Blow molded article comprising compression molded article

Abstract

A molded boat is provided that includes a plastic body having an integral one-piece construction. The plastic body also includes a substantially hollow interior and a part line extending along a portion of a circumference of the molded boat. The molded boat also includes a solid compression molded piece that is integral with the plastic body. The solid compression molded piece is configured and arranged such that the part line is not connected with the solid compression molded piece.

Description

[0001] This application is a divisional application of the invention patent application filed by the applicant on April 17, 2019, with patent application number 201780064114.4 and title "Blow Molded Part Including Compression Molding Part", the entire contents of which are incorporated herein by reference. Invention Field

[0002] This invention generally relates to blow-molded structures and any devices incorporating blow-molded structures, without limiting or restricting the specific properties of any particular blow-molded structure. Therefore, exemplary embodiments included within the scope of this application include, but are not limited to, water sports equipment and boats (such as kayaks and surfboards), tables (including picnic tables), chairs, storage sheds, sports field equipment, and storage boxes for decks and patios. More specifically, exemplary embodiments of the invention relate to blow-molded structures or blow-molded parts comprising one or more integrally compressed molded parts. Background Technology

[0003] Blow molding can be used to produce a wide variety of structures. In some cases, it is useful to include compression molded parts within a blow-molded structure. Depending on their properties and structure, some compression molded parts already incorporated into the blow-molded structure may be subject to certain restrictions regarding their position within the structure. Furthermore, compression molded parts are typically confined to a specific orientation. In particular, conventional compression molded parts are confined to a plane parallel to the parting line of the blow-molded part (i.e., the dividing line between the mold halves).

[0004] Given these kinds of problems, it is essential to be able to include compression molded parts in blow molding structures without being limited by the orientation, position, or construction of the compression molded parts.

[0005] A brief overview of some aspects of example embodiments

[0006] The disclosed embodiments generally relate to blow molding structures and any equipment incorporating blow molding structures, without limiting or restricting the specific nature of any particular blow molding structure. These blow molding structures may include one or more compression molded parts integrally formed as part of the blow molding structure during the blow molding process. Compression molded parts may exhibit a variety of different configurations and orientations and may be located anywhere within the blow molding structure. Thus, for example, some embodiments include one or more compression molded parts that are typically located in a plane not parallel to the plane containing part or all of the parting line. In some embodiments, the parting line may be horizontal or vertical.

[0007] The embodiments disclosed herein (some examples of which are described below) do not constitute an exhaustive overview of all possible embodiments, nor does this overview constitute an exhaustive enumeration of all aspects of any particular embodiment. Rather, this overview simply presents selected aspects of some exemplary embodiments. It should be noted that nothing herein should be construed as constituting a fundamental, critical, or essential element of any invention or embodiment. Rather, it will be readily understood by those skilled in the art that various aspects of the disclosed embodiments can be combined in various ways to determine further embodiments. These further embodiments are included within the scope of this disclosure. Furthermore, any embodiment included within the scope of this disclosure should not be construed as solving any particular problem or as limiting itself to a solution to any particular problem. Nor should these embodiments be construed as achieving any particular effect or as limiting itself to the implementation of any particular effect.

[0008] In particular, exemplary embodiments within the scope of this disclosure may include any combination of one or more of the following components: a blow molding structure comprising one or more compression molded parts integral with the blow molding structure and having a one-piece construction; a blow molding structure comprising a one-piece compression molded part and having a one-piece construction, the one-piece compression molded part being generally located in a plane not parallel to the plane containing part or all of the parting lines of the blow molding structure; and a blow molding structure comprising a one-piece compression molded part and having a one-piece construction, the one-piece compression molded part being generally located in a plane perpendicular to the plane containing part or all of the parting lines of the blow molding structure. A blow molding structure comprising a one-piece compression molded part and having a one-piece construction, the one-piece compression molded part being generally located in a plane parallel to the parting line plane of the blow molding structure; a blow molding structure comprising a one-piece compression molded part and having a one-piece construction, the one-piece compression molded part being generally planar with a pair of generally parallel surfaces; a blow molding structure comprising a one-piece compression molded part being generally non-planar and having a one-piece construction; a blow molding structure comprising a one-piece compression molded part having a solid (i.e., non-hollow) construction and having a one-piece construction; a blow molding structure comprising a one-piece compression molded part and having a one-piece construction. A blow molding structure with a single-piece construction, wherein the integral compression molded part is not formed by a mold used to produce other parts of the blow molding structure; a blow molding structure including an integral compression molded part and having a single-piece construction, wherein the integral compression molded part is entirely formed by a mechanism other than a mold used to produce other parts of the blow molding structure; a blow molding structure including an integral compression molded part and having a single-piece construction, wherein the integral compression molded part is partially formed by a mechanism other than a mold used to produce other parts of the blow molding structure; a blow molding structure including an integral compression molded part and having a single-piece construction, wherein the integral compression molded part is located... A blow molding structure located at or near the non-edge of a blow molding structure; a blow molding structure comprising an integral compression molded part and having an integral single-piece construction, the integral compression molded part being located at or near the non-parting line of the blow molding structure; a blow molding structure comprising an integral compression molded part and having an integral single-piece construction, the integral compression molded part being located at or near the non-edge of the blow molding structure, and the integral compression molded part including one or more holes, recesses and / or notches formed during the blow molding process; and a blow molding structure comprising an integral compression molded part having holes or recesses and having an integral single-piece construction.

[0009] Embodiments within the scope of this disclosure also include a blow molding process that can be used to produce any of the disclosed blow-molded structures. Other embodiments within the scope of this disclosure relate to a tool having one or more movable portions, such that when the tool is placed within a mold and the mold and tool are used in a blow molding process, one or more movable portions of the tool can be used to produce a compression-molded part. Therefore, embodiments within the scope of this disclosure also include a method for simultaneously and integrally forming one or more compression-molded parts with a blow-molded structure, and the compression-molded part can be located at any position within the blow-molded structure.

[0010] In any of the disclosed embodiments, the blow molding structure may be a substantially hollow, one-piece construction and / or a one-piece construction including a substantially hollow portion. Therefore, these embodiments may have a partially or completely hollow interior. These embodiments also include one or more recesses (sometimes referred to as "tack-offs") disposed within the interior. In these embodiments, these tack-offs, as part of the one-piece construction, may be integrally formed during the blow molding process. The recesses may extend from a first inner surface of the blow molding structure to a second inner surface of the blow molding structure. The ends of one or more recesses may contact or engage with the second surface, or the ends of one or more recesses may be spaced apart from the second surface. In some cases, one or more recesses on the first inner surface may be substantially aligned with corresponding recesses on the second inner surface, one or more recesses on the first inner surface may contact corresponding recesses on the second inner surface, or one or more recesses on the first inner surface may be spaced apart from corresponding recesses on the second inner surface. In other cases, contacting recesses and spaced-apart recesses may coexist in the blow molding structure. The size and construction of these recesses can reinforce and / or strengthen blow-molded structures.

[0011] The following is a brief list of various example embodiments within the scope of this disclosure. Other example embodiments are disclosed elsewhere herein.

[0012] In one example embodiment, the hollow plastic body includes one or more integrally compressed parts.

[0013] In another example embodiment, the one-piece plastic structure includes one or more integral compression-molded parts.

[0014] In another example embodiment, the blow molding structure includes a one-piece compression molded part.

[0015] In another example embodiment, the blow molding structure includes an integral compression molded part located in a plane that is not parallel to the plane containing a portion of the parting line of the blow molding structure.

[0016] In another example embodiment, the blow molding structure includes an integral compression molded part located in a plane that is at least approximately parallel to the plane containing a portion of the parting line of the blow molding structure.

[0017] In another example embodiment, the blow molding structure includes a compression-molded part that is generally planar in structure.

[0018] In another example embodiment, the blow molding structure includes an integral compression molded part that is generally non-planar in structure.

[0019] In another example embodiment, the blow molding structure includes an integral compression molded part that can be located anywhere in the blow molding structure.

[0020] In another example embodiment, the blow molding structure includes an integral compression molded part with an opening or a recess.

[0021] In another example embodiment, the blow molding structure includes a monolithic compression molded part having one or more surfaces with patterns and / or textures.

[0022] In another example embodiment, the blow molding structure includes an integral compression molded part and a recess.

[0023] In another example embodiment, the structure having a one-piece compression molded part is produced by one of the following processes: roll forming, thermoforming, vacuum molding, two-piece molding, or encapsulation molding.

[0024] In another example embodiment, the blow molding process and the compression molding process are used to produce any of the blow-molded structures in the above embodiments.

[0025] In another example embodiment, a method for simultaneously producing a compression-formed part and a blow-formed structure is provided, such that the compression-formed part and the blow-formed structure are integrally formed, and the compression-formed part can be located at any position of the blow-formed structure.

[0026] In another example embodiment, a tool comprising one or more movable portions is provided such that when the tool is placed in a mold, during the process of producing a blow-molded structure in a blow molding process, the one or more movable portions of the tool operate to form a compression-molded part integral with the blow-molded structure.

[0027] In another example embodiment, a tool comprising a plurality of movable parts is provided such that when the tool is placed in a mold, during the process of producing a blow-molded structure in a blow molding process, the plurality of movable parts of the tool operate to form a compression-molded part integral with the blow-molded structure.

[0028] In another example embodiment, a tool comprising a movable portion and a fixed portion is provided such that when the tool is placed in a mold, during the blow molding process to produce a blow-molded structure, the movable portion of the tool cooperates with the fixed portion to form a compression-molded part integral with the blow-molded structure.

[0029] In another example embodiment, a tool including a movable portion is provided such that when the tool is placed in a mold, during the blow molding process to produce a blow-molded structure, the movable portion of the tool cooperates with a portion of the mold to form a compression-molded part integral with the blow-molded structure.

[0030] In another example embodiment, a tool including a movable portion is provided such that when the tool is placed in a mold, the movable portion of the tool is located on the core side of the mold and cooperates with a portion of the cavity side of the mold during the blow molding process to form a compression molded part integral with the blow molding structure.

[0031] In another example embodiment, a component comprising more than two compression members is provided, wherein each compression member does not include a mold portion.

[0032] In another example embodiment, a component comprising more than two compression members is provided, wherein one or more of these compression members include a portion of a mold.

[0033] In another example embodiment, a component comprising more than two compression members is provided, wherein one or more of these compression members are movable relative to one or more other compression members. Attached Figure Description

[0034] The accompanying drawings include illustrations of exemplary embodiments to further illustrate and clarify the above and other aspects, advantages, and features of the invention. It should be understood that these drawings depict only exemplary embodiments of the invention and are not intended to limit its scope. The invention will be described and explained with additional features and details using the accompanying drawings, in which:

[0035] Figure 1 A comparison of the top perspective view of an example of a compression molded part located in a plane parallel to the plane containing part of the parting line and the top perspective view of an example of a compression molded part located in a plane not parallel to the plane containing part of the parting line.

[0036] Figure 2 A side view of an example blow molding structure containing a compression molded part located in a plane that is not parallel to the plane containing a portion of the parting line;

[0037] Figure 3 yes Figure 2Detailed view of an example compression-formed part;

[0038] Figure 4 yes Figure 2 Bottom view of the area near the compression-formed part;

[0039] Figures 5-9 Disclose aspects of a tool according to an example embodiment;

[0040] Figure 9A Several aspects of some example compressors and geometric features such as gaps that may be defined by these example compressors are disclosed;

[0041] Figures 10-12 Several aspects of the tool according to another example embodiment are disclosed;

[0042] Figures 13-14 Several aspects of the tool according to yet another exemplary embodiment are disclosed;

[0043] Figures 15-16 Several aspects of the sample half-model and corresponding tools have been disclosed;

[0044] Figures 17-19 Several aspects of the tool according to yet another exemplary embodiment are disclosed;

[0045] Figures 20-23 Several aspects of the tool, in yet another example embodiment, are disclosed;

[0046] Figure 24 The flowchart discloses an example embodiment of the production method; and

[0047] Figure 25 It is a block diagram of an example component containing more than two compression parts.

[0048] Detailed description of example embodiments

[0049] Embodiments of the present invention generally relate to blow-molded structures comprising one or more integral compression-molded parts. In some specific examples, one or more embodiments take the form of boats, such as surfboards, kayaks including sit-on-top and sit-inside versions, and structures such as tables (including picnic tables), chairs, storage sheds, sports field equipment, bases and backboards of basketball systems, coolers, and storage boxes for decks and patios. However, more generally, the scope of the invention is not limited to any of the foregoing example structures, but includes any blow-molded structure and any device comprising one or more blow-molded structures. In some embodiments, the compression-molded part is a solid structure rather than a hollow structure, which is relatively more robust than a hollow part of similar construction, and therefore the compression-molded parts disclosed herein may be very useful.

[0050] A. General aspects of some example structures

[0051] Exemplary molded structures within the scope of this disclosure can be made of any suitable material, including plastics such as high-density polyethylene (HDPE). According to embodiments, the molded structure can be formed by any one or a combination of blow molding, roll forming, thermoforming, vacuum molding, two-piece molding, or overmolding. The molded structure can be hollow, or at least comprise one or more hollow portions. These hollow portions may include one or more hollow sections, and / or be wholly or partially defined by one or more hollow sections. Furthermore, in the further detailed discussion below, the molded structures within the scope of this disclosure include one or more compression-formed parts integral with the molded structure.

[0052] Now for reference Figures 1-4 It provides details about some exemplary structures. Figure 1 Example blow molding structures 100 and 150 are shown. Blow molding structure 100 includes a compression molded part 102 at its edge. It can be seen that the compression molded part 102 lies in a plane generally parallel to the plane containing the parting line 104 of the blow molding structure 100. Typically, the parting line 104 is created by joining two mold halves together as part of a blow molding or other molding process.

[0053] The compression molded part 102 is constructed and positioned such that the edge of the mold (not shown) forming the blow molding structure 100 produces the compression molded part 102. Since the half-mold (not shown) joins together to form the compression molded part 102 and simultaneously defines the parting line 104, the compression molded part 102 necessarily lies in a plane parallel or substantially parallel to the plane containing part or all of the parting line 104. In the illustrated example, the compression molded part 102 also includes a hole 102a formed by drilling after the molding structure is removed from the mold. It is evident from the blow molding structure 100 that the parting line 104 defines at least a portion of the boundary of the compression molded part 102, and / or is located at the boundary of the compression molded part 102. In other words, the parting line 104 is connected to the compression molded part 102, contacts the compression molded part 102, is disposed on the compression molded part 102, and / or forms part of the compression molded part 102.

[0054] In comparison, these features are not necessarily present in the blow molding structure 150 discussed below. In other words, in at least some embodiments of the invention, the blow molding structure 150 is merely an illustrative example, and the parting line 154 is not connected to the compression molded part, does not contact the compression molded part, is not disposed on the compression molded part, and / or does not form any part of the compression molded part. Typically, the parting line 154 is an integral plastic structure formed by stitching together half-molds as part of a blow molding process or other molding process. The parting line 154 may, if only slightly, extend outward from the surface of the blow molding structure 150. In some cases, the parting line 154 may take the form of a small ridge, and one or more of its physical properties (including height, thickness, and end edge) may be non-uniform. Furthermore, the parting line 154 may be a continuous or unbroken structure, in which case the parting line 154 may extend completely around the perimeter of the blow molding structure 150. In addition, the parting line 154 may also have a discontinuous structure that breaks at one or more locations.

[0055] As illustrated in this example, the method reflected by the blow molding structure 100 is limited to producing compression molded parts, such as compression molded parts 102 located at or near the edge 106 of the blow molding structure 100. In other words, the compression molded part 102 defines a portion of the edge 106 of the blow molding structure 100. For example, another limitation of the structure of the example blow molding structure 100 is that some features (such as holes 102) must typically be produced by a separate process after molding is complete.

[0056] Compared to the exemplary blow molding structure 100, the blow molding structure 150 includes a compression molded member 152 that lies in a plane that is not parallel to the plane containing part or all of the parting line 154. For example, in this particular embodiment, the plane containing the compression molded member 152 is substantially perpendicular to the plane containing the parting line 154, although any other arrangement in which the compression molded member is not parallel to the plane associated with the parting line may be used.

[0057] Therefore, although the formation of the void involves compression molding, the compression involved in forming the void is formed only by a half-mold, not by the tools and methods disclosed herein. Accordingly, the compressed portion of the void is typically located in a plane parallel to the parting line corresponding to the structure containing the void. Thus, it is apparent that the structures, functions, and methods provided by the disclosed embodiments exhibit advantages beyond those associated with the void, and the compression molded part 152 includes an integrally formed hole 152a, but this is not mandatory. In other embodiments, the compression molded part 152 may include a notch, or may not have a notch or hole at all. The hole 152a is formed during the molding process, not after the molding process as in the blow molding structure 100. In short, the tool in this example is located in the mold and is used to compress the partially molten plastic present in the mold between a pair of elements to form the compression molded part 152.

[0058] In the illustrated example, the compression-formed part 152 is associated with a pair of recesses 155, although such recesses are not required or present in all embodiments. Figure 4 This is a bottom view of the compression molded part 152 and the recess 155, seen from inside the blow molding structure 150. Figures 1-4 It can be further concluded that one or two recesses 155 can be configured to form a concave or recessed structure on the surface of the blow-molded structure (e.g. Figures 1-3 Alternatively, it can be constructed to form a convex or convex structure inside the blow molding structure (such as...). Figure 4 ).

[0059] Generally, and as discussed in more detail below, recesses 155 can be formed by tools, for example (but not limited to) as part of the blow molding process. That is, recesses 155 and / or other features disclosed herein may have features of the configuration and / or operation of the tools used to form the compression molded part 152. Therefore, in conventionally produced blow molded structures, features such as recesses 155 do not coexist with the compression molded part, as exemplified by the blow molded structure 100 described above. Furthermore, in some embodiments, recesses 155 may also be mirror images of each other, although this is not mandatory. In other embodiments, only a single recess may exist. As further shown, the entire compression molded part 152 in the illustrated example is located within a sleeve defined by the outer edge and surface of the blow molded structure 150. And as described above, the compression molded part 102 must be located near or defining a portion of the edge 106 of the blow molded structure 100. Therefore, compared with the method reflected in the blow molding structure 100 example, the method reflected in the blow molding structure 150 example is more flexible in terms of the construction, orientation and position of the compression molded part in the blow molding structure.

[0060] B. General aspects of some example tools

[0061] Continue to refer to Figures 1-4 And also refer to Figures 5-9 According to various exemplary embodiments of the invention, details are provided regarding some exemplary tools for producing compression-formed structures. One exemplary tool, generally designated 200, includes a dynamic compressor 202. The dynamic compressor 202 cooperates with a static compressor 204 to define various aspects of the corresponding compression-formed structure. Other embodiments may employ a pair of dynamic compressors, each movable relative to the other, instead of... Figures 5-9 The static and dynamic compression components in the illustrated embodiment are shown. The dynamic and static compression components 202 and 204 can be made of suitable materials, including metals such as aluminum, aluminum alloys, steel, and stainless steel. Furthermore, the dynamic and static compression components 202 and 204 can also be manufactured by appropriate processes or procedures, including casting, machining, stamping, and forging.

[0062] Generally, the dynamic compressor 202 and the static compressor 204 are constructed or configured such that the dynamic compressor 202 has a defined range of motion and is capable of moving toward and away from the static compressor 204. In the illustrated example, the motion of the dynamic compressor 202 is essentially rotational. However, in other embodiments, the motion of the dynamic compressor 202 is essentially linear. Regardless of the embodiment, the range of motion of the dynamic compressor can be defined as needed, and the scope of the invention is not limited to any particular linear or rotational range of motion.

[0063] In the example shown, the dynamic compressor 202 is rotatably connected to the arm 220, which can move backward and forward via an intermediate connector 222, which can be directly or indirectly connected to a motor, for example. The dynamic compressor 202 can also rotate about a fixed axis 224 relative to the static compressor 204, which can be defined by, for example, a shaft or pin.

[0064] Referring again to the accompanying drawings, the dynamic compression member 202 and the static compression member 204 are configured or arranged to define a gap 205 between the dynamic compression member 202 and the static compression member 204 when the dynamic compression member 202 is in the position closest to the static compression member 204. The gap 205 thereby defines the thickness of the compression-formed part, which is formed by the mating of the dynamic compression member 202 and the static compression member 204. As described below, it should be understood that aspects of the compression-formed part can be obtained by appropriately constructing any or all of the corresponding portions of the dynamic compression member 202 and the static compression member 204 that define the gap 205.

[0065] As an illustration, both dynamic and static compression members 202 and 204 include their respective planes 202a and 204a, but other shapes and constructions may also be used, such as... Figure 9AAs shown. Furthermore, the surfaces within the scope of this disclosure can be smooth or textured in some way. In any case, as the dynamic compression member 202 moves toward the static compression member 204, the molten plastic between the two surfaces 202a and 204a will be compressed into a configuration comprising two flat sides, as in the case of the exemplary compression molded member 152 discussed above. Furthermore, one or both of the surfaces 202a and 204a may include additional elements that can be used to define the characteristics of the resulting compression molded member.

[0066] As an illustration, the exemplary dynamic compression member 202 includes one or more protrusions (such as pins 202b) configured and arranged to contact surface 204a when the dynamic compression member 202 is in its closest position to the static compression member 204. In other embodiments, pins 202b may be part of the static compression member 204, rather than part of the dynamic compression member 202. However, in either case, pins 202b may be used to form a hole in the compression-formed member (such as hole 152a discussed above).

[0067] From this disclosure as Figure 5 The examples shown clearly demonstrate that the length of a component, such as pin 202b, can define the minimum width of a gap (e.g., gap 150). Consistently, other aspects of the geometry of a component, such as pin 202b, can define corresponding aspects of the hole in the compression-formed part formed by connecting with pin 202b (e.g., the shape and diameter of the hole). However, in some alternative embodiments, pins or other protrusions can also be omitted from the surfaces (e.g., surfaces 202a and 204a). That is, the surfaces (e.g., surfaces 202a and 204a) may have no or substantially no protrusions or other projections. In these alternative embodiments, other structures or mechanisms can be used to define, for example, the range of travel of the dynamic compression member 202 relative to the static compression member 204. Therefore, these alternative embodiments can produce compression-formed parts that do not contain any holes or other openings.

[0068] Brief Reference Figure 9A It is understood that a wide variety of compression-formed parts can be produced according to the present invention. As shown, example compression-formed parts can be defined by the construction of various gaps 250 determined by the geometry of the corresponding compression-forming tool, which may: have varying thickness at different points in cross-section; be planar or non-planar; include or not have holes and / or notches; include smooth and / or textured surfaces; have non-uniform shapes; include one or more protrusions; include one or more grooves or channels; or include any combination of the foregoing.

[0069] For reference Figures 10-12Details are provided regarding another example embodiment of the tool 300 that may be employed. Since tool 300 may be similar to or equivalent to tool 200 in some respects, the following discussion focuses only on selected differences in tool 300. Similar to tool 200, tool 300 may include two compressors 302 and 304 that, in the blow molding process, collectively define a plastic-filled gap 306. The plastic in gap 306 can be compressed as one or both of compressors 302 and 304 move toward the other. As shown, compressor 302 may be a dynamic compressor that moves toward a static compressor 304, and one or the other of compressors 302 and 304 may include a component (such as pin 308) capable of forming a hole (such as hole 152a discussed above) in the compression-molded part.

[0070] In the illustrated example, compression members 302 and 304 can have similar constructions, thus forming one or more recesses during the molding process (see...). Figure 3 and Figure 4 (marked 155 in the text), compression parts 302 and 304 are relative to compression-formed parts (see...). Figure 3 and Figure 4 The marking 152) indicates a symmetrical construction and arrangement. In contrast, compression components 202 and 204 can also have their own different constructions. For example... Figures 10-12 As illustrated in the illustrative example, some or all of the compression member 302 may be housed within the compression member 304. Furthermore, compression members 302 and 304 may include respective surfaces 302a and 304a, which may be curved, planar, or a combination of both and slide against each other at the interface location “I”. As shown, surface 304a defined by compression member 304 may be part of a recess 310 or channel that at least partially houses compression member 302. In some instances, the width of the gap between the respective surfaces of the two compression members (such as surfaces 302a and 304a) ranges from about 0.003 inches to about 0.01 inches.

[0071] The relatively tight fit between these respective surfaces 302a and 304a helps ensure that little or no molten plastic overflows from the bottom of the gap 306 during molding. Therefore, a relatively clean compression molded part can be produced, requiring relatively less post-processing finishing compared to other cases. Furthermore, preventing the overflow of compressed plastic from the gap 306, for example through the relatively tight fit between surfaces 302a and 304a, helps ensure that the desired thickness of the compression molded part is achieved and maintained during molding.

[0072] For reference Figure 13 and Figure 14Another example construction of tool 350 is disclosed. Except as described in the discussion below, tool 350 may be similar to or the same as tool 200. Therefore, tool 350 may include a dynamic compressor 352, and its relationship with respect to the static compressor 354 is... Figure 13 and Figure 14 The respective positions shown are rotatably movable. As described in more detail elsewhere in this document, the dynamic compression member 352 can be in a position prior to the start of the blow molding process. Figure 13 The position shown is such that the dynamic compression member 352 can be moved to the position shown in the blow molding process. Figure 14 The position shown in the diagram allows molten plastic to be obtained in gap 355 and compressed to form a compression molded part.

[0073] The dynamic compressor 352 may include one or more protrusions 352a (such as pins) that are configured or arranged to contact the static compressor 354 when the dynamic compressor 352 is in its closest position relative to the static compressor 354. As shown, the dynamic compressor 352 is at least partially contained within a housing 356 that defines or includes the static compressor 354. As further shown, the gap 358 between the dynamic compressor 352 and the static compressor 354 is relatively small, thus substantially or completely preventing molten plastic from entering between the two compressors.

[0074] Next reference Figures 15-19 This provides details of other example embodiments of tools that can be used to produce compression-formed parts in relation to the blow molding process. First, refer to... Figure 15 and Figure 16 This demonstrates that tools, such as those disclosed in the example embodiments herein, can be placed at any position and in any orientation within a mold suitable for blow molding processes. Therefore, such tools and related methods can be used to produce compression-formed parts integral with the blow molding structure at any position or orientation within the blow molding structure. In this way, the compression-formed parts can be produced substantially simultaneously with the blow molding structure.

[0075] More specifically, for example, the half-die that can be used in the blow molding process. Figures 15-16 Generally designated 400, the first and second compression members 402 and 404 are disposed within the half-mold 400. Similar to some other disclosed embodiments, the first compression member 402 is rotatable relative to the fixed-position second compression member 404. More specifically, the first compression member 402 may be rotatable relative to the fixed-position second compression member 404. Figure 15 and Figure 16 Rotate back and forth between the indicated positions. As shown in the figure. Figure 16 The gap 406 between the first compression member 402 and the second compression member 404 is greater than that between the two compression members. Figure 15 The relative size is larger in some embodiments (such as...). Figure 15In the example, the minimum width of gap 406 may be defined, for example, by the length of pin 407.

[0076] At or approximately at the start of the blow molding process, the first compression piece 402 can be... Figure 16 The position shown. In the blow molding process, the first compression member 402 can be moved to the position shown. Figure 15 The position indicated is such that it engages with the second compression member 404 to compress the softened or partially softened plastic in the gap 406 to produce a compression-molded part, which is integral with the blow molding structure formed by the combined half mold 400. In some embodiments, the first compression member 402 extends (i.e. moves) to the position approximately 10 to 15 seconds after the preform expansion begins. Figure 15 The aforementioned position. At or approximately upon completion of the blow molding process, the first compression member 402 can be retracted (i.e., moved back). Figure 16 The position shown is such that the blow molding structure can be moved back and integrated with the compression molded part from the half mold 400.

[0077] As can be seen from the foregoing discussion, Figure 15 and Figure 16 All the half-mold structures 400 shown, as well as the first and second compression members 402 and 404, can come into contact with the softened plastic at a point during the blow molding process. It can be seen that the compression-molded component integral with the blow-molded structure can be formed during the blow molding process from components other than the half-molds 400 (i.e., the first and second compression members 402 and 404) used to generate the blow-molded structure. In other words, by contrasting with the example blow-molded structure 100 discussed above, according to embodiments of the invention, forming a compression-molded structure can be achieved without the compression action between the half-molds (such as half-molds 400) of the mold.

[0078] Next reference Figures 17-19 Details are provided regarding other example embodiments of tools (illustrated as reference 450) that can be used to produce compression-formed parts in blow-molded structures. Figures 17-19 In the example, one or more dynamic compressors 452 are provided and configured to move linearly relative to a common static compressor 454. The dynamic compressors 452 can move in unison or alternately (e.g., ...). Figure 17 This is used in conjunction with the static compression member 454 to produce a compression-formed part that serves as a blow molding structure. For example... Figures 17-19 As shown, the dynamic compression member 452 can be independently controlled by its respective control mechanism 456. Alternatively, the dynamic compression member 452 can be controlled by a common control mechanism. Furthermore, the dynamic compression member 452 may or may not include protruding structures 458 (e.g., pins). See also: Figure 17 and combined Figures 15-16Note that all components of the half mold 460 and the dynamic compression component 452 may come into contact with the softened plastic at some point during the blow molding process.

[0079] In an alternative embodiment (not shown), two dynamic compression members 452 may be configured back-to-back along their respective static compression members 454. This configuration can simultaneously produce two generally parallel compression-formed parts. Depending on the configuration of the dynamic compression members 452 and the corresponding static compression members 454, the resulting compression-formed parts may be identical or different from each other. In an alternative to the foregoing scheme, the compression members 452 and 454 may be configured such that the resulting compression-formed parts are not parallel to each other.

[0080] As will be apparent from this disclosure, the disclosed tools are exemplary structural implementations of means for producing integral compression molded parts in a molded structure (e.g., a blow molding structure). Thus, in some exemplary embodiments, these means can produce integral compression molded parts without using any part of the mold (e.g., a mold half). Furthermore, integral compression molded parts may be produced without requiring or using compression of plastic between two mold halves. Any other mechanism or device having similar functionality to the disclosed tools may be used as an alternative.

[0081] Now for reference Figures 20-23 Details are provided regarding other example embodiments of tools (one of which is indicated by 500) that can be used to produce compression-formed parts in blow molding structures. As shown, tool 500 can be used in conjunction with mold 600 that includes a half-mold (e.g., a cavity-side half-mold 602 that can be used in a blow molding process). In this example, the core-side half-mold that mates with the cavity-side half-mold 602 of mold 600 is not shown. This particular example of mold 600 is used for manufacturing boats (such as kayaks). However, any other mold construction may be employed as an alternative. Example tool 500 may be similar in some respects to tool 200 discussed earlier. Therefore, the following discussion will focus primarily on selected differences between these two embodiments.

[0082] Special Reference Figure 21 The tool 500 may include a housing 502 having two separable housing halves 504, which are in turn detachably connected to a portion of the cavity-side mold half 602. Although the tool 500 is shown attached to the cavity-side mold half 602, in blow molding and compression molding processes, a significant portion of the tool 500 is actually located in the core-side mold half (not shown).

[0083] like Figure 22 and Figure 23As shown, the housing halves 504 cooperate to define an inner portion 506, and the dynamic compression member 508 of the tool 500 is rotatably mounted in the inner portion 506, for example, via a shaft 510. The dynamic compression member 508 includes a protrusion 512 (e.g., a pin), and the range of rotational movement of the dynamic compression member 508 about the shaft 510 is defined by the dimensions and construction of the inner portion 506. More specifically, the inner wall 512 is used to define and constrain the degree to which the dynamic compression member 508 can rotate.

[0084] like Figure 23 As shown, the dynamic compression member 508 is only partially housed within the inner portion 506, with the portion of the dynamic compression member 508 including the protrusion 514 located on the outer side of the inner portion 506. This arrangement allows the protrusion 514 to selectively move in directions toward and away from the structure 604 of the cavity-side mold 602 associated with the compression molding process.

[0085] More specifically, the compression molded part is formed in a blow molding process or other type of molding process, in which the dynamic compression member 508 rotates counterclockwise toward the structure 604 until the protrusion 514 approaches or contacts the structure 604, thereby compressing the plastic between the structure 604 and the surface 508a from which the protrusion 514 extends from the dynamic compression member 508. In this example, since the structure 604, as part of the compression molding process, does not move, the structure 604 is a static compression member, and the dynamic compression member 508 moves relative to the structure 604. In this way, a compression molded part containing a recess or hole is produced, and the compression molded part is produced by the cooperation of the tool 500 (i.e., the dynamic compression member 508) and the mold 600 (i.e., the structure 604 of the cavity-side half mold 602).

[0086] C. Further aspects of some example tools

[0087] As noted in the discussion of various embodiments of the tool herein, the tool can be used in conjunction with a blow molding process to produce a monolithic compression molded part at any location within a given blow molding structure. Various embodiments of the tool involve defining a gap that defines the flow of plastic into which it is subsequently compressed. Because the plastic is in a softened or molten state when it enters the gap, it may be susceptible to burst holes (i.e., pores in the plastic) if it is stretched too thin during compression molding. Therefore, the dimensional parameters of the gap (e.g., width, length, and depth) should be chosen to ensure that the compression molded part has sufficient thickness, but not so thick / deep / wide as to create burst holes during compression molding.

[0088] For example, it has been found that in certain cases, for gaps with a generally rectangular cross-section having a perimeter of 3X (where X is the width and depth of the gap), better results can be obtained when the ratio 1 / 3X is less than about 2. Therefore, at least in some embodiments, better results are obtained when X is less than about 1 / 6 or about 0.167. However, the scope of the invention is not limited to these example dimensions or the relationship between dimensions.

[0089] It should also be noted that even if the size and configuration of the gaps could potentially create burst holes, the tools used to produce compression-molded parts can be configured to reduce or avoid the likelihood of burst holes. For example, a tool with two dynamic compressors can be operated such that each compressor pulls some plastic into the gap between the two compressors. Because the plastic is pulled out from two areas rather than one, burst holes are virtually impossible.

[0090] Other parameters (such as time-related parameters) can also be used to help ensure the formation of compression molded parts without causing accompanying problems or at least reducing the likelihood of such problems occurring. For example, relatively better results can be obtained by delaying the movement of the dynamic compression member to about 10 to 15 seconds after the preform expansion begins. This delay helps ensure that the softened plastic of the preform is in substantially contact with all parts inside the mold half and the compression member located in one or more mold halves.

[0091] D. Several aspects of some example methods

[0092] As disclosed herein, some example embodiments of the manufacturing method relate to the generation of a blow molding structure comprising one or more integral compression molded parts. The compression molded parts can be formed simultaneously with the blow molding structure integral therewith.

[0093] Generally, reference Figure 24 An example manufacturing method is shown as 700. Method 700 can begin when a tool (examples of which are disclosed herein) is placed or attached to a portion of a mold (e.g., the core-side half or cavity-side half of the mold) (illustrated as 702). Next, a preform of softened plastic is formed, for example, by extrusion using a blow molding machine (illustrated as 704), and the mold is closed around the preform (illustrated as 706). The preform is then expanded (illustrated as 708) such that the plastic is substantially in contact with part or all of the interior of the mold, and also with the tool. In some cases, a pre-blowing process is performed prior to the expansion of the preform 708.

[0094] After a suitable time interval (examples of which are disclosed herein), the tool is operated to produce a compression-formed part (illustrated as 710) integral with the blow molding structure. Operation of tool 710 may involve rotational and / or linear movement of one or both of the first and second compression members toward the other, such that the plastic in the mold is compressed between the two compression members. In a particular example embodiment, the tool may be operated for approximately 20 seconds (illustrated as 710) after the preform expands 708, but shorter or longer time intervals may also be used. The compression-formed part is located within the mold and, at least in some cases, is formed at an edge of the blow molding structure or outside the parting line. The compression-formed part may be located in a plane that is not parallel to the plane containing part or all of the parting line.

[0095] After the compression-formed part 710 is produced, it can be released from the tool after a time interval (illustrated as 711). In some example embodiments, this time interval may be approximately 60 seconds, but shorter or longer time intervals may also be used. The release 711 of the compression-formed part may involve a linear and / or rotational movement of the first compression member away from the second compression member, such that the compression-formed part is no longer held between the first and second compression members. As disclosed herein, both the first and second compression members may move relative to each other, or only one of the first and second compression members may move relative to the other.

[0096] After the compression molding part 711 is released by the compression component, the blow molding structure (shown as 712) including the integral compression molding part can be removed from the mold.

[0097] E. Some alternative embodiments

[0098] Final Reference Figure 25 Another example embodiment, typically denoted as 800, is disclosed herein. Compared to some other embodiments disclosed herein, configuration 800 includes more than two compression components. Thus, Figure 25 The arrangement of the example shown can produce multiple compression molded parts, each of which is integrally formed as part of a single blow molding process that forms a single blow molded structure. Figure 25 The exemplary arrangement can also be used with other molding processes, and is not limited to use with blow molding processes.

[0099] Therefore, from Figure 25 It is clear that a wide variety of alternative tools and structures are possible. To illustrate, Figure 25 Any three or more example compression pieces disclosed herein may be used together in a given tooling and / or die construction to produce two or more compression-formed pieces in a given molding structure.

[0100] Although the individual compression components (compression components 802...806) are shown as being arranged linearly, this is not necessary. Therefore, in one example arrangement, compression component 808 can be provided that is arranged non-linearly relative to compression components 802 and 804. Furthermore, one or more compression components (e.g., compression components 810 and 812) can be provided, which cooperate with one or more other compression components (such as compression component 808) to produce one or more compression-formed parts integral with the blow molding structure. Compression components 810 and 812 can operate uniformly or non-uniformly.

[0101] Any one or more of the compression members 802...812 may move linearly and / or rotationally relative to any one or more other compression members 802...812. Furthermore, any one or more of the compression members 802...812 may be fixed relative to any one or more other compression members 802...812. 812 may include part of a mold. Additionally, any one or more of the compression members 802...812 may include one or more straight and / or curved surfaces relating to the compression of plastic to form a compression-molded part.

[0102] like Figure 25 As shown, each compression member 802...812 can cooperate to define one or more gaps 820...830. The gaps 820...830 can have any shape, size, or orientation, and are not limited to... Figure 25 Or examples disclosed elsewhere in this document. Furthermore, gaps 820...830 can be set relative to each other in any way.

[0103] F. Possible advantages of each embodiment

[0104] As disclosed herein, embodiments of the invention can provide one or more advantages. For example, the integral compression-formed part can be produced anywhere within the blow molding structure, and is not limited to its location near the edge or periphery of the blow molding structure. As another example, the compression-formed part can be produced by tools or apparatus other than the mold half used to produce the blow molding structure integral with the compression-formed part. As a final example, the compression-formed part can be generally located in a plane that is not parallel to the plane containing the parting line.

[0105] G. Additional Example Implementations

[0106] The following are examples of other embodiments of the present invention.

[0107] Example 1. An apparatus comprising: a mold including a separable half and operable to form a blow molding structure; a tool disposed within the mold, the tool including: a first compression member; a second compression member, wherein the first and second compression members are configured and arranged such that one of the compression members is movable relative to the other compression member, and the compression members together define a gap in which plastic within the mold can be deposited.

[0108] Example 2. The apparatus according to Example 1, wherein the tool is configured to produce a compression-formed part that is entirely located within one of the half molds.

[0109] Example 3. The apparatus according to Example 1, wherein the width of the gap is variable.

[0110] Example 4. The apparatus according to Example 1, wherein the movable compression member is configured to move linearly or rotate relative to another compression member.

[0111] Example 5. The apparatus according to Example 1, wherein the gap defined by the compression member is in communication with the interior of the mold.

[0112] Example 6. The apparatus according to Example 1, wherein any portion of the gap is not defined by the structure of any of the half-molds.

[0113] Example 7. The apparatus according to Example 1, wherein the tool can operate independently of the half-mold.

[0114] Example 8. The apparatus according to Example 1, wherein each of the compression members is movable relative to the other compression member.

[0115] Example 9. An apparatus comprising: a housing; a dynamic compression member connected to the housing and configured and arranged to be movable relative to an external structure of the apparatus, wherein the compression member cooperates with the structure to jointly define a gap into which plastic within a mold can be deposited, wherein the structure is part of the mold.

[0116] Example 10. The apparatus according to Example 9, wherein the dynamic compression member is rotatable, and the range of rotation of the dynamic compression member is partially defined by the structure of the mold.

[0117] Example 11. An apparatus comprising: a mold including a separable half and operable to ensure the production of a blow molding structure; a tool disposed within the mold and including a dynamic compression member configured and arranged to be movable relative to an external structure of the apparatus, the compression member cooperating with the structure to jointly define a gap in which plastic within the mold can be deposited, wherein the structure is part of the mold.

[0118] Example 12. A method comprising: positioning an operable tool for producing a compression molded part in a mold having a separable half; placing the tool in a portion of the mold; forming a preform of softened plastic; closing the half of the mold and the tool around the preform such that the tool is positioned between the half of the mold and the preform; expanding the preform such that the plastic is substantially in contact with some or all of the interior portions of the half of the mold; operating the tool to form an integral compression molded part within the mold; operating the tool again to release the compression molded part; separating the half of the mold; and removing a blow molding structure including the integral compression molded part.

[0119] Example 13. An arbitrary molding structure generated by the method described in Example 12.

[0120] Example 14. A structure comprising: a generally hollow body having an integral, single-piece construction; and a solid compression-molded part integral with said body.

[0121] Example 15. The structure according to Example 14, wherein the compression molded part is completely disposed within a sleeve defined by the surface and edge of the structure, such that no part of the compression molded part extends to the edge of the structure.

[0122] Example 16. The structure according to Example 14, wherein the compression molded part is located in a plane that is not parallel to the parting line of the structure.

[0123] Example 17. The structure according to Example 14, wherein the structure is a blow molding structure.

[0124] Example 18. The structure according to Example 14, wherein the compression molded part is completely disposed within a sleeve defined by the surface and edge of the structure, such that no part of the compression molded part extends into the parting line of the structure.

[0125] Example 19. The structure according to Example 14, wherein the entire compression molded part is spaced apart from the parting line of the structure.

[0126] Example 20. An apparatus comprising: a mold including a separable half and operable to produce a blow-molded structure; and a tool disposed within the mold, the tool including: a first compression member, a second compression member, and a third compression member, wherein the first, second, and third compression members are configured and arranged such that one or more compression members are movable relative to one or more other compression members, thereby defining two gaps or spaces jointly, wherein plastic within the mold can be deposited in the two gaps or spaces, each of the two or more gaps or spaces corresponding to a corresponding compression-molded structure.

[0127] Although this disclosure has been described according to certain embodiments, other embodiments that will be obvious to those skilled in the art are also within the scope of this disclosure. Therefore, the scope of this disclosure is intended to be defined only by the following claims.

Claims

1. A molded ship, comprising: A plastic body with a one-piece construction, the plastic body having a substantially hollow interior, the plastic body including parting lines; as well as A solid compression molded part integral with the plastic body, the solid compression molded part being constructed and arranged such that the parting line is not part of the solid compression molded part, and the solid compression molded part being a fixed part of the molded vessel.

2. The molded vessel as claimed in claim 1, wherein, The solid compression molded part is completely contained within a sleeve defined by the outermost surface and outermost edge of the molded vessel.

3. The molded vessel as described in claim 1, wherein, The solid compression molded part is located in a plane that is not parallel to the plane containing part or all of the profile of the molded vessel.

4. The molded vessel as claimed in claim 1, wherein, The solid compression molded part is located in a plane that is nearly perpendicular to the plane containing part or all of the profile of the molded vessel.

5. The molded vessel as claimed in claim 1, wherein, The solid compression molded part includes recesses and / or holes.

6. The molded vessel of claim 1, further comprising a recess located near the solid compression molded part, and the recess being integral with the plastic body.

7. The molded vessel as claimed in claim 1, further comprising a first recess and a second recess, wherein, The first and second recesses are located near the solid compression molded part, and the first and second recesses are integral with the plastic body.

8. The molded vessel as claimed in claim 1, further comprising a first recess and a second recess, wherein, The first recess and the second recess are located near the solid compression molded part, and the first recess and the second recess are positioned opposite each other and are not connected to each other, and the first recess and the second recess are integral with the plastic body.

9. The molded vessel of claim 1, further comprising a first recess and a second recess, each of the first recess and the second recess being integral with the plastic body, wherein, The first and second recesses are located on approximately opposite sides of the solid compression molded part, and the first and second recesses are substantially mirror images of each other.

10. The molded vessel of claim 1, further comprising a recess located near the solid compression molded part, wherein the recess is integral with the plastic body and the recess has a concave structure located on the outer surface of the molded vessel.

11. The molded vessel of claim 1, further comprising a recess located near the solid compression molded part, wherein the recess is integral with the plastic body, and the recess has a convex configuration within the substantially hollow interior of the molded vessel.

12. The molded vessel of claim 1, further comprising a first recess and a second recess, each of the first recess and the second recess being located near the solid compression molded part, wherein the first recess and the second recess are integral with the plastic body, and both the first recess and the second recess have a convex configuration inside the substantially hollow interior of the molded vessel, and both the first recess and the second recess have a concave configuration on the exterior surface of the molded vessel.

13. The molded vessel as claimed in claim 1, wherein, The molded vessels include kayaks.

14. The molded vessel as claimed in claim 1, wherein, The molded vessels include sit-on kayaks.

15. The molded vessel as claimed in claim 1, wherein, The molded vessels include inboard kayaks.

16. The molded vessel as claimed in claim 1, wherein, The molded boat includes a surfboard.

17. The molded vessel as claimed in claim 1, wherein, The molded vessel comprises a single, one-piece construction.

18. The molded vessel as claimed in claim 1, wherein, The molded vessel includes one or more complete hollow sections located within a generally hollow interior.

19. The molded vessel as claimed in claim 1, wherein, The molded vessels include blow-molded vessels or roll-molded vessels.

20. The molded vessel as claimed in claim 1, wherein, The molded vessels include thermoformed vessels.

21. The molded vessel as claimed in claim 1, wherein, The molded vessels include vessels molded using vacuum molding.

22. The molded vessel as claimed in claim 1, wherein, The molded vessels include vessels molded from two pieces.

23. The molded vessel as claimed in claim 1, wherein, The molded vessels include vessels formed by encapsulation molding.

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