WO2017137997A1

WO2017137997A1 - A method and system for molding a panel member, and a molded panel member

Info

Publication number: WO2017137997A1
Application number: PCT/IL2017/050168
Authority: WO
Inventors: Efraim Haimoff; Yaron Brunner
Original assignee: Travel Smart Ltd
Current assignee: Travel Smart Ltd
Priority date: 2016-02-11
Filing date: 2017-02-09
Publication date: 2017-08-17
Anticipated expiration: 2018-08-11
Also published as: IL245768A0

Abstract

The present disclosure concerns layered molded articles, panels and methods of their preparation. The layered molded articles comprise an injection-molded rigid carrier layer, a sheet layer disposed over at least a portion of said carrier layer, and a grid layer integrally molded out of and extending over at least a portion of said carrier layer through said sheet layer, and exposing portions of the sheet layer.

Description

A METHOD AND SYSTEM FOR MOLDING A PANEL MEMBER, AND A

MOLDED PANEL MEMBER

TECHNOLOGICAL FIELD

The present disclosure is generally concerned with plastic molding and more particularly it is concerned with a method and a system for molding a panel member. The disclosure is also concerned with panel member molded accordingly.

The term 'panel member' as used herein denotes any rigid article that can be used as a construction panel portion or a decorative panel portion of an article.

The term 'article', as referred to herein suggests, any article of manufacture having a three dimensional shape or constituting part of a three dimensional article. By way of example, an article can be a flat panel-like article or a shell-like article (or any 3D article), such as a cabinet, a cabinet panel (e.g. door or other), a basket, a container, a suitcase, a partition panel, a ceiling panel, and the like.

BACKGROUND ART

References considered to be relevant as background to the presently disclosed subject matter are listed below:

- DE 280560618

Acknowledgement of the above references herein is not to be inferred as meaning that these are in any way relevant to the patentability of the presently disclosed subject matter.

BACKGROUND

DE 280560618 discloses a method for surface designing injection-molded, flat and non-flat plastic parts in which an insert is placed into the mold and this insert is perforated in some places during the back injection so that a pattern of lines or dots is produced on the insert, characterized in that a permeable insert is placed into an injection mold and is back injected with plastic. The desired pattern is produced in that the plasticized plastic penetrates through the insert into corresponding engravings in the male part or female part of the injection molding tool and fills these engravings.

GENERAL DESCRIPTION

According to a first aspect of the present disclosure there is provided a method for molding a panel member, the method comprising the following steps:

a) obtaining an injection mold comprising a male mold member and an associated female mold member; wherein said female mold member is configured with molding cavities and with a sheet material gripping arrangement;

b) applying a sheet material over at least a molding portion of the female mold member and securing it by the sheet material gripping arrangement;

c) advancing the male mold member towards the female mold member leaving a gap before the sheet material;

d) applying molten polymeric material through the male mold member, whereby the polymeric material occupies said gap and then passes through at least portions of the sheet material and flows into the molding cavities of the female mold member.

Once the molded article is sufficiently cured (or sufficiently hardened or solidified), the male mold member is removed from the female mold member and the panel member is removed, wherein the resulting panel member comprises a rigid carrier layer, a sheet layer disposed over at least a portion thereof, and a grid layer integrally molded with said carrier layer, through said sheet layer, and exposing portions of the sheet layer.

The term grid layer, as used herein, denoted a rigid layer of material extending over the sheet material and comprising open portions at which the sheet material is exposed and visible. Said open portions can be constituted by openings defining a gridlike pattern or openings extending over major surface portions of the grid layer.

The female mold member can further be configured with one or more cavities for creating one or more functional zones at the panel member, said functional zones extending at the grid layer of said panel.

According to a second aspect of the present disclosure there is provided a panel comprising a substantially rigid carrier layer, made of injection-molded polymeric material, a sheet layer disposed over at least a portion of said carrier layer, and a grid layer integrally molded out of and extending over at least a portion of said carrier layer through said sheet layer, and exposing portions of the sheet layer.

According to a third aspect of the present disclosure there is provided an article comprising a frame portion integrally molded with at least a panel portion, said panel portion comprising a substantially rigid carrier layer, made of injection-molded polymeric material, a sheet layer disposed over at least a portion of said carrier layer, and a grid layer integrally molded out of, and extending over at least a portion, of said carrier layer, through said sheet layer, and exposing portions of the sheet layer.

Any one or more of the following features, designs and configurations, can be implemented in a method of manufacturing an article or in an article according to the present disclosure, individually or in various combinations thereof:

• The molded panel can be made of thermoplastic polymeric materials or rubber material. Examples of such materials can be Polypropylene, Polyethylene (LDPE & LLDPE), acrylonitrile-butadiene-styrene block copolymer (ABS), polycarbonate (PC), polyester, thermoplastic elastomers (TPE), thermoplastic rubbers (TPR), styrene - butadiene-styrene copolymers (SBS), styrene ethylene butylene styrene copolymer (SEBS), NYLON, etc., as well as mixtures, copolymers and derivatives thereof;

• The sheet material is porous to an extent sufficient to facilitate passage of molten plastic material from the carrier layer to the grid layer during molding;

• The sheet material can be a mesh-like or woven sheet of material;

• The sheet material can be a fabric of any kind (e.g. organic - such as cotton, jute, etc., or synthetic such as Lycra), any organic or artificial material, however porous;

• The sheet material can be configured with a decorative pattern, at least at a face thereof visible through the openings at the grid layer;

• The sheet material can be configured with a texturized surface visible through openings of the grid layer;

• The sheet material can be made of thermoplastic substance, or a portion thereof may comprise at least one thermoplastic substance;

• The carrier layer substantially does not project over the sheet layer at exposed portions of the gird layer; • The carrier member and the sheet layer and the grid layer are integrated one with the other by the molding process;

• The integrated panel is strengthened by the reinforcing properties imparted by the sheet layer and the grid layer, whilst the weight of the panel is less than that of a solid panel of same dimensions however without a grid layer;

• Portions of the molding cavities of the female mold member can have a grid-like pattern;

• The sheet material gripping arrangement can be an array of gripping pins;

• The gripping pins can be biased to project from an inside surface of the female mold member;

• the gripping pins fully retract into the female mold member upon positioning of the male mold member within the female mold member, at the mold position;

• The gripping pins can be displaceable between a projecting position at which they project from a surface of the female mold member and are configured for gripping the sheet material, and a retracted potion at which they retract simultaneously as the male mold member is introduced into the female mold portion;

• The sheet material can be applied over the female mold member by a robotic manipulator configured with a sheet material gripping mechanism for transferring the sheet material and applying it over the female mold member;

• The panel can be a two-sided panel whereby the rigid carrier layer is configured at both faces thereof, with a sheet layer disposed over at least a portion thereof, and an external grid layer integrally molded with said carrier layer through said sheet layer and exposing portions of the sheet layer;

• The grid layer can be of non-uniform surface, i.e. its thickness can alter measured over the sheet material;

• The grid layer can assume a decorative pattern of molded material;

• The grid layer can be continuous or interrupted (non-continuous);

• The one or more functional zones extending at the grid layer of the panel can be any of solid reinforcing portions (e.g. bash-guards, corner protection, etc.), articulation portions configured for attaching thereto different elements (e.g. wheels, handles, fasteners, etc.)

• The sheet layer is integrated with the carrier layer of the panel, whereby molded material occupied pores of the sheet material, however not projecting through exposed surfaces of the sheet material;

• The carrier layer can be substantially uniform, at least behind portions of the sheet layer;

• The grid layer can project from a surface of the sheet layer and thus provide abrasion and wear protection to said sheet material;

• The grid layer can be an external layer reinforcing the panel and rendering it impact resistance;

• The grid layer can constitute a flexible portion that constitutes a flexible hinge (i.e. a living hinge) articulated to a neighboring panel member (optionally by integrally molding);

• The panel can be configured such that the carrier layer is an inner layer and the grid layer is external, such that the sheet layer is visible through openings at an external face of the panel.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to better understand the subject matter that is disclosed herein and to exemplify how it may be carried out in practice, embodiments will now be described, by way of non-limiting examples only, with reference to the accompanying drawings, in which:

Fig. 1 is an isometric view of a suitcase manufactured according to a method of the present disclosure;

Fig. 2A is a perspective view of the portion marked II in Fig. 1 ;

Fig. 2B is a portion of a section of a panel according to an example of the disclosure;

Fig. 2C is an exploded view of a section taken along line I-I in Fig. 1 ;

Figs. 3A to 3H are schematic illustrations of steps the molding process and a mold used according to an example of the disclosure; Figs. 4A and 4B are exploded views illustrating a panel according to another example of the disclosure, configured with functional articulation zones and functional respective elements;

Fig. 5A is a perspective view of an example of a suitcase according to the disclosure;

Fig. 5B is an enlargement of a top corner portion of suitcase of Fig. 5A;

Figs. 6A and 6B are perspective views of a basket and a toolbox according to embodiments of the disclosure; and

Figs. 7 A and 7B are schematic cross-sections through a one-sided and a double sided panel according to examples of the present disclosure.

DETAILED DESCRIPTION OF EMBODIMENTS

Attention is first directed to Fig. 1 of the drawings illustrating an article according to the present disclosure, namely a suitcase (wheeled trolley) generally designated 20 and comprising wall panels 22. As seen in Figs. 2A and 2B the panel 22 has an external face 24, configured with a plurality of ribs 26 projecting from a porous sheet layer designated 30, said ribs arranged in a grid-like pattern, discussed hereinafter in further detail.

It is seen in Fig. 2B that the panel 22 comprises a rigid carrier layer 36, with said sheet layer 30 disposed over at least a portion of the carrier layer 36, and a grid layer composed by said ribs 26, and being integrally molded with said carrier layer 36, through said sheet layer 30. Namely, as the sheet layer is porous to an extent that allows molten plastic material to flow therethrough, the carrier layer 36 and the grid layer 26 are integrally molded, with the sheet layer 30 disposed therebetween.

Turning now to Figs. 3A to 3H, it is explained how a panel according to the present disclosure and an article comprising such a panel are manufactured.

A mold 40, designed for manufacturing a panel according to the disclosure, comprises a female mold member 42 and a male mold member 44. The female mold member 42 is configured with a main depression (basin-like portion 45 best seen in Fig. 3D) having the shape of the final shell-like panel to be molded, configured with an array of molding cavities 46 being a negative impression of the grid pattern of the gird layer molding cavity designated 48 and four corner cavities 52, the two later to be discussed hereinafter. Further included in the female mold member 42 is a sheet material gripping arrangement configured as an array of peripherally disposed gripping pins 56, said pins being normally biased to project from surface 58 of the female mold member 42 and being axially displaceable between a normally projecting position when the mold 40 is open, and a retracted position. In the retracted position, the gripping pins 56 are displaced against the biasing effect of respective biasing members (schematically designated 57 in Figs. 3D and 3E) when the mold 40 is at its fully closed position (Fig. 3E), such that the gripping pins are flush with the inside face 58 of the female mold member 42.

Male mold member 44 has a negative shape of the basin 45 with a projection 62 configured for insertion into the basin 45, such that at the fully closed position (Fig. 3E) there is only a tight gap 66 between the surface 68 of the male mold member 44 and the sheet material attached to the basin surface 58 of the female mold member 42. Male mold member 44 is further configured with one or more injection nozzles 72 through which molten material is applied under pressure as will be discussed.

A manipulator generally designated 76 (Fig. 3B) is configured for collecting a sheet material layer 78 and attaching same to a bearing surface 80 of the manipulator, where it is temporarily retained by a plurality of gripers 82. The manipulator can be controlled by a controller and be fully automated for collecting a sheet material from a work station (not shown) and transferring same to the female mold member 42 (Fig. 3C).

The sheet material 78 is a porous sheet of martial, made for example of fabric, or other woven material and may also comprise polymeric agents for improving integration with the final panel during the molding process. The sheet material can bare a pattern or be texturized such that it is visible at in outside of a manufactured panel. The sheet material is cut into a shape corresponding with the basin 45 at the female mold member 42. Once introduced into the basin (Fig. 3B), the sheet material 78 is applied and positioned into the basin 45, it is discharged from the manipulator 76 and in turn is arrested by the arresting pins 56 of the female mold member 42. The manipulator then moves, allowing the male mold member 44 to displace towards the female mold member 42, in direction of arrow 88 (Fig. 3D). The gap 66 between the surface 68 of the male mold member 44 and the sheet material snugly following and attached to the basin surface 58 of the female mold member 42 is defined upon encountering of forehead surfaces 90 and 92 of the female mold member 42 and the male mold member 44, respectively.

Upon securing the female mold member 42 and the male mold member 44 at the closed (molding) position (Figs. 3E - 3G) molten resin 95 is pressurized through the one or more injection nozzles 72 (Fig. 3H), whereby it occupies the space of gap 66 (thus constituting the carrier layer 36), then passes through the porous sheet material 78 into the molding cavities 46 within the female mold member 42, whereby the ribs 26 constitute the grid layer, resulting in that the carrier layer 36 is integrated with the grid layer and the sheet layer is attached to the carrier layer. However, it is appreciated that at areas other than the ribs of the grid later or at functional surfaces (see below) the sheet material is exposed and visible however wherein the plastic material does not project from a surface of the sheet material (Figs. 2A and 2B).

The molded panel can be made of any suitable thermoplastic polymeric materials or rubber material.

Turning now to Figs. 4A and 4B there are illustrated examples of panels configured with integral functional zones. In Fig. 4A the panel 100 is configured, as discussed herein before, with a carrier layer 102, a sheet layer 104 and a grid layer 106 composed of plurality of intersecting ribs. A wheel attachment boss 110 is integrally molded with the panel 100, i.e. integral with the carrier layer 102, a sheet layer 104 and a grid layer 106, imparting it rigidity sufficient for attaching thereto a swivel wheel (caster) 112 by snap engagement.

For integrally forming said functional zone, namely boss 110, the female mold member is configured with a cavity e.g. central molding cavity designated 48 seen in Fig. 3 A, giving rise to the respective functional element namely boss 110.

In Fig. 4B a similar arrangement is illustrated, whereby panel 120 is configured, as discussed herein before, with a carrier layer 122, a sheet layer 124 and a grid layer 126 composed of plurality of intersecting ribs. A handle attachment 110 is integrally molded with the panel 120, i.e. integral with the carrier layer 122, a sheet layer 124 and a grid layer 126, imparting it rigidity sufficient for attaching thereto a handle 132 articulated by a hinge (Not shown).

Figs. 5A and 5B illustrate yet further examples of functional elements or functional zones of a panel, for example a molded shell-like panel 140 of a suitcase 142. The shell like panel 140 is molded according to the method described hereinabove and it is seen that external portions of the panel 142, are configured at corners thereof, with bash-guard members integrally molded therewith. Also noted, a peripheral rim 148 of the shell-like panel is integrally molded therewith, thereby improving rigidity of the suitcase.

Fig. 6A and 6B are examples of articles composed of or made of shell like panels according to the present disclosure, manufactured as described hereinabove, wherein Fig. 6A illustrates a tool box 150 configured with reinforced wall panels of the described configuration and a functional zone articulated with a handle 151. Fig. 6B illustrates a paper basket 156 having a smooth inside surface 158 (namely a carrier layer) and an integrated external grid layer configured with ribs 160 and a texturized sheet layer 162.

Fig. 7A is a schematic representation of a portion of a panel according to an example of the present disclosure generally designated 170, said panel configured as a one-sided panel, comprising a carrier layer 172 integrally molded with a sheet layer 174 and a grid layer 176 extending at a top face thereof and manufactured as explained hereinabove. However, Fig 7B is a schematic representation of a portion of a different panel according to an example of the present disclosure, generally designated 180, said panel configured as a two-sided panel, comprising a common carrier layer 182 integrally molded and disposed between a top sheet layer 184 and a bottom sheet layer 186, with a respective top grid layer 188 extending at a top face thereof and a bottom grid layer 190 extending at a bottom face thereof, wherein said panel 180 is manufactured as explained hereinabove mutates mutandis as far as the differences required at the mold members.

Claims

CLAIMS:

1. A panel comprising a substantially rigid carrier layer made of injected polymeric material, a sheet layer disposed over at least a portion of said carrier layer, and a grid layer integrally molded out of and extending over at least a portion of said carrier layer through said sheet layer, and exposing portions of the sheet layer.

2. The panel of claim 1 , wherein the sheet material is porous to an extent sufficient to facilitate passage of molten molding material from the carrier layer to the grid layer during injection-molding process.

3. The panel of claim 1 or 2, wherein the sheet material is configured with a decorative pattern or a texturized surface, at least at a face thereof visible through opening at the grid layer.

4. The panel of any one of claims 1 to 3, wherein the sheet material is made of, or comprises at least one thermoplastic substance.

5. The panel of any one of claims 1 to 4, wherein the carrier layer substantially does not project over the sheet layer at exposed portions of the gird layer.

6. The panel of any one of claims 1 to 5, wherein the sheet layer and the grid layer become integrated one with the other by a molding process.

7. The panel of any one of claims 1 to 6, wherein the panel is a two-sided panel, wherein the rigid carrier layer is configured at both faces thereof with a sheet layer disposed over at least a portion thereof, and an external grid layer integrally molded with said carrier layer, through said sheet layer, and exposing portions of the sheet layer.

8. The panel of any one of claims 1 to 7, wherein the grid layer is of non-uniform thickness extending over the sheet material.

9. The panel of any one of claims 1 to 8, wherein the grid layer is configured with a decorative pattern of molded material.

10. The panel of any one of claims 1 to 9, wherein the sheet layer is integrated with the carrier layer of the panel, such that the molded material occupies pores of the sheet material without projecting through exposed surfaces of the sheet material.

11. The panel of any one of claims 1 to 10, wherein the grid layer projects from a surface of the sheet layer to provide abrasion and wear protection to said sheet material.

12. The panel of any one of claims 1 to 11, wherein the grid layer is an external layer reinforcing the panel and rendering it impact resistance.

13. The panel of any one of claims 1 to 12, wherein the grid layer is integrally molded with a flexible portion constituting a flexible hinge articulated to a neighboring panel member.

14. The panel of any one of claims 1 to 13, wherein the panel is configured such that the carrier layer is an inner layer and the grid layer is external, whereby the sheet layer is visible through openings at an external face of the panel.

15. An article comprising a frame portion integrally molded with at least a panel portion, said panel portion being a panel according to any one of claims 1 to 14.

16. A method for molding a panel member, the method comprising the following steps:

b) applying a sheet material over at least a molding portion the female mold member and securing it by the sheet material gripping arrangement;

17. The method of claim 16, wherein said application at step (d) is by injection molding.

18. The method of claim 16 or 17, wherein after the molded panel is sufficiently cured, the male mold member is removed from the female mold member and the panel member is removed, wherein the resulting panel comprises a rigid carrier layer, a sheet layer disposed over at least a portion thereof, and a grid layer integrally molded with said carrier layer through said sheet layer and exposing portions of the sheet layer.

19. The method of any one of claims 16 to 18, wherein the female mold member is further configured with one or more cavities for creating one or more functional zones at the panel member, said functional zones extending at the grid layer of said panel.

20. The method of any one of claims 16 to 19, wherein the sheet material gripping arrangement is an array of gripping pins.

21. The method of claim 20, wherein the gripping pins are biased to project from an inside surface of the female mold member.

22. The method of claim 20 or 21, wherein the gripping pins fully retract into the female mold member upon positioning of the male mold member within the female mold member at the molding position.

23. The method of any one of claims 20 to 22, wherein the gripping pins are displaceable between a projecting position at which they project from a surface of the female mold member and are configured for gripping the sheet material, and a retracted potion at which they retract simultaneously as the male mold member is introduced into the female mold portion.

24. The method of any one of claims 16 to 23, wherein the sheet material is applied over the female mold member by a robotic manipulator configured in turn with a sheet material gripping mechanism for transferring the sheet material and applying it over the female mold member.