Grid-reinforced elastomeric composite article

Abstract

The composite article includes a lattice and an elastomeric section. The lattice includes a plurality of members forming an open mesh frame defining a plurality of voids between adjacent members of the frame. The elastomeric section is formed of an elastomer disposed around the lattice and within the voids of the lattice. The composite article can be a circular gasket, a gasket with a grip, a rectangular gasket, a container cap, a flask stand, and a handle for a hand tool.

Description

[Technical Field]

[0001] FIELD OF THE DISCLOSURE The present disclosure relates to composite articles, and more particularly to articles containing lattice structures that reinforce elastomeric materials. [Background technology]

[0002] Molded elastomers are used in a variety of applications, including, but not limited to, gaskets, handles, non-slip bottoms, and container caps or lids. To form some molded elastomeric articles, the elastomer can be placed in a mold to form the article entirely from the elastomer. Molded elastomeric articles formed entirely from elastomers lack stiffness and can deform and / or stretch under tension or compression.

[0003] Some molded elastomeric articles include an internal frame or structure that can provide additional rigidity to the molded elastomeric article. To form a molded elastomeric article, the internal frame or structure can be formed and inserted into a mold, then overmolded with an elastomer. Typically, after the internal frame or structure is formed and before it is overmolded with the elastomer, the internal frame or structure is surface treated to enhance adhesion of the elastomer to the internal frame or structure. In some cases, the elastomer may delaminate from the frame when compressed or under tension. This delamination may occur after one load cycle and may increase over subsequent load cycles. Summary of the Invention [Problem to be solved by the invention]

[0004] There is a continuing need for composite articles with enhanced stiffness and / or increased toughness. In addition, there is a continuing need for composite articles with improved delamination resistance when the composite article includes an overmolded frame. Furthermore, there is a constant need for reducing the manufacturing steps and / or reducing the manufacturing costs of composite articles. [Means for solving the problem]

[0005] In an embodiment of the present disclosure, a composite article includes a lattice structure and an elastomeric section. The lattice structure is formed by an additive manufacturing process and includes a plurality of members forming an open mesh frame defining a plurality of voids between adjacent members of the frame. The elastomeric section is formed of an elastomer at least partially around the lattice structure and disposed within the voids of the lattice structure.

[0006] In some embodiments, the lattice structure is monolithically formed. Each of the plurality of voids has a size ranging from 0.05 mm to 5 mm. The elastomeric section may include a thermoset elastomer or a thermoplastic elastomer. The elastomeric section may include a silicone, or may include a styrene-isobutylene-styrene block polymer or a thermoplastic polyurethane.

[0007] In an embodiment, the article includes a body forming a gasket and integrally formed with a lattice structure. The body can form a ring, and the lattice structure can extend inwardly from an inner surface of the ring. The elastomeric section can include a flange extending inwardly from the lattice structure. The elastomeric section can include a rib having a thickness greater than the flange. The rib can be disposed between the flange and the body.

[0008] In some embodiments, the elastomeric section extends across the body. The body may be monolithically formed with the lattice structure. The body may include one or more grips extending away from a surface thereof.

[0009] In certain embodiments, the article includes a base ring, a plurality of flask arms, and a leg. The base ring can be configured to support a lower portion of a flask. Each flask arm can be configured to extend from the base ring to secure the lower portion of the flask to the base ring. The leg can extend outward from the base ring and include a body integrally formed with the lattice structure. An elastomeric section can form a bottom of the leg and be configured to engage a surface to support the leg against the surface.

[0010] In certain embodiments, the article is a circular gasket, a gasket with a grip, a rectangular gasket, a container cap, a flask stand, or a handle for a hand tool.

[0011] In an embodiment of the present disclosure, a composite article includes a lattice and an elastomeric section. The lattice includes a plurality of members forming an open mesh frame defining a plurality of voids between adjacent members of the frame. The elastomeric section is formed of an elastomer disposed around the lattice and within the voids of the lattice.

[0012] In some embodiments, the lattice is monolithically formed. The lattice may be formed by additive manufacturing methods. Each void of the plurality of voids may range in size from 0.05 mm to 5 mm. The elastomer of the elastomeric section may be disposed around the entire lattice structure. The elastomeric section may include a thermoset elastomer or a thermoplastic elastomer. The elastomeric section may include silicone, or may include a styrene-isobutylene-styrene block polymer or a thermoplastic polyurethane.

[0013] In an embodiment, the article includes a body forming a gasket and integrally formed with a lattice. The body can form a ring, and the lattice can extend inwardly from an inner surface of the ring. The elastomeric section can include a flange extending inwardly from the lattice. The elastomeric section can include a rib having a thickness greater than the flange. The rib can be disposed between the flange and the body.

[0014] In some embodiments, the elastomeric section extends across the body. The body may be monolithically formed with the lattice. The body may include one or more grips extending away from a surface thereof.

[0015] In certain embodiments, the article includes a base ring, a plurality of flask arms, and a leg. The base ring can be configured to support a lower portion of a flask. Each flask arm can be configured to extend from the base ring to secure the lower portion of the flask to the base ring. The leg can extend outward from the base ring and include a body integrally formed with the grid. An elastomeric section can form a bottom of the leg and be configured to engage a surface to support the leg against the surface.

[0016] In certain embodiments, the article is a circular gasket, a gasket with a grip, a rectangular gasket, a container cap, a flask stand, or a handle for a hand tool.

[0017] In another embodiment of the present disclosure, a method of manufacturing a composite article includes positioning a lattice within a cavity of a mold and flowing an elastomer into the cavity of the mold such that the elastomer flows through and around the lattice. The lattice includes a plurality of members forming an open mesh frame and defining a plurality of voids between adjacent members of the frame. The method can include solidifying the elastomer into its final shape within the voids and at least partially around the lattice.

[0018] In an embodiment, the method includes additively manufacturing a lattice. The method can include three-dimensionally printing the lattice. Three-dimensionally printing the lattice can include the lattice comprising a cross-linked cyanate ester or a cross-linked polyurethane. Positioning the lattice within the cavity of the mold can include forming a plurality of voids sized in a range of 0.05 mm to 5 mm.

[0019] In some embodiments, the step of flowing the elastomer into the mold cavity is performed without a surface treatment of the lattice. The step of flowing the elastomer into the cavity can form at least one of a circular gasket, a gasket with a grip, a rectangular gasket, a container cap, a portion of a flask stand, or a handle for a hand tool. The step of flowing the elastomer can include flowing a liquid elastomer, such as liquid silicone or liquid perfluoropolyether.

[0020] In another embodiment of the present disclosure, a flask stand configured to support a flask includes a base ring and a plurality of legs. The base ring is configured to support a lower portion of the flask. Each leg is secured to the base ring and extends outward from the base ring. Each leg includes a body, a lattice, and an elastomeric bottom. The body includes a first end portion secured to the base ring. The bottom portion faces the first end portion. The lattice is formed within the bottom portion and includes a plurality of members forming an open mesh frame that defines a plurality of voids between adjacent members of the frame. The elastomeric bottom is formed of an elastomer and is disposed around the lattice and within the voids of the lattice. The bottom is configured to engage a surface and support the body against the surface.

[0021] In an embodiment, the first end portion includes a mounting tab. The mounting tab is secured to a leg of the base ring. The plurality of legs may include four legs. The body and lattice of each leg may be monolithically formed. Each void of the lattice may range in size from 0.05 mm to 5 mm. The elastomer section may include a thermoset elastomer or a thermoplastic elastomer.

[0022] In some embodiments, the flask stand includes a plurality of flask arms, each of which can extend from a base ring and be configured to secure a lower portion of a flask to the base ring.

[0023] In another embodiment of the present disclosure, a method of manufacturing a flask stand includes placing a leg including a body and a grid into a cavity of a mold with at least the grid disposed within the mold. The grid includes a plurality of members forming an open mesh frame defining a plurality of voids between adjacent members of the frame. The method also includes flowing an elastomer into the cavity of the mold with the elastomer flowing through the voids in the grid and around the grid.

[0024] In embodiments, the method includes additively manufacturing the lattice or the body. The lattice and body can be additively manufactured as a monolithic structure. The method can include three-dimensionally printing the body and lattice. Three-dimensionally printing the lattice can include the lattice comprising a cross-linked cyanate ester or a cross-linked polyurethane.

[0025] In some embodiments, positioning the lattice within the mold cavity includes forming a plurality of voids sized in a range of 0.05 mm to 5 mm. Flowing an elastomer into the mold cavity occurs without surface treating the lattice. Flowing an elastomer can include flowing a liquid elastomer, such as liquid silicone or liquid perfluoropolyether.

[0026] In certain embodiments, the method includes securing the legs to the base ring. Securing the legs to the base ring can include inserting mounting tabs of the legs into recesses defined in the base ring.

[0027] Additionally, to the extent not inconsistent, any aspect described herein may be used in combination with any or all of the other aspects described herein.

[0028] Various aspects of the present disclosure are described below with reference to the drawings, which are incorporated in and constitute a part of this specification. [Brief explanation of the drawings]

[0029] [Figure 1] FIG. 1 is a perspective view of an elastomeric gasket provided in accordance with an embodiment of the present disclosure. [Figure 2] FIG. 2 is a perspective view of the main body of the gasket of FIG. 1. [Figure 3] FIG. 3 is a cross-sectional view taken along section line 3-3 of FIG. 1. [Figure 4] 2 is a flow diagram of a method for manufacturing the gasket of FIG. 1 according to an embodiment of the present disclosure. [Figure 5] FIG. 1 is a perspective view of another elastomeric gasket provided in accordance with an embodiment of the present disclosure. [Figure 6] FIG. 6 is a perspective view of the main body of the gasket of FIG. 5. [Figure 7] FIG. 1 is a perspective view of another elastomeric gasket provided in accordance with an embodiment of the present disclosure. [Figure 8] 8 is a cross-sectional view taken along section line 8-8 of FIG. 7. [Figure 9] FIG. 8 is a perspective view of the main body of the gasket of FIG. 7. [Figure 10] 1 is a perspective view of a container cap provided in accordance with an embodiment of the present disclosure. [Figure 11] FIG. 11 is a longitudinal cross-sectional view of the container cap of FIG. [Figure 12]FIG. 1 is a perspective view of another container cap provided in accordance with an embodiment of the present disclosure. [Figure 13] FIG. 1 is a perspective view of a flask stand provided in accordance with an embodiment of the present disclosure. [Figure 14] FIG. 14 is a perspective view of a leg of the flask stand of FIG. 13. [Figure 15] FIG. 1 is a perspective view of another flask stand provided in accordance with an embodiment of the present disclosure. [Figure 16] FIG. 16 is a side view of a leg of the flask stand of FIG. 15. [Figure 17] FIG. 17 is a bottom view of the leg frame of FIG. 16. [Figure 18] 1 is a perspective view of a hand tool provided in accordance with an embodiment of the present disclosure; [Figure 19] 19 is a cross-sectional view taken along section line 19-19 of FIG. 18. [Figure 20] FIG. 19 is a side view of the handle of the hand tool of FIG. 18. DETAILED DESCRIPTION OF THE INVENTION

[0030] Referring now to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views, the present disclosure will now be described more fully with reference to exemplary embodiments thereof. These exemplary embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. As used in the specification and claims, the singular forms "a," "an," "the," and the like include plural references unless the context clearly dictates otherwise. Similarly, although references are made herein to quantitative measurements, values, geometric relationships, and the like, unless otherwise specified, any one or more, but not all, of these may be absolute or approximate, taking into account possible tolerances due to manufacturing or engineering tolerances, for example.

[0031] 1 and 2, a composite gasket 10 is provided in accordance with an embodiment of the present disclosure. The gasket 10 includes a frame 20 and an elastomeric section 30. The frame 20 is provided to increase the rigidity and retention of the gasket 10 compared to gaskets formed entirely of molded elastomer. The frame 20 may be rigid or flexible. The frame 20 may be formed of a thermoplastic resin, polysulfone, polyetheretherketone, thermoset resin, or metal. For example, a preferred thermoplastic resin may include polyamide, a preferred thermoset resin may include acrylic, polyurethane, or cyanate ester, and preferred metals may include stainless steel, copper, and aluminum.

[0032] With particular reference to FIG. 2 , the frame 20 includes a body 22 and a lattice 24. The body 22 forms a ring, and the lattice 24 extends inward from the inner surface of the ring. The body 22 and the lattice 24 are integrally formed with one another. In some embodiments, the body 22 and the lattice 24 are monolithically formed with one another. For example, the body 22 and the lattice 24 may be formed by an additive manufacturing process, such as three-dimensional printing. The body 22 may be substantially solid and exposed to the external environment after overmolding. Specifically, portions or the entire body 22 may not be overmolded with an elastomer. Alternatively, portions or the entire body 22 may be overmolded with an elastomer.

[0033] The lattice 24 is configured to be overmolded with an elastomer to form an open-cell structure and to form an elastomeric section 30 therearound. The lattice 24 is formed by a plurality of members or arms that form an open mesh frame. The lattice 24 defines a plurality of openings or voids 25 between adjacent arms throughout. The arms can be cylindrical with a circular cross-section, or can have a triangular, rectangular, pentagonal, hexagonal, or other polygonal cross-section. The arms can be open cubic, pyramidal, or other open frames. The voids 25 are sized to allow the elastomer to flow through the voids 25 in the lattice 24 and solidify or harden within and around the lattice 24. In embodiments, the voids 25 can range in size from 0.05 mm to 5 mm.

[0034] The lattice 24 may define rib segments 26 adjacent the body 22 and flange segments 28 extending from the rib segments 26 away from the body 22. The rib segments 26 may have a greater thickness than the flange segments 28. In certain embodiments, the lattice 24 may include a tapered end 29 at the flange segment 28 away from the body 22. In some embodiments, the lattice 24 has a substantially uniform thickness from the body 22 to the end 29 of the lattice 24.

[0035] 3 , to form the elastomeric section 30 around the lattice 24, a mold 40 is secured around the lattice 24 with the lattice 24 disposed within a cavity 42 defined by the mold 40. As shown, the mold 40 forms a seal with the body 22 with the body 22 outside of the cavity 42. In some embodiments, a portion or all of the body 22 may be disposed within the cavity 42 of the mold 40.

[0036] When elastomeric section 30 is molded over lattice 24, elastomeric section 30 includes ribs 36 and flanges 38. The dimensions of ribs 36 and flanges 38 are determined by cavity 42 of mold 40. Elastomeric section 30 can include ribs 36 even when lattice 24 has a substantially uniform thickness from the body to ends 29 of lattice 24, i.e., when lattice 24 does not include rib segments 26.

[0037] 4, a method of forming a composite article 50 will be described in accordance with an embodiment of the present disclosure with reference to the gasket 10 and mold 40 of Figures 1-3. Although the method 50 will be described in detail with respect to the gasket 10, the method 50 may be used to form a variety of composite articles, including, but not limited to, a gasket, a handle, a non-skid base, a cap or lid for a container, or a handle for a hand tool.

[0038] Initially, the frame 20 is formed into a desired shape (step 52). The desired shape of the frame 20 can be determined by various factors, including, but not limited to, the desired shape of the final composite article, e.g., gasket 10, the shape of the elastomeric sections of the final article, the desired stiffness of the final composite article, and other performance factors associated with the final composite article. The desired shape of the frame 20 includes the shape of the body section 22 and the shape of the lattice 24. The shape of the lattice 24 includes the outer dimensions of the lattice 24 and the size of the voids 25 in the lattice 24. The size of the voids 25 in the lattice 24 can be determined based on the complexity of the shape of the lattice 24, the elastomer to comprise the elastomeric section 30, the desired stiffness of the elastomeric section 30, the material forming the lattice 24, and / or the desired performance characteristics of the elastomeric section 30. Forming the frame 20 including the lattice 24 can include forming the lattice 24 using an additive manufacturing method. For example, the lattice 24 may be three-dimensionally printed and formed of a cross-linked cyanate ester or a cross-linked polyurethane.

[0039] Once the frame 20 is formed, it is positioned within the mold 40 with at least the lattice 24 disposed within the cavity 42 of the mold 40 (step 54). An elastomer is then injected into the cavity 42 of the mold 40 to overmold at least the lattice 24 of the frame 20 (step 56). As the elastomer is injected into the mold 40, it flows around the lattice 24 and through the voids 25 of the lattice 24 such that the elastomer is molded around and within the lattice 24. As the elastomer solidifies or cures within the mold 40, it may bond to the lattice 24 to form the elastomeric section 30 of the gasket 10. The elastomer may flow through the mold 40 as a liquid, such as liquid silicone or liquid perfluoropolyether.

[0040] When the elastomer is sufficiently cured, the gasket 10 is removed from the mold 40 (step 58). The elastomer can be thermoset or thermoplastic. For example, suitable thermoplastic elastomers can include Santoprene®, a block copolymer of styrene-isobutylene-styrene, a blend of ethylene propylene diene terpolymer (EPDM) and polypropylene, or a thermoplastic polyurethane, while suitable thermoset elastomers can include silicones such as silicone (VMQ), phenyl silicone (PMVQ), perfluoropolyether elastomers, polyurethanes, perfluoroelastomers (FFKM), or fluoroelastomers (FKM).

[0041] The lattice 24 provides an increased surface area for the elastomer to bond to, such that the elastomeric section 30 forms an improved bond to the frame 20 compared to the body 22 without the lattice 24. The improved bond is believed to be the result of an enhanced mechanical attachment between the elastomeric section 30 and the frame 20. The improved bond provided by the lattice 24 can improve the durability of the elastomeric section 30 and can improve the peel strength between the lattice 24 and the elastomeric section 30, reducing the likelihood of delamination between the frame 20 and the elastomeric section 30. In addition, the lattice 24 within the elastomeric section 30 can increase the toughness of the elastomeric section 30. The increased toughness of the elastomeric section 30 can be the result of the micro-reinforcement that the lattice 24 provides to the elastomeric section 30.

[0042] Additionally, the increased surface area between the elastomer and the lattice 24 may allow for overmolding of the lattice 24 without surface treating the lattice 24. Eliminating processing steps associated with conventional overmolding may reduce the number of steps to manufacture a composite article, such as the gasket 10, and thus reduce the cost of the overmolded elastomeric article.

[0043] In some embodiments where a portion of the overmolded elastomeric article is compressed, the lattice 24 can improve the extrusion resistance of the compressed portion. For example, in use, the flange 38 of the gasket 10 may be compressed between two elements that form a passageway 12 ( FIG. 1 ) through the gasket 10. The lattice 24 can improve the extrusion resistance of the flange 38 to being extruded into the passageway 12 while maintaining a seal between the two elements compressing the flange 38.

[0044] 5 and 6, another composite gasket 110 is provided in accordance with an embodiment of the present disclosure. Gasket 110 is similar to gasket 10, detailed above, and like elements have like reference numerals with a "1" preceding the previous reference numeral. For reasons of brevity, only the differences between gasket 110 and gasket 10 will be detailed herein. Gasket 110 includes a frame 120 and an elastomeric section 130. Elastomeric section 130 is similar to elastomeric section 30, detailed above.

[0045] With particular reference to FIG. 6 , frame 120 includes body 122, grip 123, and lattice 124 integrally formed with one another. In some embodiments, body 122, grip 123, and lattice 124 are monolithically formed with one another. For example, body 122, grip 123, and lattice 124 may be formed by an additive manufacturing process, such as three-dimensional printing. Body 122 and grip 123 may be substantially solid and exposed to the external environment after overmolding. Specifically, portions or the entire body 122 or grip 123 may not be overmolded with an elastomer. Alternatively, the entire body 122 or grip 123, or portions thereof, may be overmolded with an elastomer.

[0046] The grips 123 can provide a surface for gripping the gasket 110. The grips 123 can be flexible or rigid. The body 122 can include three grips 123 as shown, or can include fewer grips 123, such as a single grip 123, or more than three grips 123. The grips 123 can extend between 30 and 360 degrees around the circumference of the body 122.

[0047] 7-9, another composite gasket 210 is provided in accordance with an embodiment of the present disclosure. Gasket 210 is similar to gasket 10, detailed above, and like elements have like reference numerals with the previous reference numerals preceded by a "2." For reasons of brevity, only the differences between gasket 210 and gasket 10 will be detailed herein. Gasket 210 includes a frame 220 and an elastomeric section 230. Elastomeric section 230 is similar to elastomeric section 30, detailed above.

[0048] With particular reference to FIGS. 7-9 , frame 220 includes a body 222 and a lattice 224 integrally formed with one another. In some embodiments, body 222 and lattice 224 are monolithically formed with one another. For example, body 222 and lattice 224 may be formed by an additive manufacturing process, such as three-dimensional printing. Body 222 is substantially solid and is entirely overmolded with an elastomer. In some embodiments, portions or the entire body 222 may be exposed to the external environment after overmolding. Specifically, portions or the entire body 222 may not be overmolded with an elastomer.

[0049] Body 222 forms a rectangular shape with passages 212 defined therethrough. Grille 224 extends from body 222 toward passages 212, as shown in FIG. 9. Body 222 or grille 224 may define recesses 227 adjacent each corner of body 222 and at one or more points between the corners of body 222. The structure of grille 224 is substantially similar to the structure of grille 24 detailed above with respect to gasket 10.

[0050] 10 and 11, a composite container cap 310 is provided in accordance with an embodiment of the present disclosure. The container cap 310 includes a frame or body 320 and an elastomeric section or seal 330. The body 320 includes a sidewall 322 and a cover 323 at one end of the sidewall 322. The cover 323 is circular or disc-shaped, with the sidewall 322 surrounding the circumference of the cover 323 and extending away from the cover 323. The inner surface of the sidewall 322 can be threaded and configured to thread onto the neck of a container to close the opening therethrough. Alternatively, the inner surface of the sidewall 322 can include a feature, such as a snap ring or protrusion, configured to pass over and secure to the neck of a container to close the opening therethrough. The cover 323 can define one or more ports 326 therethrough, each port 326 receiving a conduit 340 therethrough. The conduit 340 may be sealingly engaged by an elastomeric seal 330. In some embodiments, the cover 323 is a solid disk and does not include the port 326.

[0051] 11 , the body 320 also includes a grid 324 extending from the cover 323 and positioned within the sidewall 322. As shown, the grid 324 is also connected to the sidewall 322, although in some embodiments, the grid 324 may be spaced apart from the sidewall 322. The grid 324 extends from the cover 323 to a portion of the length of the sidewall 322 and is configured to receive an elastomer to form an elastomeric seal 330. The grid 324 defines portions of ports 326 that pass through the cover 323 and can receive portions of a conduit 340 therethrough. The structure of the grid 324 is substantially similar to the structure of the grid 24 detailed above with respect to the gasket 10.

[0052] The sidewall 322, the cover 323, and the lattice 324 are integrally formed with one another. In some embodiments, the sidewall 322, the cover 323, and the lattice 324 are monolithically formed with one another. For example, the sidewall 322, the cover 323, and the lattice 324 can be formed by an additive manufacturing process, such as three-dimensional printing. The sidewall 322 and the cover 323 can be substantially solid and exposed to the external environment after overmolding. Specifically, portions or the entirety of the sidewall 322 or the cover 323 may not be overmolded with an elastomer. Alternatively, portions or the entirety of the sidewall 322 or the cover 323 can be overmolded with an elastomer.

[0053] An elastomeric seal 330 is disposed within sidewall 322 and is overmolded with grid 324. Elastomeric seal 330 can form a seal with a conduit 340 passing through port 326 to secure conduit 340 within port 326. Elastomeric seal 330 can be configured to form a seal with the neck of a container received within sidewall 322 and around an opening of the container passing through the neck.

[0054] The lattice 324 can improve the quality of the seal formed between the elastomeric seal 330 and the conduit 340 or between the elastomeric seal 330 and the neck of the container. For example, the lattice 324 can improve the extrusion resistance of the elastomeric seal 330 into the port 326 to prevent compression of the conduit 340 within the port 326.

[0055] 12, there is provided a frame 320 of another composite container cap 360 in accordance with an embodiment of the present disclosure. Container cap 360 is similar to container cap 310 with only the differences detailed herein for the sake of brevity.

[0056] The frame or body 320 of the container cap 360 includes a lattice 324 around the periphery of the cover 323 such that a central portion 323a of the cover 323 does not include the lattice 324. The lattice 324 can be configured to be disposed around the portion of the cover 323 engaged by the neck of the container. When the frame 320 is overmolded, an elastomeric section (not shown) does not extend over the central portion 323a, but is molded only over the portion of the frame that includes the lattice.

[0057] 13 and 14 , a shaker flask stand 400 having a composite bottom 430 is provided in accordance with an embodiment of the present disclosure. The stand 400 includes an upper ring 402, a base ring 404, a base 406, and legs 410. The base ring 404 is secured to the base 406 with the upper ring 402 supported above and in axial alignment with the base ring 404 and base 406. The base 406 is circular in shape and forms a disk. The base ring 404 is secured to and can be positioned above the base 406. The base ring 404 can be configured to hold the lower portion of a flask, such as an Erlenmeyer flask, when the flask is shaken. The base 406 can be configured to act as a platform for the lower portion of the flask while allowing the lower portion to slide along its surface when the stand 400 and flask are shaken.

[0058] The legs 410 extend from the base 406 or base ring 404 to the upper ring 402. Each leg 410 can be secured to the base 406, particularly to the underside of the base 406. Additionally or alternatively, each leg 410 can be secured to the base ring 404. Each leg 410 includes an upper hook 412 that releasably couples to the upper ring 402. The upper hook 412 allows the upper ring 402 to be secured to the over-base 406 after a flask is received on the base 406 and within the base ring 404. The upper ring 402 is configured to prevent a flask received in the stand 400 from tipping or tipping during shaking or balancing. The upper ring 402 can have a diameter equal to or substantially smaller than the diameter of the base ring 404. The diameter of the upper ring 402 may be determined by the diameter of the neck of the flask received within the stand 400 .

[0059] The upper ring 402, base ring 404, and base 406 can be constructed from a variety of materials, including metals such as aluminum or steel, and plastics such as thermoplastics or thermosets. The upper ring 402, base ring 404, and base 406 can be rigid and coated with a material that reduces impact forces with a flask received within the stand 400.

[0060] Each leg 410 includes a body 420 and a molded elastomeric section or bottom 430. With particular reference to FIG. 13 , the body 420 includes an upper hook 412 at one end portion and a lattice 424 at the other end portion opposite the upper hook 412. The lattice 424 extends outwardly from a lower end portion of the body 420. The lattice 424 may extend completely to the end portions of the legs 410 or may terminate spaced apart from the end portions of the legs 410. The structure of the lattice 424 is substantially similar to the structure of the lattice 24 detailed above with respect to the gasket 10.

[0061] The body 420 can be integrally formed with the upper hooks 412 and the lattice 424, which are integrally formed with one another. In some embodiments, the entire body 420 is monolithically formed. For example, the body 420 can be formed by an additive manufacturing process, such as three-dimensional printing. The body 420 can be substantially solid, portions of which are exposed to the external environment after overmolding. Specifically, portions of the body 420 may not be overmolded with an elastomer. Alternatively, the entire body 420 can be overmolded with an elastomer.

[0062] The elastomeric section or elastomeric bottom 430 is formed by overmolding the lattice 424 with an elastomer. For example, the lower end portion of each leg 410 can be placed in a mold such that the lattice 424 is placed within the mold cavity. An elastomer is then flowed through the mold cavity, flowing through and around the voids 428 in the lattice 424. Once the elastomer has cured, the elastomeric bottom 430 is formed over the lattice 424 such that the elastomeric bottom 430 is molded over the lattice 424.

[0063] In use, the elastomeric bottoms 430 are configured to contact a surface and support the stand 400. The bottoms 430 can be configured to contact a shaker plate or platform and resist movement of the stand 440 relative to the shaker plate or platform. The lattice 424 in each bottom 430 can improve the durability of the bottom 430 compared to a bottom without the lattice 424. The lattice 424 in each bottom 430 can improve the peel strength between the bottom 430 and the body 420 to resist separation or delamination of the bottom 430 from the body 420.

[0064] 15-17, another shaker flask stand 500 having a composite bottom 530 (FIG. 16) is provided in accordance with an embodiment of the present disclosure. The stand 500 includes flask arms 502, a base ring 504, and legs 510. The flask arms 502 extend from the base ring 504 and are configured to secure a flask to the flask stand 500. Specifically, the flask arms 502 are configured to hold the lower portion of a flask, e.g., an Erlenmeyer flask, as the flask is shaken. The flask arms 502 are configured to prevent a flask received within the stand 500 from tipping or falling while the flask is being manipulated. The flask arms 502 can extend from the base ring 504 adjacent each of the legs 510. The flask arms 502 can be resilient to flex outward when a flask is received thereon across the stand 500 and engage the flask to secure the flask to the flask stand 500. As shown, the stand 500 includes four flask arms 502 and four legs 510 spaced radially relative to the base ring 504. In some embodiments, the stand 500 includes three flask arms 502 or three legs 510, and in some embodiments, the stand 500 includes more than four flask arms 502 or more than four legs 510. In certain embodiments, the stand 500 includes an unequal number of flask arms 502 and legs 510.

[0065] The base ring 504 is configured to act as a platform for the lower portion of the flask while allowing the lower portion to slide along its surface when the stand 500 and flask are shaken. Legs 510 extend outwardly from the base ring 504. Each leg 510 is secured to the base ring 504 by a mounting tab 527 extending from one end of the leg 510 and configured to secure the leg 510 to the base ring 504. The base ring 504 may define a recess configured to receive the mounting tab 527 therein. The mounting tabs 527 may be secured to the base ring 504 by a fastener, may be secured to the base ring 504 by an adhesive, and / or may be welded, e.g., ultrasonically welded, to the base ring 504.

[0066] The flask arms 502 and base ring 504 can be constructed from a variety of materials, including metals such as aluminum or steel, plastics such as thermoplastics or thermosets, etc. The flask arms 502 and base ring 504 may be substantially rigid and coated with a material that reduces impact forces with a flask received within the stand 500.

[0067] Each leg 510 includes a frame or body 522 and a molded elastomeric section or bottom 530. With particular reference to FIG. 17 , the body 522 includes a bottom portion 523 at the end of the leg 510 opposite the mounting tab 527. The bottom portion 523 includes a lattice 524 that extends into the bottom portion 523 of the leg 510. The lattice 524 may extend outward from the underside of the body 522. The structure of the lattice 524 is substantially similar to the structure of the lattice 24 detailed above with respect to the gasket 10.

[0068] Body 522 can be integrally formed with lattice 524. In some embodiments, the entire body 522 is monolithically formed. For example, body 522 can be formed by an additive manufacturing process, such as three-dimensional printing. Body 522 can be substantially solid, portions of which are exposed to the external environment after overmolding. Specifically, portions of body 522 may not be overmolded with an elastomer. Alternatively, the entire body 522 can be overmolded with an elastomer.

[0069] The elastomeric section or elastomeric bottom 530 is formed by overmolding the lattice 524 with an elastomer. For example, the bottom portion 523 of each leg 510 can be placed in a mold such that the lattice 524 is placed within the mold cavity. The elastomer is then flowed through the mold cavity such that the elastomer flows through and around the voids 528 in the lattice 524. Once the elastomer has cured, the elastomeric bottom 530 is formed over the lattice 524 such that the elastomeric bottom 530 is molded over the lattice 524.

[0070] In use, the elastomeric bottom 530 is configured to contact a surface to support the stand 500. The bottom 530 can be configured to contact a shaker plate or platform to resist movement of the stand 500 relative to the shaker plate or platform. The lattice 524 in each bottom 530 can improve the durability of the bottom 530 compared to a bottom without the lattice 524. The lattice 524 in each bottom 530 can improve the peel strength between the bottom 530 and the body 522 to resist separation or delamination of the bottom 530 from the body 522.

[0071] 18-20 , there is provided a hand tool 600 including a composite handle 610 in accordance with an embodiment of the present disclosure. As shown, the hand tool 600 is a screwdriver, however, it is contemplated that the molded elastomeric handle 610 may be used with a variety of hand tools including, but not limited to, screwdrivers, pliers, surgical tools, knives, kitchen tools, carpentry tools, metalworking tools, laboratory equipment, and the like.

[0072] The hand tool 600 includes a shaft 602 having a manipulation portion 604 and a shank 606. The shank 606 can include a locking feature, such as a recess, extending radially outward from or defined within the shank 606 and configured to improve securement of the handle 610 to the shank 606. For example, the shank 606 can include a plurality of wings (not shown) arranged radially around the shank 606. Additionally or alternatively, the surface of the shank 606 can be roughened to enhance bonding of the elastomeric section 630 to the shank 606. While the shank 606 of the hand tool 600 is shown as a straight shank, in some embodiments, the shank may be curved, loop-forming, hook-forming, etc. Additionally, the shank 606 may be provided without an attachment feature. The shank 606 can include a plurality of longitudinal grooves (not shown) configured to receive an elastomer during molding.

[0073] The handle 610 includes a frame 620 and an elastomeric section 630. The frame 620 is disposed within and overmolded by an elastomer that forms the elastomeric section 630. The frame 620 includes bodies 622 and a lattice 624 therethrough that defines a passageway 627 configured to receive the shank 606. As shown, the lattice 624 extends between the bodies 622, forming webs between the bodies 622. In some embodiments, the lattice 624 forms a shell between the bodies 622, defining a hollow core between the bodies 622. The hollow core can be filled with an elastomer. The lattice 624 can form an outer shell around the passageway 627 with the elastomer. The structure and formation of the lattice 624 is substantially similar to the structure and formation of the lattice 24 described above in detail with respect to the gasket 10.

[0074] With the lattice 624 positioned over the shank 606, a mold is placed over the shank 606 and lattice 624. Elastomer is then flowed into the mold cavity, through and around the lattice 624 and shank 606, to form the elastomeric section 630 of the handle 610. The elastomer mechanically attaches to the lattice 624, which can improve the durability of the handle 610. Additionally, the lattice 624 can reinforce the elastomeric section 630, improving its retention and fixation to the shank 606.

[0075] The present disclosure is intended to be as broad as the art will permit, and as this specification is intended to be read in the same manner, although several embodiments of the disclosure have been shown in the drawings, the disclosure is not intended to be limited thereto; all combinations of the above embodiments are contemplated and are within the scope of the appended claims. Therefore, the above description should not be construed as limiting, but rather merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope of the claims appended hereto.

Claims

1. a lattice structure formed by an additive manufacturing process, the lattice structure including a plurality of members forming an open mesh frame defining a plurality of voids between adjacent members of the frame; an elastomeric section formed of an elastomer disposed at least partially around the lattice structure and within an interior void of the lattice structure; a body monolithically formed with the lattice structure, a portion of the body extending from the lattice structure, the portion of the body being disposed outside the elastomeric section; and A composite article including:

2. The article of claim 1 , wherein each void of the plurality of voids has a size in the range of 0.05 mm to 5 mm.

3. The article of claim 1 , wherein the elastomeric section comprises a thermoset elastomer.

4. The article of claim 3 , wherein the thermoset elastomer comprises a silicone.

5. The article of claim 1 , wherein the elastomeric section comprises a thermoplastic elastomer.

6. The article of claim 5 , wherein the elastomeric section comprises a styrene-isobutylene-styrene block polymer or a polyurethane.

7. the body forms a ring and the lattice structure extends inwardly from an inner surface of the ring; The article of claim 1.

8. The article of claim 7 , wherein the elastomeric section includes a flange extending inwardly from the lattice structure.

9. The article of claim 8 , wherein the elastomeric section includes a rib having a thickness greater than the flange, the rib being disposed between the flange and the body.

10. The article of claim 7 , wherein the elastomeric section extends across the body.

11. 8. The article of claim 7, wherein the body includes one or more grips extending away from a surface thereof.

12. 10. The article of claim 1, wherein the article is selected from the group consisting of a circular gasket, a gasket with a grip, a rectangular gasket, a container cap, a flask stand, and a handle for a hand tool.

13. a lattice structure including a plurality of members forming an open mesh frame defining a plurality of voids between adjacent members of the frame, the lattice structure being formed from a thermoplastic resin, a polysulfone, a polyetheretherketone, or a thermosetting resin; an elastomer section formed of an elastomer disposed around the lattice structure, the elastomer filling the plurality of voids in the lattice structure; and a body monolithically formed with the lattice structure, a portion of the body extending from the lattice structure, the portion of the body being disposed outside the elastomeric section; and A composite article including:

14. 14. The article of claim 13, wherein each void of the plurality of voids is sized in the range of 0.05 mm to 5 mm.

15. The article of claim 13 , wherein the elastomer of the elastomeric section is disposed around the entire lattice structure.

16. The article of claim 13 , wherein the elastomeric section comprises a thermoset elastomer or a thermoplastic elastomer.

17. the body forms a ring and the lattice structure extends inwardly from an inner surface of the ring; 14. The article of claim 13.

18. 18. The article of claim 17, wherein the elastomeric section includes a flange extending inwardly from the lattice structure.

19. 20. The article of claim 18, wherein the elastomeric section includes a rib having a thickness greater than the flange, the rib being disposed between the flange and the body.

20. The article of claim 17 , wherein the elastomeric section extends across the body.

21. 18. The article of claim 17, wherein the body includes one or more grips extending away from a surface thereof.

22. 14. The article of claim 13, wherein the article is selected from the group consisting of a circular gasket, a gasket with a grip, a rectangular gasket, a container cap, a flask stand, and a handle for a hand tool.

23. A composite article comprising: a grid structure including a plurality of members forming an open mesh frame defining a plurality of voids between adjacent members of the frame; an elastomeric section formed of an elastomer disposed at least partially around the lattice structure and within an interior void of the lattice structure; selected from the group consisting of a container cap, a flask stand, and a handle for a hand tool; further comprising a body monolithically formed with said grid structure; a portion of the body extending from the lattice structure, the portion of the body disposed outside the elastomeric section.

24. 24. The composite article of claim 23, wherein the lattice structure is formed from a thermoplastic, a polysulfone, a polyetheretherketone, or a thermoset.

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