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WO2004048068B1 - Method for retrofitting existing molds for use with an in-mold coating system - Google Patents

Method for retrofitting existing molds for use with an in-mold coating system

Info

Publication number
WO2004048068B1
WO2004048068B1 PCT/US2003/036289 US0336289W WO2004048068B1 WO 2004048068 B1 WO2004048068 B1 WO 2004048068B1 US 0336289 W US0336289 W US 0336289W WO 2004048068 B1 WO2004048068 B1 WO 2004048068B1
Authority
WO
WIPO (PCT)
Prior art keywords
mold
coating composition
modifying
flow
mold cavity
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2003/036289
Other languages
French (fr)
Other versions
WO2004048068A1 (en
Inventor
Douglas Mcbain
Elliott Straus
John Thompson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Omnova Solutions Inc
Original Assignee
Omnova Solutions Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Omnova Solutions Inc filed Critical Omnova Solutions Inc
Priority to AU2003290839A priority Critical patent/AU2003290839A1/en
Publication of WO2004048068A1 publication Critical patent/WO2004048068A1/en
Publication of WO2004048068B1 publication Critical patent/WO2004048068B1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C37/00—Component parts, details, accessories or auxiliary operations, not covered by group B29C33/00 or B29C35/00
    • B29C37/0025—Applying surface layers, e.g. coatings, decorative layers, printed layers, to articles during shaping, e.g. in-mould printing
    • B29C37/0028—In-mould coating, e.g. by introducing the coating material into the mould after forming the article
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B29C45/1679—Making multilayered or multicoloured articles applying surface layers onto injection-moulded substrates inside the mould cavity, e.g. in-mould coating [IMC]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/76—Measuring, controlling or regulating
    • B29C45/7693—Measuring, controlling or regulating using rheological models of the material in the mould, e.g. finite elements method

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)

Abstract

A method of modifying an existing mold allows the mold to produce an article having at least one coated surface. The method including evaluating the mold to determine its existing characteristics, the optimal flow of the coating composition to be used, and the optimal location of the coating composition injector and modifying the mold based on the evaluation. The mold can be modified further to control the flow of the in-mold coating composition used to provide the coating.

Claims

AMENDED CLAIMS[received by the International Bureau on 15 June 2004 (15.06.04); original claims 1-15 replaced by new claims 1-17 (9 pages)]We claim:1. A method of modifying a mold that comprises first and second mold sections which together define a mold cavity in which articles are injection molded, said mold(i) not accommodating introduction of a coating composition into said mold cavity when said mold sections are in a closed relation,(ii) being operable with a molding machine such that machine actuates one of said first and second mold sections relative to the other between an opened and a closed condition, and (iii) comprising at least one nozzle for directing a substrate-forming material into said mold cavity when said mold sections are in a closed relation to produce an article having at least one surface to be coated, said mold cavity having an inner surface corresponding with the at least one surface to be coated, said method comprising: a) determining a point where said coating composition desirably can be contacted with said at least one surface of said article while said article is in said mold cavity; b) creating in said mold an access hole to accept a second nozzle, said second nozzle being capable of directing said coating composition into said mold cavity and onto said at least one surface of said article while said mold sections are in a closed relation; c) modifying said mold to utilize substrate compressibility to control the flow of said coating.2. The method of claim 1 wherein the creation of said access hole does not substantially modify said inner mold surface.3. The method of any of claims 1 to 2 further comprising at least one of the following steps: before creating said access hole, evaluating the operating conditions of said mold utilizing bracketing procedures, and determining one of a mold temperature and an article surface temperature at which injection of said coating composition produces an optimal flow thereof. 4. The method of any of claims 1 to 3 further comprising the step of performing a flow simulation of said mold before creating said access hole so as to evaluate the flow of at least one of said substrate-forming material and said coating composition.5. The method of claim 4 wherein said flow simulation determines siad desired point for said second nozzle.6. The method of any of claims 1 to 5 wherein said modifying step includes modifying said mold cavity so as to include at least one of a flow enhancer and a flow restricter.7. The method of claim 6 wherein said coating flow enhancer includes a mold runner or a means for adjusting the temperature of a portion of said mold cavity.8. The method of claim 7 further comprising the steps of evaluating the type and position of said mold runner and modifying said moid to account for heat produced by said mold runner and to maintain the desired flow of coating composition.9. The method of any of claims 1 to 8 further comprising modifying said mold so as to include at least one of the following: at least one sensor for measuring variables in at least one of the machine and the mold, and at least one sensor for measuring mold temperatures.10. The method of any of claims 1 to 9 wherein said modifying step includes means for at least one of cooling and heating said mold, such modification assisting in the control of at least one of the flow of coating composition in said mold cavity and the temperature of said at least one surface of said article so as to enhance coating flow thereover.11. The method of any of claims 1 to 10 further including the step of evaluating said article in relation to said at least one surface to be coated including sub steps of (i) evaluating relative positioning of parting lines and ejector pins and (ii) evaluating at least one of relative positioning of cores, slides, shutoffs, internal parting lines, and first nozzles. 12. The method of any of claims 1 to 11 wherein multiple access holes are created in said mold so as to accept multiple second nozzles.13. The method of claim 12 further comprising positioning said multiple second nozzles such that flow of coating composition from said second nozzles is laminar across said at least one surface to be coated.14. The method of any of claims 1 to 13 further comprising at least one of the following steps: determining optimal parameters for at least one of (i) volume of said coating composition to be injected into said mold cavity, (ii) time at which to inject said coating composition into said mold cavity, and (iii) pressure at which to inject said coating composition into said mold cavity; and said modifying step including modifying said mold cavity such that it is capable of molding an article having a thickened portion which can enhance flow of coating composition thereacross.15. The method of any of claims 1 to 14 wherein said modifying step includes modifying said mold cavity so as to utilize substrate compressibility to direct said coating composition across said at least one surface.16. The method of claim 11 wherein said modifying step includes modifying said mold to prevent said coating from reaching at least one of said parting lines, said ejector pins, said cores, said slides, said shutoffs, said internal parting lines and said first nozzle.17. The method of claim 11 wherein said modifying step includes modifying said mold cavity to prevent said coating from reaching at least one of said parting lines, said ejector pins, said cores, said slides, said shutoffs, said internal parting lines and said first nozzle. We claim:1. A method of modifying a mold that comprises first and second mold sections which together define a mold cavity in which articles are injection molded, said mold(i) not accommodating introduction of a coating composition into said mold cavity when said mold sections are in a closed relation,(ii) being operable with a molding machine such that machine actuates one of said first and second mold sections relative to the other between an opened and a clpsed condition, and (iii) comprising at least one nozzle for directing a substrate-forming material into said mold cavity when said mold sections are in a closed relation to produce an article having at least one surface to be coated, said mold cavity having an inner surface corresponding with the at least one surface to be coated, said method comprising: a) determining a point where said coating composition desirably can be contacted with said at least one surface of said article while said article is in said mold cavity; b) creating in sgid mold an access hole to accept a second nozzle, said second nozzle being capable of directing said coating composition into said mold cavity and onto said at least one surface of said article while said mold sections are in a closed relation; c) modifying said mold to utilize substrate compressibility to control the flow of said coating.2. The method of claim 1 wherein the creation of said access hole does not substantially modify said inner mold surface.3. The method of any of claims 1 to 2 further comprising at least one of the following steps: before creating said access hole, evaluating the operating conditions of said mold utilizing bracketing procedures, and determining one of a mold temperature and an article surface temperature at which injection of said coating composition produces an optimal flow thereof. 4. The method of any of claims 1 to 3 further comprising the step of performing a flow simulation of said mold before creating said access hole so as to evaluate the flow of at least one of said substrate-forming material and said coating composition.5. The method of claim 4 wherein said flow simuiation determines siad desired point for said second nozzle.6. The method of any of claims 1 to 5 wherein said modifying step includes modifying said mold cavity so as to include at least one of a flow enhancer and a flow restricter.7. The method of claim 6 wherein said coating flow enhancer includes a mold runner or a means for adjusting the temperature of a portion of said mold cavity.8. The method of claim 7 further comprising the steps of evaluating the type and position of said mold runner and modifying said mold to account for heat produced by said mold runner and to maintain the desired flow of coating composition.9. The method of any of claims 1 to 8 further comprising modifying said mold so as to include at least one of the following: at least one sensor for measuring variables in at least one of the machine and the mold, and at least one sensor for measuring mold temperatures.10. The method of any of claims 1 to 9 wherein said modifying step includes means for at least one of cooling and heating said mold, such modification assisting in the control of at least one of the flow of coating composition in said mold cavity and the temperature of said at least one surface of said article so as to enhance coating flow thereover.11. The method of any of claims 1 to 10 further including the step of evaluating said article in relation to said at least one surface to be coated including sub steps of (i) evaluating relative positioning of parting lines and ejector pins and (ii) evaluating at least one of relative positioning of cores, slides, shutoffs, internal parting lines, and first nozzles. 12. The method of any of claims 1 to 11 wherein multiple access holes are created in said mold so as to accept multiple second nozzles.13. The method of claim 12 further comprising positioning said multiple second nozzles such that flow of coating composition from said second nozzles is laminar across said at least one surface to be coated.14. The method of any of claims 1 to 13 further comprising at least one of the following steps: determining optimal parameters for at least one of (i) volume of said coating composition' to be injected into said mold cavity, (ii) time at which to inject said coating composition into said mold cavity, and (iii) pressure at which to inject said coating composition into said mold cavity; and said modifying step including modifying said mold cavity such that it is capable of molding an article having a thickened portion which can enhance flow of coating composition thereacross.15. The method of any of claims 1 to 14 wherein said modifying step includes modifying said mold cavity so as to utilize substrate compressibility to direct said coating composition across said at least one surface.16. The method of claim 11 wherein said modifying step includes modifying said mold to prevent said coating from reaching at least one of said parting lines, said ejector pins, said cores, said slides, said shutoffs, said internal parting lines and said first nozzle.17. The method of claim 11 wherein said modifying step includes modifying said mold cavity to prevent said coating from reaching at least one of said parting lines, said ejector pins, said cores, said slides, said shutoffs, said internal parting lines and said first nozzle. We claim:
1. A method of modifying a mold that comprises first and second mold sections which together define a mold cavity in which articles are injection molded, said mold
(i) not accommodating introduction of a coating composition into said mold cavity when said mold sections are in a closed relation,
(ii) being operable with a molding machine such that machine actuates one of said first and second mold sections relative to the other between an opened and a closed condition, and (iii) comprising at least one nozzle for directing a substrate-forming material into said mold cavity when said mold sections are in a closed relation to produce an article having at least one surface to be coated, said mold cavity having an inner surface corresponding with the at least one surface to be coated, said method comprising: a) determining a point where said coating composition desirably can be contacted with said at least one surface of said article while said article is in said mold cavity; b) creating in said mold an access hole to accept a second nozzle, said second nozzle being capable of directing said coating composition into said mold cavity and onto said at least one surface of said article while said moid sections are in a closed relation; c) modifying said mold to utilize substrate compressibility to control the flow of said coating.
2. The method of claim 1 wherein the creation of said access hole does not substantially modify said inner mold surface.
3. The method of any of claims 1 to 2 further comprising at least one of the following steps: before creating said access hole, evaluating the operating conditions of said mold utilizing bracketing procedures, and determining one of a mold temperature and an article surface temperature at which injection of said coating composition produces an optimal flow thereof.
4. The method of any of claims 1 to 3 further comprising the step of performing a flow simulation of said mold before creating said access hole so as to evaluate the flow of at least one of said substrate-forming material and said coating composition.
5
5. The method of claim 4 wherein said flow simulation determines siad desired point for said second nozzle.
6. The method of any of claims 1 to 5 wherein said modifying step includes 10 modifying said mold cavity so as to include at least one of a flow enhancer and a flow restricter.
7. The method of claim 6 wherein said coating flow enhancer includes a mold runner or a means for adjusting the temperature of a portion of said mold cavity.
15
8. The method of claim 7 further comprising the steps of evaluating the type and position of said mold runner and modifying said mold to account for heat produced by said mold runner and to maintain the desired flow of coating composition.
20 9. The method of any of claims 1 to 8 further comprising modifying said mold so as to include at least one of the following: at least one sensor for measuring variables in at least one of the machine and the mold, and at least one sensor for measuring mold temperatures.
25
10. The method of any of claims 1 to 9 wherein said modifying step includes means for at least one of cooling and heating said mold, such modification assisting in the control of at least one of the flow of coating composition in said mold cavity and the temperature of said at least one surface of said article so as to enhance coating flow 30 thereover.
11. The method of any of claims 1 to 10 further including the step of evaluating said article in relation to said at least one surface to be coated including sub steps of (i) evaluating relative positioning of parting lines and ejector pins and (ii)
' 35 evaluating at least one of relative positioning of cores, slides, shutoffs, internal parting lines, and first nozzles.
12. The method of any of claims 1 to 11 wherein multiple access holes are created in said mold so as to accept multiple second nozzles.
13. The method of claim 12 further comprising positioning said multiple second nozzles such that flow of coating composition from said second nozzles is laminar across said at least one surface to be coated.
14. The method of any of claims 1 to 13 further comprising at least one of the following steps: determining optimal parameters for at least one of (i) volume of said coating composition to be injected into said mold cavity, (ii) time at which to inject said coating composition into said mold cavity, and (ϊii) pressure at which to inject said coating composition into said moid cavity; and said modifying step including modifying said mold cavity such that it is capable of molding an article having a thickened portion which can enhance flow of coating composition iherea cross.
15. The method of any of claims 1 to 14 wherein said modifying step includes modifying said mold cavity so as to utilize substrate compressibility to direct said coating composition across said at least one surface.
16. The method of claim 11 wherein said modifying step includes modifying said mold to prevent said coating from reaching at least one of said parting lines, said ejector pins, said cores, said slides, said shutoffs, said internal parting lines and said first nozzle.
17. The method of claim 1 wherein said modifying step includes modifying said mold cavity to prevent said coating from reaching at least one of said parting lines, said ejector pins, said cores, said slides, said shutoffs, said internal parting lines and said first nozzle.
PCT/US2003/036289 2002-11-22 2003-11-13 Method for retrofitting existing molds for use with an in-mold coating system Ceased WO2004048068A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2003290839A AU2003290839A1 (en) 2002-11-22 2003-11-13 Method for retrofitting existing molds for use with an in-mold coating system

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US42847002P 2002-11-22 2002-11-22
US60/428,470 2002-11-22

Publications (2)

Publication Number Publication Date
WO2004048068A1 WO2004048068A1 (en) 2004-06-10
WO2004048068B1 true WO2004048068B1 (en) 2004-07-29

Family

ID=32393411

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2003/036289 Ceased WO2004048068A1 (en) 2002-11-22 2003-11-13 Method for retrofitting existing molds for use with an in-mold coating system

Country Status (2)

Country Link
AU (1) AU2003290839A1 (en)
WO (1) WO2004048068A1 (en)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7906047B2 (en) 2005-12-21 2011-03-15 Essilor International (Compagnie Generale D'optique) Injection molding a lens onto a coated ophthalmic wafer
US7833442B2 (en) 2005-12-21 2010-11-16 Essilor International (Compagnie Generale D'optique) Method for coating an ophthalmic lens within an injection molding machine
US7820082B2 (en) 2007-06-20 2010-10-26 Essilor International (Compagne Generale D'optique) Method for adding a thermoset overmold layer to a lens within a mold
US7759433B2 (en) 2007-06-20 2010-07-20 Essilor International (Compagnie Generale D'optique) High adhesion acrylate coating for a photochromic ophthalmic lens

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5066214A (en) * 1988-11-02 1991-11-19 Encore Molding Systems, Inc. Injection molding apparatus
US4881715A (en) * 1988-12-30 1989-11-21 Holdt J W Von Safety lift lock with internal member
DE19624386C1 (en) * 1996-06-19 1998-02-26 Battenfeld Gmbh Multicomponent pressure injection moulding machine
US6793861B2 (en) * 2000-07-12 2004-09-21 Omnova Solutions Inc. Optimization of in-mold coating injection molded thermoplastic substrates

Also Published As

Publication number Publication date
WO2004048068A1 (en) 2004-06-10
AU2003290839A1 (en) 2004-06-18

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