Plastic and nonmetallic article shaping or treating: processes – With step of making mold or mold shaping – per se
Patent
1989-01-23
1991-10-29
Heitbrink, Jill L.
Plastic and nonmetallic article shaping or treating: processes
With step of making mold or mold shaping, per se
249135, 249158, 419 2, B29C 3338
Patent
active
050614274
DESCRIPTION:
BRIEF SUMMARY
The invention relates to a mold body and to a method for producing same.
The possibilities of the application for such mold bodies lie in the field of deforming foils, specifically plastic foils, of the deep drawing of foils as such, such for instance for blister packagings and similar, or also at molding masses to be cast, for which a temperature during the casting and the setting which does not damage the foil placed as separating means, specifically about 250.degree. C., is not exceeded. A main field of application encompasses the production of cast parts of materials containing plastic materials, specifically such which contain grit or granulated material, but also cementitious bound or water soluble casting masses.
The numerous possibilities of application of deep drawn foil sections or of cast, settable structural pieces of materials having in part a plastic material content are known. Materials having a content partly of a plastic material which may be mentioned are specifically compound materials of granulated material and binding materials out of plastic materials, foamed materials, gypsum and similar which are materials which set by a chemical process. Here the granules of the granulated material may be metallic or nonmetallic and can have a diameter of a few micrometers up to more than 4 mm. Such as will be explained more in detail further below, the main application of the mold body in accordance with the invention is the casting of polymer concrete or polymer mortar where a deep drawn plastic foil is used as separating means layer.
Specifically for the production of cast bodies of the above mentioned materials a known method is to soften foils by heat and to press them pneumatically onto a shape giving surface. This may be arrived at by a subatmospheric pressure generated in the mold itself and/or by a positive pressure acting from the outside.
In order to practice this method mold bodies are applied which include specifically at the contours of the surface giving the shape which are critical regarding the deforming fine holes (jets). As a rule these mold bodies are produced of massive plastic material, also from metal (aluminum, steel) and the necessary holes or jets, respectively, are drilled into the mold body. Because a broad and continuously developing field of application is arising for cast bodies of e.g. structural material containing plastic material the mixtures of such structural materials and the corresponding mixing machines have been developed further steadily. It is here remarkable that until today no substantial progress has been attained regarding the molds themselves and correspondingly the main obstacles regarding an economical production of cast bodies of a material containing plastic material are at the mold itself.
The molding tools used up to this date have the following drawbacks:
The optimal placing, density and producing of the bores for the necessary holes or jets, respectively, demand much experience; an optimizing is often possible only by practical tests. The producing of a mold body is quite intrinsic, mistakes in the mold body cannot be corrected later. Furthermore, the mold bodies of plastic material heat speedily at a repeated deep drawing of foils and thus limit the station times; this is also true in case of metal molds. In addition, the making of the mold bodies is intrinsic, specially in case of complicated contours of the mold; the costs for the individual pieces in case of mold bodies made of several pieces cannot be reduced decisively. A specific drawback which has an impact is that very fine contours in the shaping surface and special structures of surfaces can hardly be realized or then only by means of a large number of holes which are difficult to place. As a rule, it is not possible to attain a complete and errorless deep drawing of the foil down onto the shape giving surface in order to have the form giving surface impeccably produced on the foil. Accordingly, not only the shape determining character of the foil is insufficient; the foil itself is
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