carrier side edges are sealed together to form a closed container.

9. The polymer transfer and deposition system as defined in claim 1, wherein an undercarriage is provided beneath the carrier to support it during the depositing of the first layer of plasticized molten polymer on the carrier, said undercarriage separating from the carrier when the carrier and first layer of plasticized polymer enters said forming device to produce an article of a desired shape.

10. The polymer transfer and deposition system as defined in claim 9, wherein said undercarriage holds the carrier via a vacuum, with the vacuum being discontinued prior to forming an article of a desired shape in said forming device.

11. The polymer transfer and deposition system as defined in claim 9, wherein said undercarriage holds the carrier with clamps, said clamps separating from the carrier and the first layer of plasticized polymer prior to forming an article of a desired shape in said forming device.

12. A polymer transfer and deposition system comprising:

a polymer plasticating machine for providing a flow of a molten polymer;

a discharge device connected to said plasticating machine containing one or more valves to discharge the molten polymer;

a movable non-rotatable hollow first transport and deposition device separate and independent from said plasticating machine;

said first transport and deposition device including top and bottom walls and a pair of end walls;

an entrance port in said top wall and an exit port in said bottom wall;

said first transport and deposition device when said entrance port is aligned with one of said valves of said discharge device accepting the molten polymer from said plasticating machine;

a ram located within said first transport and deposition device for moving the molten polymer toward said exit port;

a forming device;

a conveyor having a carrier of generally planar shape attached thereto, with the carrier being made from a ployolefin or polyester material of non-woven construction with a weight of at least 0.75 oz./square yard;

drive means for operating said conveyor and thereby moving said first transport and deposition device into alignment with said discharge device and then with said forming device;

said drive means moving said conveyor and carrier to a first position beneath the exit port of said first transport and deposition device where said ram discharges through said exit port a first layer of plasticized molten polymer which is deposited on and adheres to the carrier; and

said drive means thereafter capable of moving said conveyor and carrier with said first layer of plasticized molten polymer into said forming device, with the carrier forming the finish surface of the article produced in said forming device.

13. The polymer transfer and deposition system defined in claim 12, said system including a first robotic device wherein, prior to said conveyor moving the carrier into said forming device, said robotic device is energized to place an insert on the first layer of plasticized polymer on the carrier;

said conveyor again moving the carrier into a position underneath the exit port of said first transport and deposition device where said ram discharges through said exit port a second layer of plasticized molten polymer which is deposited on the carrier over the insert and the first layer; and

said drive means being effective to operate said conveyor to move the carrier, insert and the first and second layers of plasticized polymer into said forming device to produce an article of a desired shape.

14. A polymer transfer and deposition system as defined in claim 12, wherein a second transport and deposition device, similar in construction to said first transport and deposition device is provided, said second transport and deposition device containing a plasticized molten polymer which is different in polymer composition than the polymer in said first transport and deposition device, said first transport and deposition device being aligned, spaced apart and arranged parallel to said second transport and deposition device;

said drive means being effective to operate said conveyor and to move the carrier with the first layer of plasticized polymer thereon under the exit port of said second transport and deposition device to place a second layer of plasticized molten polymer over the first layer of plasticized polymer deposited on the carrier.

15. The polymer transfer and deposition system as defined in claim 14, wherein the system includes a first robotic device which places an insert made from a rigid foam material on the first layer of plasticized molten polymer on the carrier prior to the second layer of plasticized molten polymer being placed on the insert and over the first layer where the insert is encapsulated by the first and second layers, all prior to moving the combined carrier with the insert and, deposited layers of plasticized polymer into said forming device to produce an article of a desired shape.

16. The polymer transfer and deposition system as defined in claim 12, wherein said forming device contains a cavity or concave section on one side and a core or convex section on the opposite side where said forming device compresses the carrier and the layer of plasticized polymer into an article of a desired shape.

17. The polymer transfer and deposition system as defined in claim 12, wherein an undercarriage is provided beneath the carrier to support it during the depositing of the first layer of plasticized molten polymer on the carrier, said undercarriage separating from the carrier when the carrier and first layer of plasticized polymer enters said forming device to produce an article of a desired shape.

18. A polymer transfer and deposition system comprising:

a polymer plasticating machine for providing a flow of a molten polymer;

a discharge device connected to said plasticating machine containing one or more valves to discharge the molten polymer;

a movable non-rotatable hollow first transport and deposition device separate and independent from said plasticating machine;

said first transport and deposition device including top and bottom walls and a pair of end walls;

an entrance port in said top wall and an exit port in said bottom wall;

said first transport and deposition device when said entrance port is aligned with one of said valves of said discharge device accepting the molten polymer from said plasticating machine;

a ram located within said first transport and deposition device for moving the molten polymer toward said exit port;

a forming device;

a conveyor having a carrier of generally planar shape attached, thereto, with the carrier being made from material taken from the group including a fluoropolymer film, a coated film, and a pre-printed film to provide a specific surface characteristic in the article to be formed in said forming device;

drive means for operating said conveyor and thereby moving said first transport and deposition device into alignment with said discharge device and then with said forming device;

said drive means capable of moving said conveyor and carrier to a first position beneath the exit port of said first transport and deposition device where said ram discharges through said exit port a first layer of plasticized molten polymer which is deposited on and adheres to the carrier; and

said drive means thereafter capable of moving said conveyor and carrier with said first layer of plasticized molten polymer into said forming device which produces an article of a desired shape from the combined carrier and the first layer of plasticized polymer.

19. The polymer transfer and deposition system defined in claim 18, said system including a first robotic device wherein, prior to said conveyor moving the carrier into said forming device, said first robotic device is energized to place an insert made from a material taken from the group including rigid foam, open wall or honeycomb core construction on the first layer of plasticized polymer on the carrier;

said conveyor again moving the carrier into a position underneath the exit port of said first transport and deposition device where said ram discharges through said exit port a second layer of plasticized molten polymer which is deposited on the carrier over the insert and the first layer; and

said drive means being effective to operate said conveyor to move the carrier, insert and the first and second layers of plasticized polymer into said forming device to produce an article of a desired shape.

20. The polymer transfer and deposition device defined in claim 19, wherein a second robotic device is located between said first transport and deposition device and said forming device;

an undercarriage provided beneath the carrier to support it during the depositing of the first layer, insert and second layer of plasticized molten polymer on the carrier;

said second robotic device having a vertically mounted robot guide having at the bottom edge thereof a curved surface located in close proximity to said undercarriage and the carrier and the first layer, insert and second layer of plasticized molten polymer;

said robot guide carrying and supporting a surface layer of material;

said drive means being effective to move said undercarriage with the carrier, first layer, insert and second layer of plasticized molten polymer thereon into a position underneath the curved surface of said robot guide where the surface layer of material is placed by said robot guide over the carrier, insert and layers of polymer;

said robot guide thereafter applying a compressive force between said undercarriage and the surface layer of material, the first layer, insert and second layer and carrier to laminate the layers and carrier together;

said undercarriage separating from the carrier when the carrier and laminated layers are moved by said conveyor into said forming device.

21. A polymer transfer and deposition system as defined in claim 18, wherein a second transport and deposition device, similar in construction to said first transport and deposition device is provided, said second transport and deposition device containing a plasticized molten polymer, said first transport and deposition device being aligned, spaced apart and arranged parallel to said second transport and deposition device;

said drive means being effective to operate said conveyor and to move the carrier with the first layer of plasticized polymer thereon under the exit port of said second transport and deposition device to place a second layer of plasticized molten polymer over the first layer of plasticized polymer deposited on the carrier.

22. The polymer transfer and deposition system as defined in claim 21, wherein the system includes a robotic device which places an insert made from a material taken from the group including rigid foam, open wall or honeycomb core construction on the first layer of plasticized molten polymer on the carrier prior to the second layer of plasticized polymer being placed on the insert and over the first layer where the insert is encapsulated by the first and second layers, all prior to moving the combined carrier with the insert and deposited layers of plasticized polymer into said forming device to produce an article of a desired shape.

23. The polymer transfer and deposition system as defined in claim 18, wherein said forming device contains a cavity or concave section on one side and a core or convex section on the opposite side where said forming device compresses the carrier and the layer of plasticized polymer into an article of a desired shape.

24. The polymer transfer and deposition system as defined in claim 23, wherein said forming device has at least two formed shapes having matching edges on the concave side when said matching edges are opposite each other, with each matching edge having the carrier side on the matching edge surface where the carrier side edges are sealed together to form a closed container.

25. The polymer transfer and deposition system as defined in claim 18, wherein an undercarriage is provided beneath the carrier to support it during the depositing of the first layer of plasticized molten polymer on the carrier, said undercarriage separating from the carrier when the carrier and first layer of plasticized polymer enters said forming device to produce an article of a desired shape.