Plastic article or earthenware shaping or treating: apparatus – Preform severing means – Severing means is perforator
Patent
1996-09-19
1998-05-12
Davis, Robert
Plastic article or earthenware shaping or treating: apparatus
Preform severing means
Severing means is perforator
249116, 264227, 425403, 427135, 427250, B29C 5132, C23C 1606
Patent
active
057501602
DESCRIPTION:
BRIEF SUMMARY
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to a nickel vapour deposition shell mold and, more particularly, relates to a nickel shell mold and steel base composite insert ("nickel shell insert") having an authentic, textured mold surface reproduction of the original wood, leather, cloth and the like material and to the method of production of a nickel shell and a nickel shell insert.
2. Description of the Related Art
The reproduction of textured surfaces, such as wood, leather or cloth, can be obtained on nickel mold surfaces by electrodeposition of nickel onto a surface to be reproduced. However, several preliminary steps are required to prepare a master bath mold for electrodeposition. Electrodeposition of nickel then normally requires 6-8 weeks to provide the prescribed build-up of 0.8 to 1 centimeter (5/16-3/8 inch) nickel thickness. Normally the first reproduction is not acceptable due to imperfections, necessitating a repeat of the deposition process, thereby requiring a total of 10-14 weeks to produce an acceptable mold.
Plastic products such as door panels molded from steel molds with textured surface produced by photoetching normally do not appear authentic and, in fact, have the appearance of an obvious reproduction due largely to lack of definition and texture.
There accordingly is a need for a method of producing a mold which is capable of accurately reproducing the original texture of materials such as wood, leather or cloth to permit production of plastic products having an authentic, hence realistic, textured surface appearance, and for a modular shell mold insert for a mold press capable of producing products having an authentic appearance.
Nickel shells commonly are formed on aluminum alloy mandrels by nickel vapour deposition. However, nickel and aluminum have different coefficients of expansion and composites of nickel and aluminum accordingly tend to warp when cooled. Nickel vapour deposition on steel mandrels, which have essentially the same coefficient of thermal expansion, permits the deposition of a nickel shell onto a steel substrate including a hardened steel shear insert which is free of distortion such as warping when heated or cooled. The nickel shell with encapsulated steel shear insert is then mounted on a steel base to form a composite nickel shell insert having component parts with essentially the same coefficient of expansion.
SUMMARY OF THE INVENTION
Canadian Patent Application No. 2,076,578 discloses methods for the manufacture of nickel shells by vapour deposition of nickel from gaseous nickel carboxyl. The nickel shells have use as molds in the mass production of plastic articles.
In its broad aspect, the present invention relates to a novel method of producing a mold of nickel using a positive master silicone reproduction of a textured shape which allows nickel vapour deposition thereon in about 30 hours compared to 6-8 weeks for conventionally electrodeposited molds.
The method of the invention for forming a nickel shell for a mold to reproduce an article surface comprises the steps of securing the article to be reproduced to a base having a perimeter, forming a dam about the perimeter, filling the interior of the dam with a silicone, mounting a register plate over the article within the dam in contact with the silicone, and allowing the silicone to cure whereby the silicone forms a negative master of the article surface. The negative master is removed from the article and a steel mandrel is positioned over the negative master to define a cavity therebetween, a silicone which is not adherent to the negative master is fed into said cavity to fill the cavity and the silicone allowed to cure whereby the silicone forms a positive master which adheres to the steel mandrel. The negative master is removed from the positive master, and a layer of nickel is deposited by nickel vapour deposition onto the positive master, such as by the method disclosed in U.S. Pat. No. 5,169,549, to form a nickel shell having an authentic negative surface
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Sheppard Robert E.
Weber Reinhart
Davis Robert
Fors, Reg.#20,775 Arne I.
Weber Manufacturing Limited
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