Mould with sealable post and method for producing product using same

Abstract

A mold and a method of producing a product using the mold are provided. The mold includes: a first mold piece having a first wall from which a first post member protrudes, the first post member including a first side wall and a first distal end; and a second mold piece having a second wall from which a second post member protrudes, the second post member including a second side wall and a second distal end. The first mold piece and the second mold piece are configured to releasably cooperate to define a mold cavity therebetween and such that the first column member releasably cooperates with the second column member with the first distal end received within the cavity of the second distal end to form a seal therebetween. The mold cavity is configured to receive a product material therein and form a product therefrom. The first side wall and the second side wall are configured to define a channel in the product.

Description

[0001] The technical field generally relates to molds, and more particularly to a mold having a post in its mold cavity for forming a passage in a product formed in the mold cavity, wherein the post includes a pair of post members that cooperate to form a seal therebetween. BACKGROUND OF THE INVENTION

[0002] Molds for producing products in a molding process may include one or more features located within the mold cavity that are configured to create passages within the product. For example, a mold for producing a foam pad may include one or more posts configured to create vent holes within the foam pad. In some molds, each post includes a pair of post members having flat distal ends that are configured to contact (e.g., “kiss-off”) when the mold is closed. During the molding process, foam material enters between the post members, resulting in flashing. In some instances, the flashing must be removed in a subsequent processing step to provide airflow through the vent holes.

[0003] Accordingly, there is a desire to provide molds and methods of producing products with the mold that prevent or reduce the likelihood of flashing. Additionally, other desired features and characteristics of the present disclosure will become apparent from the following detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing introduction. SUMMARY OF THE INVENTION

[0004] A mold for producing a product is provided. In one example, the mold includes: a first mold member having a first wall with a first post member protruding therefrom, wherein the first post member includes a first sidewall and a first distal end; and a second mold member having a second wall with a second post member protruding therefrom, wherein the second post member includes a second sidewall and a second distal end, the second distal end including an opening leading to a cavity defined by an inner wall of the second post member. The first mold member and the second mold member are configured to releasably mate, wherein the first wall and the second wall define a mold cavity therebetween. The first post member and the second post member are configured to releasably mate when the first mold member and the second mold member are mated, wherein the first distal end of the first post member is received within the cavity of the second distal end of the second post member, and a seal is formed between the first distal end and the second distal end. The mold cavity is configured to receive product material therein and form a product therefrom. The first sidewall and the second sidewall are configured to define a passage within the product.

[0005] In various examples, the first mold member and the second mold member of the mold are fixed using a hinge and are configured to pivot about the hinge to mate with each other.

[0006] In various examples, the first sidewall of the mold is flush with the second sidewall when the first post member and the second post member are mated.

[0007] In various examples, a first distal end of a first post member includes a first angled parting line surface that terminates at a protruding surface, a second distal end of a second post member includes a second angled parting line surface that terminates at a recessed surface, and the first parting line surface and the second parting line surface are configured to mate to form a seal between the first distal end and the second distal end.

[0008] In various examples, the first distal end includes more than one protrusion, and the second distal end includes more than one recess, and each of the more than one recesses is configured to receive a corresponding one of the more than one protrusions.

[0009] In various examples, the first post member is the first of more than one first post members protruding from a first wall of a first tooling piece, and the second post member is the first of more than one second post members protruding from a second wall of a second tooling piece.

[0010] In various examples, the tooling includes a sealing element on at least one of the first distal end and the second distal end, the sealing element being configured to facilitate a seal between the first post member and the second post member when the first post member mates with the second post member. In some examples, the sealing element includes an epoxy material or a silicone material.

[0011] In various examples, the product is a seat cushion for a vehicle, the seat cushion is formed of a foam material, and the channels are ventilation holes.

[0012] In various examples, when mated, the first post member and the second post member together have a total longitudinal dimension of six millimeters or less.

[0013] A method for producing a product is provided. In one example, the method includes: coupling a first tooling piece and a second tooling piece of a tooling to provide a sealed tooling cavity therebetween, the tooling cavity being defined by a first wall of the first tooling piece and a second wall of the second tooling piece, wherein coupling the first tooling piece and the second tooling piece causes a first post member protruding from the first wall to mate with a second post member protruding from the second wall, wherein a first distal end of the first post member is received in a cavity in a second distal end of the second post member, and a seal is formed between the first distal end and the second distal end; disposing a product material into the tooling cavity; and curing the product material to form the product therefrom, wherein a first sidewall of the first post member and a second sidewall of the second post member define channels in the product.

[0014] In various examples, the first tooling piece and the second tooling piece are fixed using a hinge, and coupling the first tooling piece and the second tooling piece includes pivoting the first tooling piece and / or the second tooling piece about the hinge to mate with each other.

[0015] In various examples, coupling the first post member and the second post member includes setting the first sidewall and the second sidewall flush with each other when the first post member mates with the second post member.

[0016] In various examples, a first distal end of the first post member includes a first inclined parting line surface that terminates at a protruding surface, a second distal end of the second post member includes a second inclined parting line surface that terminates at a recessed surface, and coupling the first post member and the second post member includes mating the first parting line surface with the second parting line surface to form a seal between the first distal end and the second distal end.

[0017] In various examples, the first distal end includes more than one protrusion, and the second distal end includes more than one recess, and the method includes mating each of the first distal end and the second distal end by setting each of the more than one protrusions with a corresponding one of the more than one recesses.

[0018] In various examples, the first post member is the first of more than one first post members protruding from a first wall of a first tooling piece, the second post member is the first of more than one second post members protruding from a second wall of a second tooling piece, and the method includes coupling pairs of the first post members and the second post members.

[0019] In various examples, the tooling includes a sealing element on at least one of the first distal end and the second distal end, and the method includes mating the first post member with the second post member such that the sealing element facilitates a seal between the first post member and the second post member.

[0020] In various examples, the tooling includes a sealing element on at least one of the first distal end and the second distal end, and the method includes mating the first post member with the second post member such that the sealing element reduces the likelihood of wear on the first post member and the second post member.

[0021] In various examples, the product is a seat cushion for a vehicle, the seat cushion is formed of a foam material, the channels are ventilation holes, and the method includes installing the seat cushion in the vehicle.

[0022] A mold for producing a product is provided. In one example, the mold includes: a first mold piece having a first wall from which a first column member protrudes, wherein the first column member includes a first sidewall and a first distal end; a second mold piece having a second wall from which a second column member protrudes, wherein the second column member includes a second sidewall and a second distal end, and the second distal end includes an opening to a cavity defined by an inner wall of the second column member, wherein the first mold piece and the second mold piece are configured to releasably mate, wherein the first wall and the second wall define a mold cavity therebetween, wherein the first column member and the second column member are configured to be releasably mated between the first mold piece and the second mold piece The mold pieces are releasably mated when mated, wherein the first distal end of the first column member is at least partially received within a cavity of the second distal end of the second column member, and a seal is formed between the first distal end and the second distal end, wherein the first distal end includes more than one protrusion and the second distal end includes more than one recess, and each of the more than one recess is configured to receive a corresponding one of the more than one protrusion; and a sealing element on at least one of the first distal end and the second distal end, the sealing element being configured to facilitate a seal between the first column member and the second column member when the first column member is mated with the second column member. The mold cavity is configured to receive product material therein and form a product therefrom, and wherein the first sidewall and the second sidewall are configured to define a channel in the product. Brief Description of the Figures

[0023] Exemplary embodiments will be described below in conjunction with the following drawings, wherein like numbers denote like elements, and wherein:

[0024] Figure 1 is a perspective view of a mold according to an example;

[0025] Figure 2 is a cross-sectional view of a first non-limiting interface of a column member of a mold according to an example;

[0026] Figure 3 is a cross-sectional view of a second non-limiting interface of a column member of a mold according to an example;

[0027] Figure 4 is a cross-sectional view of a third non-limiting interface of a column of a mold according to an example; and

[0028] Figure 5 is a flow chart illustrating a method for producing a product from a mold according to an example. Specific implementation method

[0029] The following detailed description is merely exemplary in nature and is not intended to limit the application and uses. Furthermore, no one is intended to be bound by any expressed or implied theory presented in the preceding introduction or the following detailed description.

[0030] First referenceFigure 1 , a non - limiting example of a mold 100 is provided. The mold 100 can be configured to be used in a molding process for producing various products from various materials. Specifically, the mold 100 is configured to receive a ductile or viscous liquid product material within its mold cavity and allow the product material to cure to form a product.

[0031] A variety of materials can be used to form a product within the mold 100, including certain polymer materials. In some examples, the product can be formed from a thermosetting polymer material, and the product material used in the mold 100 can be a prepolymer mixture (reactive resin, reactive material, etc.) that is poured into the mold 100 and allowed to cure, i.e., a chemical reaction occurs to create cross - links between the polymer chains to form a polymer network. The prepolymer mixture can include, for example, resin, hardener or cross - linker, filler, catalyst, plasticizer, modifier (e.g., toughening agent), solvent, inhibitor, and / or colorant or pigment. In one example, the product material is a thermosetting prepolymer mixture including isocyanate resin. In some examples, the chemical reaction can cause foaming of the product material, resulting in the product being formed from a foam material. In other examples, the product material can include a melt of a thermoplastic resin. In some examples, the mold 100 can be used in an open casting process (e.g., open - cast foam process).

[0032] The mold 100 can be used to produce a variety of products. In some examples, the mold 100 can be configured to produce certain components for a vehicle, such as a cushion for a vehicle seat. However, the mold 100 is not limited to any specific application, and the mold 100 is also not limited to any specific size, structure, or configuration.

[0033] The mold 100 can include a pair of mold parts (e.g., a lid - type and a bowl - type), which are referred to herein as a first mold part 110 and a second mold part 120. The pair of mold parts are configured to releasably mate or couple to provide a sealed mold cavity therebetween. The first mold part 110 and the second mold part 120 can be separated from each other or can be fixed to each other, e.g., by one or more joints that provide relative movement of the first mold part 110 with respect to the second mold part 120. In some examples, the first mold part 110 and the second mold part 120 can be fixed to each other by one or more hinges, and the first mold part 110 and / or the second mold part 120 can be configured to pivot about the (one or more) hinges to mate and thereby form the mold cavity.

[0034] The first mold member 110 includes a core or body having a first outer surface 112, a first seal or parting line surface 114, and a first inner surface 116. Similarly, the second mold member 120 includes a core or body having a second outer surface 122, a second seal or parting line surface 124, and a second inner surface 126. When the first mold member 110 is mated with the second mold member 120, the first inner surface 116 and the second inner surface 126 define a mold cavity and thus define the outermost boundary of the product formed with the mold 100. The first parting line surface 114 and the second parting line surface 124 are configured to contact each other and facilitate a sufficient seal of the mold cavity to prevent or reduce the likelihood of leakage of the prepolymer mixture from the mold cavity during the molding process. Although not shown, the mold 100 may include various components and / or structures to facilitate the production of a product with the mold 100. By way of non-limiting example, the mold 100 may include one or more sprue basins, injection ports, mold cavities, gates, runners, clamps, etc.

[0035] The mold 100 includes one or more pairs of first post members 130 and second post members 140. Each of the first post members 130 projects from the first inner surface 116 of the first mold member 110, and each of the second post members 140 projects from the second inner surface 126 of the second mold member 120. The (plural) first post members 130 include a first sidewall 132 and a first distal end 134, and the (plural) second post members 140 include a second sidewall 142 and a second distal end 144. In the example shown in the figures, the first sidewall 132 and the second sidewall 142 include cylindrical or frustoconical cross-sections. However, the first sidewall 132 and the second sidewall 142 are not limited to any particular cross-sectional configuration.

[0036] Each pair of first post members 130 and second post members 140 is configured to releasably mate at the interface therebetween when the first mold member 110 is mated with the second mold member 120 and a sealed mold cavity is formed. Specifically, the first distal end 134 of the first post member 130 includes a first interface feature that is configured to interact with a second interface feature of the second distal end 144 of the second post member 140 to form a seal between the first distal end 134 and the second distal end 144 when mated. For example, the first interface feature may include a tapered surface, and the second interface feature may include a recess or cavity that is configured to receive the tapered surface therein, and vice versa.

[0037] When the (multiple) first post members 130 cooperate with the (multiple) second post members 140, the first sidewall 132 and the second sidewall 142 are exposed in the mold cavity, and their adjacent surfaces can optionally be substantially flush. When the mold cavity is filled with product material and cured to form a product therefrom, the first sidewall 132 and the second sidewall 142 serve as barriers defining the boundaries of a channel (e.g., a channel hole) within the product. In some examples, the interface between the (multiple) first post members 130 and the (multiple) second post members 140 is sufficiently sealed such that flash of the product material during the molding process is prevented or substantially reduced.

[0038] The mold 100 can include various materials, including certain polymers, metals, ceramics, and composite materials. In some examples, the mold 100 can be formed of steel, aluminum, or aluminum alloy. The mold cavity defined by the first inner surface 116 and the second inner surface 126 can have various shapes and sizes. Similarly, the first post member 130 and the second post member 140 can have various shapes and sizes. In various examples, when the first post member 130 and the second post member 140 are in a sealing fit with each other, they can have a total longitudinal dimension (e.g., from the first inner surface 116 to the second inner surface 126) of ten millimeters or less (such as eight millimeters or less, such as six millimeters or less). In some examples, the first post member 130 and the second post member 140 can have different longitudinal dimensions. In some examples, the longitudinal dimension of the first post member 130 is greater than the longitudinal dimension of the second post member 140.

[0039] Figures 2 - 4 The drawings illustrate various non-limiting examples of pairs of first post members 130 and second post members 140. It should be noted that these examples are for illustrative purposes only, and Figure 1 the mold 100 can have other configurations, including various combinations of components and / or structures represented in Figures 2 - 4 the drawings.

[0040] For convenience, consistent reference numerals are always used in Figures 1 - 4 the drawings to identify the same or functionally related / equivalent elements, but a numerical prefix (1, 2, or 3, etc.) is added to distinguish a particular example from other examples of the drawings. Given the similarities between the examples, Figures 2 - 4 the following discussion of the examples will primarily focus on aspects of the examples that are different from other examples in some obvious or significant way. Other aspects of the examples that are not discussed in detail (in terms of structure, function, material, etc.) can be substantially as described for one or more of the other examples (including Figure 1 the examples of the drawings).

[0041] Now refer to Figure 2, a first post member 230 is provided, which includes an opening at its first distal end 234, and the opening provides an entrance to a cavity defined by a first tapered or inclined parting line wall 236 and a first recessed wall 238. A second post member 240 is provided, which includes a second distal end 244 having a second tapered or inclined parting line wall 246 and a second protruding wall 248. In some examples, the first inclined parting line wall 236 and the second inclined parting line wall 246 can respectively extend completely around the perimeters of the first distal end 234 and the second distal end 244. In some examples, the first inclined parting line wall 236 and the second inclined parting line wall 246 can be radially symmetric (e.g., annular). In some examples where the first inclined parting line wall 236 and the second inclined parting line wall 246 are radially symmetric, the first recessed wall 238 and the second protruding wall 248 can be defined by the symmetric shapes of the first inclined parting line wall 236 and the second inclined parting line wall 246 (e.g., circular, square, etc.). Although not shown, the first inclined parting line wall 236 and the second inclined parting line wall 246 are configured to contact each other when mating or be set close enough to form a seal between the first post member 230 and the second post member 240.

[0042] In some examples, one or more sealing elements can be disposed on the first distal end 234 of the first post member 230 and / or on the second distal end 244 of the second post member 240. The (multiple) sealing elements can facilitate a leak-proof seal when the first post member 230 and the second post member 240 are mated, and / or can provide a protection function to the first post member 230 and the second post member 240 to reduce their wear. In Figure 2 an example, the first post member 230 includes a first sealing element 250 disposed on the first distal end 234, and the second post member 240 includes a second sealing element 260 disposed on the second distal end 244. In some examples, the first sealing element 250 can cover the entire first distal end 234. In some examples, the second sealing element 260 can cover the entire second distal end 244. The first sealing element 250 and the second sealing element 260 can include the same material or different materials. Non-limiting materials for the (multiple) sealing elements can include certain epoxy materials or silicone materials.

[0043] Now refer to Figure 3 , provided with having the same as the reference Figure 2The first column member 330 and the second column member 340 of substantially the same structure as discussed in the example, i.e., the first distal end 334 includes an opening that provides an entrance to a cavity defined by the first inclined parting line wall 336 and the first recessed wall 338, and the second distal end 344 includes a second inclined parting wall 346 and a second protruding wall 348. The first inclined parting line wall 336 and the second inclined parting line wall 346 are configured to contact each other or be set close enough to form a seal between the first column member 330 and the second column member 340.

[0044] In this example, the first column member 330 includes a first sealing element 350 disposed on the first distal end 334, and the second column member 340 includes a second sealing element 360 disposed on the second inclined parting wall 346 and a third sealing element 362 disposed on the second protruding wall 348 of the second distal end 344. The second sealing element 360 and the third sealing element 362 include different materials. The first sealing element 350 may include the same material as the second sealing element 360 or the third sealing element 362, or may include a different material. In this configuration, the second sealing element 360 and the third sealing element 362 can provide different functions. For example, the second sealing element 360 may be mainly configured to facilitate a leak-proof seal, while the third sealing element 370 may be mainly configured to provide increased wear resistance to the first column member 330 and the second column member 340, such as by providing a buffer.

[0045] Now referring to Figure 4 , a first column member 430 is provided, which includes a first distal end 434 having a pair of protrusions, each protrusion including a first inclined parting line wall 436 and a first protruding wall 438. A second column member 440 is provided, which includes a second distal end 444 having a pair of recesses, each recess defined by a second inclined parting line wall 446 and a second recessed wall 448. The protrusions and the recesses are provided in pairs and are configured such that when mated, the corresponding first inclined parting line wall 436 and the second inclined parting line wall 446 contact each other or are set close enough to form a seal between the first column member 430 and the second column member 440.

[0046] In this example, the first column member 430 includes a first sealing element 450 disposed on the first distal end 434, and the second column member 440 includes a second sealing element 460 disposed on the second distal end 444. The first sealing element 450 and the second sealing element 460 may include the same material or different materials.

[0047] Now referring to Figure 5 And continuing to refer to Figures 1 - 4, The flow chart provides a method 500 for producing a product according to an example by a molding process performed, for example, with a mold 100. As can be understood according to the present disclosure, the order of operations within method 500 is not limited to being performed in the order shown in Figure 5 but can be performed in one or more different orders when applicable and according to the present disclosure.

[0048] In one example, method 500 can start at 510. At 512, method 500 can include coupling or mating a first mold member and a second mold member of the mold to provide a sealed mold cavity therebetween. The mold cavity can be defined by a first wall of the first mold member and a second wall of the second mold member. Coupling the first mold member and the second mold member causes a first post member protruding from the first wall to mate with a second post member protruding from the second wall. A first distal end of the first post member is received in a cavity within a second distal end of the second post member, and a seal is formed between the first distal end and the second distal end.

[0049] At 514, method 500 can include disposing a product material into the mold cavity when the first mold member and the second mold member are mated and sealed. Various methods can be used to dispose the product material within the mold cavity, such as pouring. In certain examples, the product material can be disposed within the mold cavity in a manner that creates foaming (i.e., high porosity) of the product material.

[0050] At 516, method 500 can include curing the product material within the mold cavity to form a product therefrom. The external shape of the product can be defined by the first wall and the second wall. A first sidewall of the first post member and a second sidewall of the second post member define channels in the product. In certain examples, the product can be a foam material. In certain examples, the channels can be vent holes.

[0051] Method 500 can end at 518.

[0052] The molds and methods disclosed herein provide various benefits over certain existing molds and methods. For example, providing a seal between the first post member and the second post member can prevent or reduce flash during curing of the product material, thereby facilitating proper functionality of the product and / or reducing post-curing processing steps to remove such flash.

[0053] Although at least one exemplary embodiment has been presented in the foregoing detailed description, it should be understood that there are numerous variations. It should also be understood that the exemplary embodiment or exemplary embodiments are merely examples and are not intended to limit in any way the scope, applicability, or configuration of the present disclosure. Rather, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing the exemplary embodiment or exemplary embodiments. It should be understood that various changes may be made to the functions and arrangements of the elements without departing from the scope of the present disclosure as set forth in the appended claims and their legal equivalents.

Claims

1. A mold, comprising: a first mold piece having a first wall with a first column member projecting from the first wall, wherein the first column member includes a first sidewall and a first distal end; as well as a second mold piece having a second wall from which a second column member projects, wherein the second column member includes a second sidewall and a second distal end, the second distal end including an opening to a cavity defined by an inner wall of the second column member; wherein the first mold piece and the second mold piece are configured to releasably mate, wherein the first wall and the second wall define a mold cavity therebetween, wherein the first column member and the second column member are configured to releasably mate when the first mold piece is mated with the second mold piece, wherein the first distal end of the first column member is at least partially received within the cavity of the second distal end of the second column member and a seal is formed between the first distal end and the second distal end, Wherein the mold cavity is configured to receive a product material therein and form a product therefrom, and wherein the first sidewall and the second sidewall are configured to define a channel in the product.

2. The mold of claim 1 , wherein the first distal end of the first column member includes a first inclined parting line surface terminating in a protruding surface, the second distal end of the second column member includes a second inclined parting line surface terminating in a recessed surface, and the first inclined parting line surface and the second inclined parting line surface are configured to cooperate to form the seal between the first distal end and the second distal end. 3 . The mold of claim 1 , wherein the first distal end includes more than one protrusion, and the second distal end includes more than one recess, and each of the more than one recess is configured to receive a corresponding one of the more than one protrusion.

4. The mold of claim 1, wherein the first column member is a first of more than one first column member of the first mold piece that protrudes from the first wall, and the second column member is a first of more than one second column member of the second mold piece that protrudes from the second wall.

5. The mold according to claim 1 further includes a sealing element on at least one of the first distal end and the second distal end, the sealing element being configured to promote the seal between the first column member and the second column member when the first column member is mated with the second column member, wherein the sealing element includes an epoxy material or a silicone material.

6. A method comprising: coupling a first mold piece and a second mold piece of a mold to provide a sealed mold cavity therebetween, the mold cavity being defined by a first wall of the first mold piece and a second wall of the second mold piece, wherein coupling the first mold piece and the second mold piece results in mating of a first post member projecting from the first wall with a second post member projecting from the second wall, wherein a first distal end of the first post member is received within the cavity in the second distal end of the second post member, and a seal is formed between the first distal end and the second distal end; placing product material into the mold cavity; as well as The product material is cured to form a product therefrom, wherein the first sidewall of the first column member and the second sidewall of the second column member define a channel in the product.

7. The method of claim 6, wherein the first distal end of the first column member includes a first inclined parting line surface terminating in a protruding surface, the second distal end of the second column member includes a second inclined parting line surface terminating in a recessed surface, and coupling the first column member and the second column member includes mating the first inclined parting line surface with the second inclined parting line surface to form the seal between the first distal end and the second distal end.

8. The method of claim 6, wherein the first distal end comprises more than one protrusion and the second distal end comprises more than one recess, and the method comprises mating each of the first distal end and the second distal end by arranging each of the more than one protrusion together with a corresponding one of the more than one recess.

9. The method of claim 6, wherein the first column member is the first of more than one first column members of the first mold piece protruding from the first wall, the second column member is the first of more than one second column members of the second mold piece protruding from the second wall, and the method includes coupling the more than one first column members and the more than one second column members in pairs.

10. The method of claim 6, wherein the mold includes a sealing element on at least one of the first distal end and the second distal end, and the method includes mating the first column member with the second column member so that the sealing element promotes the seal between the first column member and the second column member or reduces the possibility of wear on the first column member and the second column member.

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