Composite article of lattice-reinforced elastomer

Abstract

The composite article comprises a grid and an elastomer section. The grid comprises a plurality of members forming an open mesh frame that defines a plurality of voids between adjacent members of the frame. The elastomer section is formed of an elastomer disposed around the grid and within the voids of the grid. The composite article may be a circular gasket, a gasket having a grip, a rectangular gasket, a container cap, a flask stand, and a handle for a hand tool.

Description

Technology Field

[0001] The present invention relates to composite articles, and more specifically, to articles containing a lattice structure that reinforces an elastomer material. Background Technology

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

[0003] Some molded elastomer articles include an internal frame or structure that can provide additional stiffness to the molded elastomer article. To form the molded elastomer article, the internal frame or structure may be formed and inserted into a mold, and then overmolded with elastomer. Generally, after the internal frame or structure is formed and before it is overmolded with elastomer, the internal frame or structure is surface-treated to improve the adhesion of the elastomer to said internal frame or structure. In some cases, when compressed or tensioned, the elastomer may peel off from the frame. Such peeling may occur after a single load cycle and may increase over subsequent load cycles. The problem to be solved

[0004] There is a continuing demand for composite articles with enhanced stiffness and / or increased toughness. Additionally, where the composite article includes an overmolded frame, there is a continuing demand for composite articles with improved peel resistance. Furthermore, there is always a need to reduce the manufacturing steps of the composite article and / or reduce manufacturing costs. means of solving the problem

[0005] In an embodiment of the present invention, the composite article comprises a grid structure and an elastomer section. The grid structure formed by an additive manufacturing method comprises a plurality of members forming an open mesh frame that defines a plurality of voids between adjacent members of the frame. The elastomer section is formed of an elastomer that is disposed at least partially around the grid structure and within the voids of the grid structure.

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

[0007] In the embodiments, the article comprises a body that forms a gasket and is also integrally formed with the lattice structure. The body may form a ring, and the lattice structure may extend inwardly from the inner surface of the ring. The elastomer section may include a flange extending inwardly from the lattice structure. The elastomer section may include a rib having a thickness greater than that of the flange. The rib may be disposed between the flange and the body.

[0008] In some embodiments, the elastomer section extends over the body. The body may be formed integrally with the lattice structure. The body may include one or more grips extending in a direction away from its surface.

[0009] In certain embodiments, the article comprises a base ring, a plurality of flask arms, and a leg. The base ring may be configured to support the lower part of the flask. Each flask arm may be configured to extend from the base ring and secure the lower part of the flask to the base ring. The leg may extend outwardly from the base ring and may also include a body formed integrally with the lattice structure. The elastomer section may form the foot of the leg and may also be configured to engage with a surface to support the leg against the surface.

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

[0011] In one embodiment of the present invention, the composite article comprises a grid and an elastomer section. The grid comprises a plurality of members forming an open mesh frame that defines a plurality of voids between adjacent members of a frame. The elastomer section is formed of an elastomer disposed around the grid and within the voids of the grid.

[0012] In some embodiments, the grid is formed monolithically. The grid may be formed by an additive manufacturing method. Each of the plurality of voids may have a size in the range of 0.05 mm to 5 mm. The elastomer of the elastomer section may be disposed around the entire grid structure. The elastomer section may comprise a thermosetting elastomer or a thermoplastic elastomer. The elastomer section may comprise silicone or a block polymer of styrene-isobutylene-styrene or thermoplastic polyurethane.

[0013] In the embodiments, the article comprises a body that forms a gasket and is also integrally formed with the grid. The body may form a ring, and the grid may extend inwardly from the inner surface of the ring. The elastomer section may include a flange extending inwardly from the grid. The elastomer section may include a rib having a thickness greater than that of the flange. The rib may be disposed between the flange and the body.

[0014] In some embodiments, the elastomer section extends over the body. The body may be formed integrally with the grid. The body may include one or more grips extending away from its surface.

[0015] In certain embodiments, the article comprises a base ring, a plurality of flask arms, and a leg. The base ring may be configured to support the lower portion of the flask. Each flask arm may extend from the base ring and be configured to secure the lower portion of the flask to the base ring. The leg may extend outwardly from the base ring and also includes a body formed integrally with the grid. The elastomer section may form the leg portion of the leg and may also be configured to engage with a surface to support the leg against the surface.

[0016] In certain embodiments, the article is a round 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 invention, a method for manufacturing a composite article comprises the steps of positioning a grid within a cavity of a mold, and flowing an elastomer into the cavity of the mold together with an elastomer flowing around the grid through the pores of the grid. The grid comprises a plurality of members forming an open mesh frame and defining a plurality of pores between adjacent members of the frame. The method may include the step of allowing the elastomer to solidify into its final shape within the pores and at least partially around the grid.

[0018] In the embodiments, the method comprises the step of additively manufacturing the grid. The method may comprise the step of three-dimensionally printing the grid. The three-dimensional printing of the grid may include grids comprising cross-linked cyanate esters or cross-linked polyurethanes. The step of positioning the grid within the cavity of the mold may include a plurality of voids having a size in the range of 0.05 mm to 5 mm.

[0019] In some embodiments, the step of flowing the elastomer into the cavity of the mold occurs when the grid is not surface-treated. The step of flowing the elastomer into the cavity may form at least one of a circular gasket, a gasket with a grip, a rectangular gasket, a container cap, part of a flask stand, or a handle for a hand tool. The step of flowing the elastomer may include the step of flowing a liquid elastomer, such as liquid silicone or liquid perfluoropolyether.

[0020] In another embodiment of the present invention, a flask stand configured to support a flask comprises a base ring and a plurality of legs. The base ring is configured to support the lower portion of the flask. Each leg is fixed to the base ring and also extends outwardly from the base ring. Each leg comprises a body, a grid, and an elastic leg portion. The body comprises a first end portion fixed to the base ring. The leg portion is located opposite the first end portion. The grid comprises a plurality of members formed within the leg portion and also forming an open mesh frame that defines a plurality of voids between adjacent members of the frame. The elastomer leg portion is formed of an elastomer and is also disposed around the grid and within the voids of the grid. The leg portion is configured to be coupled to a surface and to support the body against the surface.

[0021] In the embodiments, the first end portion includes an attachment tab. The attachment tab is fixed to a leg of the base ring. The plurality of legs may include four legs. The grid and body of each leg may be formed monolithically. Each gap of the grid may have a size in the range of 0.05 mm to 5 mm. The elastomer section may include a thermosetting elastomer or a thermoplastic elastomer.

[0022] In some embodiments, the flask stand includes a plurality of flask arms. Each flask arm may extend from the base ring and may also be configured to secure the lower part of the flask to the base ring.

[0023] In another embodiment of the present invention, a method for manufacturing a flask stand comprises the step of positioning a leg including a body and a grid within a cavity of a mold, at least with a grid disposed within the mold. The grid comprises a plurality of members forming an open mesh frame that defines a plurality of voids between adjacent members of the frame. The method also comprises the step of flowing an elastomer into the cavity of the mold, along with an elastomer flowing through the voids of the grid and around the grid.

[0024] In the embodiments, the method comprises the step of additively manufacturing the grid or the body. The grid and the body may be additively manufactured in a monolithic structure. The method may comprise the step of three-dimensionally printing the body and the grid. The three-dimensional printing of the grid may include a grid comprising a cross-linked cyanate ester or a cross-linked polyurethane.

[0025] In some embodiments, the step of positioning the grid within the cavity of the mold comprises a plurality of pores having a size ranging from 0.05 mm to 5 mm. The step of flowing the elastomer into the cavity of the mold occurs when the grid is not surface-treated. The step of flowing the elastomer may include the step of flowing a liquid elastomer, such as liquid silicone or liquid perfluoropolyether.

[0026] In certain embodiments, the method comprises the step of securing the leg to the base ring. The step of securing the leg to the base ring may include the step of inserting the attachment tab of the leg into a recess defined in the base ring.

[0027] Additionally, within a consistent scope, any of the embodiments described herein may be used together with any or all of the other embodiments described herein. Brief explanation of the drawing

[0028] Various aspects of the present invention are described below with reference to the drawings incorporated herein and constituting part of this specification: FIG. 1 is a perspective view of an elastomeric gasket provided according to an embodiment of the present invention. Figure 2 is a perspective view of the gasket body of Figure 1. Figure 3 is a cross-sectional view taken along the 3-3 cross-sectional line of Figure 1. FIG. 4 is a flowchart illustrating a method for manufacturing the gasket of FIG. 1 according to an embodiment of the present invention. FIG. 5 is a perspective view of another elastomeric gasket provided according to one embodiment of the present invention. FIG. 6 is a perspective view of the gasket body of FIG. 5. FIG. 7 is a perspective view of another elastomer gasket provided according to an embodiment of the present invention. Figure 8 is a cross-sectional view taken along the 8-8 cross-sectional line of Figure 7. FIG. 9 is a perspective view of the gasket body of FIG. 7. FIG. 10 is a perspective view of a container cap provided according to one embodiment of the present invention. Fig. 11 is a cross-sectional view of the container cap of Fig. 10. FIG. 12 is a perspective view of another container cap provided according to one embodiment of the present invention. FIG. 13 is a perspective view of a flask stand provided according to one embodiment of the present invention. Fig. 14 is a perspective view of the leg of the flask stand of Fig. 13. FIG. 15 is a perspective view of another flask stand provided according to one embodiment of the present invention. Fig. 16 is a side view of the leg of the flask stand of Fig. 15. Fig. 17 is a bottom view of the frame of the leg of Fig. 16. FIG. 18 is a perspective view of a hand tool provided according to one embodiment of the present invention. FIG. 19 is a cross-sectional view taken along the 19-19 cross-sectional line of FIG. 18. FIG. 20 is a side view of the handle of the hand tool of FIG. 18. Specific details for implementing the invention

[0029] The present invention will be described more fully with reference to exemplary embodiments below, with reference to the drawings, in which similar reference numerals indicate identical or corresponding components in each of the drawings. Such exemplary embodiments are described so that the present invention may be thorough and complete, and so that the scope of the present invention may be sufficiently conveyed to those skilled in the art. In practice, the present invention may be embodied in a number of different forms and should not be interpreted as being limited to the embodiments described herein; rather, such embodiments are provided to satisfy applicable legal requirements. As used in this specification and the appended claims, singular forms (“a,” “an,” “the,” etc.) include multiple referents unless the context clearly indicates otherwise. Additionally, while standards for quantitative measurements, values, geometric relationships, etc. may be mentioned herein, unless otherwise specified, at least one of these, if not all, may be absolute or approximate to describe acceptable variables that may arise due to manufacturing or engineering tolerances, etc.

[0030] Now, referring to FIGS. 1 and 2, a composite gasket (10) according to one embodiment of the present invention is provided. The gasket (10) comprises a frame (20) and an elastomer section (30). The frame (20) is provided to increase the rigidity of the gasket (10) or to increase the holding power of the gasket (10) compared to a gasket formed entirely of molded elastomer. The frame (20) may be rigid or flexible. The frame (20) may be formed of a thermoplastic material, polysulfone, polyether ether ketone, a thermosetting material, or a metal. For example, a suitable thermoplastic material may include polyamide, a suitable thermosetting material may include acrylic, polyurethane, or cyanate ester, and a suitable metal may include stainless steel, copper, and aluminum.

[0031] Referring particularly to FIG. 2, the frame (20) comprises a body (22) and a grid (24). The body (22) forms a ring in which the grid (24) extends inward from the inner surface of the ring. The body (22) and the grid (24) are formed integrally. In some embodiments, the body (22) and the grid (24) are formed monolithically with respect to each other. For example, the body (22) and the grid (24) may be formed through an additive manufacturing process, such as 3D printing. The body (22) is substantially solid and may also be exposed to the external environment after overmolding. Specifically, part or all of the body (22) may not be overmolded with an elastomer. Alternatively, part or all of the body (22) may be overmolded with an elastomer.

[0032] The grid (24) is configured to form an open cell structure and also to be overmolded with elastomer to form an elastomer section (30) around it. The grid (24) is formed by a plurality of members or arms forming an open mesh frame. The grid (24) defines a plurality of openings or voids (25) between adjacent arms throughout. The arms may be cylindrical with a circular cross-section or may have a triangular, rectangular, pentagonal, hexagonal, or other polygonal cross-section. The arms may form an open cubic frame, an open pyramidal frame, or other open frames. The voids (25) have a size that allows the elastomer to flow through the voids (25) of the grid (24) and also to solidify or harden inside and around the grid (24). In embodiments, the voids (25) may be in the range of 0.05 mm to 5 mm.

[0033] The grid (24) may define a rib segment (26) adjacent to the main body (22) and a flange segment (28) extending from the rib segment (26) away from the main body (22). The rib segment (26) may have a greater thickness than the flange segment (28). In certain embodiments, the grid (24) may include a tapered end (29) on the flange segment (28) away from the main body (22). In some embodiments, the grid (24) has a substantially uniform thickness from the main body (22) to the end (29) of the grid (24).

[0034] Referring further to FIG. 3, in order to form an elastomer section (30) around the grid (24), a mold (40) is fixed around the grid (24) together with the grid (24) disposed within a cavity (42) defined by the mold (40). As illustrated, the mold (40) forms a seal with the body (22) outside the cavity (42). In some embodiments, part or all of the body (22) may be disposed within the cavity (42) of the mold (40).

[0035] When the elastomer section (30) is molded onto the grid (24), the elastomer section (30) includes ribs (36) and flanges (38). The dimensions of the ribs (36) and flanges (38) are determined by the cavity (42) of the mold (40). The elastomer section (30) may include ribs (36) even when the grid (24) has a substantially uniform thickness from the main body to the end (29) of the grid (24), i.e., when the grid (24) does not include rib segments (26).

[0036] Now, referring to FIG. 4, a method for forming a composite article (50) is described according to an embodiment of the present invention with reference to the gasket (10) and mold (40) of FIG. 1 to 3. Although the method (50) has been described in detail with respect to the gasket (10), the method (50) can be used to form various composite articles including, but not limited to, a gasket, a handle, an anti-slip leg portion, a cap or lid for a container, or a handle for a hand tool.

[0037] First, the frame (20) is formed into a desired shape (step 52). The desired shape of the frame (20) may be determined by various factors including, but is not limited to, the desired shape of the final composite article, e.g., the gasket (10); the shape of the elastomer section of the final article; the desired stiffness of the final composite article; and other performance factors related to the final composite article. The desired shape of the frame (20) includes the shape of the main body section (22) and the shape of the grid (24). The shape of the grid (24) includes the external dimensions of the grid (24) and the size of the voids (25) of the grid (24). The size of the voids (25) of the grid (24) may be determined based on the complexity of the shape of the grid (24), the elastomer including the elastomer section (30), the desired stiffness of the elastomer section (30), the material forming the grid (24), and / or the desired performance characteristics of the elastomer section (30). The step of forming a frame (20) including the grid (24) may include the step of forming the grid (24) by an additive manufacturing method. For example, the grid (24) may be printed three-dimensionally and may also be formed of a cross-linked cyanate ester or a cross-linked polyurethane.

[0038] With the frame (20) formed, the frame (20) is positioned within the mold (40) along with a grid (24) placed within at least the cavity (42) of the mold (40) (step 54). Next, the elastomer is injected into the cavity (42) of the mold (40) to overmold at least the grid (24) of the frame (20) (step 56). As the elastomer is injected into the mold (40), the elastomer flows around the grid (24) and through the pores (25) of the grid (24), so that the elastomer is molded around and within the grid (24). As the elastomer solidifies or hardens within the mold (40), the elastomer can bond to the grid (24) to form an elastomer section (30) of the gasket (10). The above elastomer can flow through the mold (40) as a liquid, such as liquid silicone or liquid perfluoropolyether.

[0039] When the elastomer is sufficiently cured, the gasket (10) is removed from the mold (40) (step 58). The elastomer may be a thermosetting resin or a thermoplastic resin. For example, suitable thermoplastic elastomers may include a block copolymer of styrene-isobutylene-styrene, Santoprene™, a blend of ethylene propylene diene terpolymer (EPDM) and polypropylene, or a thermoplastic polyurethane, and suitable thermosetting elastomers may include silicone such as silicone (VMQ), phenyl silicone (PMVQ), perfluoropolyether elastomer, polyurethane, perfluorinated elastomer (FFKM), or fluoroelastomer (FKM).

[0040] The grid (24) provides an increased surface area for the bonding elastomer so that the elastomer section (30) forms an improved bond to the frame (20) compared to the main body (22) without the grid (24). The improved bond may be the result of reinforced mechanical adhesion between the elastomer section (30) and the frame (20). The improved bond provided by the grid (24) can improve the durability of the elastomer section (30) and also improve the peel strength between the grid (24) and the elastomer section (30) to reduce the possibility of peeling between the frame (20) and the elastomer section (30). Additionally, the grid (24) within the elastomer section (30) can increase the toughness of the elastomer section (30). The increased toughness of the elastomer section (30) may be the result of micro-reinforcement provided to the elastomer section (30) by the grid (24).

[0041] Additionally, the increased surface area between the elastomer and the grid (24) may allow the overmolding of the grid (24) without surface treatment of the grid (24). Eliminating the processing steps associated with traditional overmolding can reduce the number of steps required to produce composite articles, e.g., gaskets (10); and thus, reduce the cost of the overmolded elastomer article.

[0042] In some embodiments where a portion of an overmolded elastomer article is compressed, the grid (24) can improve the extrusion resistance of the compressed portion. For example, when in use, the flange (38) of the gasket (10) can be compressed between two components along with a path (12) (Fig. 1) formed through the gasket (10). The grid (24) can improve the extrusion resistance of the flange (38) as it is extruded into the path (12) while maintaining a seal between the two components compressing the flange (38).

[0043] Now, referring to FIGS. 5 and 6, another composite gasket (110) according to one embodiment of the present invention is provided. The gasket (110) is similar to the gasket (10) described in detail above, with similar components having a similar label having "1" before the previous label. For brevity, only the differences between the gasket (110) and the gasket (10) will be described in detail here. The gasket (110) includes a frame (120) and an elastomer section (130). The elastomer section (130) is similar to the elastomer section (30) described in detail above.

[0044] In particular, as illustrated in FIG. 6, the frame (120) comprises a body (122), a grip (123), and a grid (124) formed integrally with each other. In some embodiments, the body (122), the grip (123), and the grid (124) are formed monolithically with each other. For example, the body (122), the grip (123), and the grid (124) may be formed through an additive manufacturing process, such as 3D printing. The body (122) and the grip (123) are substantially solid and may be exposed to the external environment after overmolding. Specifically, part or all of the body (122) or the grip (123) may not be overmolded with an elastomer. Alternatively, part or all of the body (122) or the entire grip (123) may be overmolded with an elastomer.

[0045] The grip (123) may provide a surface for gripping the gasket (110). The grip (123) may be flexible or rigid. The body (122) may include three grips (123) as illustrated, or may include several or more than three grips (123) as a single grip (123). The grip (123) may extend in a range of 30 to 360 degrees around the body (122).

[0046] Now, referring to FIGS. 7 through 9, a different composite gasket (210) is provided according to an embodiment of the present invention. The gasket (210) is similar to the gasket (10) described in detail above, with similar components having a similar label having "2" before the previous label. For brevity, only the differences between the gasket (210) and the gasket (10) will be described in detail here. The gasket (210) includes a frame (220) and an elastomer section (230). The elastomer section (230) is similar to the elastomer section (30) described in detail above.

[0047] In particular, as illustrated in FIGS. 7 through 9, the frame (220) comprises a body (222) and a grid (224) formed integrally with each other. In some embodiments, the body (222) and the grid (224) are formed monolithically with each other. For example, the body (222) and the grid (224) may be formed through an additive manufacturing process, such as 3D printing. The body (222) is substantially solid and is also entirely overmolded by an elastomer. In some embodiments, part or all of the body (22) may be exposed to the external environment after overmolding. In particular, part or all of the body (222) may not be overmolded by an elastomer.

[0048] The main body (222) forms a rectangular shape having a path (212) penetrating the main body (222). The grid (224) extends from the main body (222) toward the path (212) as shown in FIG. 9. The main body (222) or the grid (224) may form recesses (227) adjacent to each corner of the main body (222) and at one or more points between the corners of the main body (222). The structure of the grid (224) is substantially similar to the structure of the grid (24) described in detail above in relation to the gasket (10).

[0049] Now, referring to FIGS. 10 and 11, a composite container cap (310) according to one embodiment of the present invention is provided. The container cap (310) comprises a frame or body (320) and an elastomer section or seal (330). The body (320) comprises a side wall (322) having a cover (323) at one end of the side wall (322). The cover (323) is circular or disc-shaped, having the side wall (322) which surrounds the perimeter of the cover (323) and extends away from the cover (323). A thread may be formed on the inner surface of the side wall (322) and a thread may also be formed over the neck of the container to close the opening of the container passing through the neck. Alternatively, the inner surface of the side wall (322) may include features, such as snap rings or protrusions, configured to pass through the neck of the container and be secured thereto to close the opening of the container passing through the neck. The cover (323) may define one or more ports (326) through each port (326) that accommodates a penetrating conduit (340). The conduits (340) may be sealed by an elastomer seal (330). In some embodiments, the cover (323) is a solid disc and does not include a port (326).

[0050] Referring particularly to FIG. 11, the main body (320) also includes a grid (324) that extends from the cover (323) and is also located within the side wall (322). As illustrated, the grid (324) is also connected to the side wall (322); however, in some embodiments, the grid (324) may be spaced apart from the side wall (322). The grid (324) extends from the cover (323) by a portion of the length of the side wall (322) and is configured to accommodate an elastomer to form the elastomer seal (330). The grid (324) may define a portion of the ports (326) passing through the cover (323) and may also accommodate a portion of the conduits (340) through it. The structure of the grid (324) is substantially similar to the structure of the grid (24) described in detail above in relation to the gasket (10).

[0051] The sidewall (322), cover (323), and grid (324) are formed integrally with each other. In some embodiments, the sidewall (322), cover (323), and grid (324) are formed monolithically with each other. For example, the sidewall (322), cover (323), and grid (324) may be formed through an additive manufacturing process, such as 3D printing. The sidewall (322) and the cover (323) are substantially solid and may also be exposed to the external environment after overmolding. Specifically, part or all of the sidewall (322) or the cover (323) may not be overmolded with an elastomer. Alternatively, part or all of the sidewall (322) or the entire cover (323) may be overmolded with an elastomer.

[0052] The elastomer seal (330) is positioned within the side wall (323) and is also overmolded into the grid (324). The elastomer seal (330) may form a seal with conduits (340) passing through the ports (326) and may also secure the conduits (340) within the ports (326). The elastomer seal (330) may be configured to form a seal with the neck of the container housed within the side wall (322) and to form a seal around the opening of the container passing through the neck.

[0053] The grid (324) can improve the quality of the seal formed between the elastomer seal (330) and the conduit (340) or between the elastomer seal (330) and the neck of the container. For example, the grid (324) can improve the extrusion resistance of the elastomer seal (330) within the ports (326) to prevent compression of the conduit (340) within the ports (326).

[0054] Now, referring to 12, a frame (320) of another composite container cap (360) is provided according to an embodiment of the present invention. The container cap (360) is similar to the container cap (310) except for the differences described herein for brevity.

[0055] The frame or body (320) of the container cap (360) includes a grid (324) near the perimeter of the cover (323) so that the central portion (323a) of the cover (323) does not include the grid (324). The grid (324) may be configured to be placed around the perimeter of the portion of the cover (323) that is joined by the neck portion of the container. When the frame (320) is overmolded, the elastomer section (not shown) is not extended over the central portion (323a) but is molded only over the portion of the frame including the grid.

[0056] Now, referring to FIGS. 13 and 14, a shaker flask stand (400) having a composite leg portion (430) is provided according to an embodiment of the present invention. The stand (400) comprises an upper ring (402), a base ring (404), a base (406), and a leg (410). The base ring (404) is fixed to the base (406) such that the upper ring (402) is supported and axially aligned with the base ring (404) and the base (406). The base (406) is circular in shape and also forms a disc. The base ring (404) may be fixed to the base (406) and may also be positioned on the base (406). The base ring (404) may be configured to hold the lower part of the flask, e.g., a triangular flask, when the flask is shaken. The base (406) may be configured to serve as a support for the lower part of the flask while allowing the lower part to slide along the surface of the flask when the stand (400) and the flask are shaken.

[0057] The legs (410) extend from the base (406) or the base ring (404) to the upper ring (402). Each leg (410) may be fixed to the base (406), particularly to the lower surface of the base (406). Additionally or alternatively, each leg (410) may be fixed to the base ring (404). Each leg (410) includes an upper hook (412) that is releasedably coupled to the upper ring (402). The upper hook (412) allows the upper ring (402) to be fixed to the over-base (406) after the flask is received on the base (406) and within the base ring (404). The upper ring (402) is configured to prevent the flask received within the stand (400) from tipping over or falling while the flask is shaken or positioned in balance. The upper ring (402) may have a diameter equal to the diameter of the base ring (404) or a diameter 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 accommodated in the stand (400).

[0058] The upper ring (402), base ring (404), and base (406) may be composed of various materials, including metals such as aluminum or steel, and plastics such as thermoplastic resins or thermosetting resins. The upper ring (402), base ring (404), and base (406) may be coated with a material that is rigid and also reduces impact force with the flask contained within the stand (400).

[0059] Each leg (410) comprises a body (420) and a molded elastomer section or leg portion (430). Referring particularly to FIG. 13, the body (420) includes an upper hook (412) at one end portion and also includes a grid (424) at the other end portion opposite the upper hook (412). The grid (424) extends outwardly from the lower end portion of the body (420). The grid (424) may extend completely to the end of the leg (410) or terminate spaced apart from the end of the leg (410). The structure of the grid (424) is substantially similar to the structure of the grid (24) described in detail above in relation to the gasket (10).

[0060] The body (420) may be formed integrally with the upper hook (412), and the grid (424) may be formed integrally with each other. In some embodiments, the entire body (420) is formed monolithically. For example, the body (420) may be formed through an additive manufacturing process, such as 3D printing. The body (420) may be substantially solid, with a portion thereof exposed to the external environment after overmolding. Specifically, a portion of the body (420) may not be overmolded with an elastomer. Alternatively, the entire body (420) may be overmolded with an elastomer.

[0061] The above elastomer section or elastomer leg portion (430) is formed by overmolding the grid (424) with elastomer. For example, the lower end portion of each leg (410) may be placed within the mold so that the grid (424) is placed within the cavity of the mold. Next, the elastomer flows through the cavity of the mold to flow through the voids (428) of the grid (424) and around the grid (424). When the elastomer hardens, the elastomer leg portion (430) is formed on the grid (424) so ​​as to be molded on the grid (424).

[0062] When in use, the elastomer leg portion (430) is configured to contact a surface and also support the stand (400). The leg portion (430) may be configured to contact a shaker plate or platform and also resist movement of the stand (440) relative to the shaker plate or platform. The grid (424) within each leg portion (430) can improve the durability of the leg portion (430) compared to a leg portion without a grid (424). The grid (424) within each leg portion (430) improves the peel strength between the leg portion (430) and the main body (420), thereby resisting separation or peeling of the leg portion (430) from the main body (420).

[0063] Now, referring to FIGS. 15 through 17, another shaker flask stand (500) having a composite leg portion (530) (Fig. 16) is provided according to an embodiment of the present invention. The stand (500) comprises flask arms (502), base rings (504), and legs (510). The flask arms (502) extend from the base rings (504) and are also configured to secure a flask to the flask stand (500). Specifically, the flask arms (502) are configured to hold the lower part of a flask, such as an Erlenmeyer flask, when the flask is shaken. The flask arms (502) are configured to prevent the flask contained within the stand (500) from tipping over or falling while the flask is being manipulated. The flask arms (502) may extend from a base ring (504) adjacent to each leg (510). The flask arms (502) may be flexible so as to bend outward when a flask is received on the stand (500) and also to engage with the flask to secure the flask to the flask stand (500). As illustrated, the stand (500) comprises four flask arms (502) and four legs (510) radially spaced around the base ring (504). In some embodiments, the stand (500) comprises three flask arms (502) or three legs (510), and in some embodiments, the stand (500) comprises four or more flask arms (502) or four or more legs (510). In a specific embodiment, the stand (500) includes a non-equal number of flask arms (502) and legs (510).

[0064] The base ring (504) is configured to support the lower part of the flask as it slides along the surface when the stand (500) and the flask are shaken. The legs (510) extend outwardly from the base ring (504). Each leg (510) is secured to the base ring (504) by an attachment tab (527) that extends from one end of the leg (510) and is configured to secure the leg (510) to the base ring (504). The base ring (504) may define a recess configured to accommodate the attachment tab (527) inside. The attachment tab (527) may be secured to the base ring (504) by a fastener, secured to the base ring (504) by an adhesive, and / or welded to the base ring (504), for example, ultrasonically welded.

[0065] The flask arms (502) and the base ring (504) may be made of various materials, including metals such as aluminum or steel, and plastics such as thermoplastic resins or thermosetting resins. The flask arms (502) and the base ring (504) may be substantially rigid and may also be coated with a material to reduce impact force together with the flask housed in the stand (500).

[0066] Each leg (510) includes a frame or body (522) and a molded elastomer section or leg portion (530). Referring particularly to FIG. 17, the body (522) includes a leg portion (523) at the end of the leg (510) opposite the attachment tab (527). The leg portion (523) includes a grid (524) extending into the leg portion (523) of the leg (510). The structure of the grid (524) is substantially similar to the structure of the grid (24) described in detail above in relation to the gasket (10).

[0067] The body (522) may be formed integrally with the grid (524). In some embodiments, the entire body (522) is formed monolithically. For example, the body (522) may be formed through an additive manufacturing process, such as 3D printing. The body (522) may be substantially solid, with the portion exposed to the external environment after overmolding. Specifically, a portion of the body (522) may not be overmolded with an elastomer. Alternatively, the entire body (522) may be overmolded with an elastomer.

[0068] The above elastomer section or elastomer leg portion (530) is formed by overmolding the grid (524) with elastomer. For example, the leg portion (523) of each leg (510) may be placed within the mold such that the grid (524) is placed within the cavity of the mold. Next, the elastomer flows through the cavity of the mold to flow through the pores (528) of the grid (524) and around the grid (524). When the elastomer is cured, the elastomer leg portion (530) is formed on the grid (524) so ​​that the elastomer leg portion (530) is molded on the grid (524).

[0069] When in use, the elastomer leg portion (530) is configured to contact a surface and also support the stand (500). The leg portion (530) may be configured to contact a shaker plate or platform and also resist movement of the stand (500) relative to the shaker plate or platform. A grid (524) within each leg portion (530) can improve the durability of the leg portion (530) compared to a leg portion without the grid (524). A grid (524) within each leg portion (530) improves the peel strength between the leg portion (530) and the main body (523), thereby resisting separation or peeling of the leg portion (530) from the main body (523).

[0070] Now, referring to FIGS. 18 through 20, a hand tool (600) including a composite handle (610) is provided according to an embodiment of the present invention. As illustrated, the hand tool (600) is a screwdriver; however, it is considered that the molded elastomer handle (610) can be used with various hand tools including, but not limited to, screwdrivers, pliers, surgical tools, knives, kitchen tools, woodworking tools, metalworking tools, laboratory equipment, etc.

[0071] The hand tool (600) comprises a shaft (602) having a working portion (604) and a shank (606). The shank (606) may include fixed features, such as recesses, that extend radially outward from the shank (606) or are confined within the shank (606), and the fixed features are configured to improve the fixation of the handle (610) to the shank (606). For example, the shank (606) may include a plurality of wings (not shown) arranged radially around the shank (606). Additionally or alternatively, the surface of the shank (606) may be roughened to improve the bonding between the shank (606) and the elastomer section (630). The shank (606) of the hand tool (600) is illustrated as a linear shank; In some embodiments, the shank may be curved, form a loop, and form a hook. Additionally, the shank (606) may be provided without an attachment feature. The shank (606) may include a plurality of longitudinal grooves (not shown) configured to receive an elastomer during molding.

[0072] The handle (610) comprises a frame (620) and an elastomer section (630). The frame (620) is placed within the elastomer forming the elastomer section (630) and is overmolded therein. The frame (620) comprises a grid (624) defining a body (622) and a passage (627) penetrating it, the passage configured to accommodate the shank (606) therethrough. As illustrated, the grid (624) extends between the bodies (622) and also forms a web between the bodies (622). In some embodiments, the grid (624) forms a shell between the bodies (622) and also forms a hollow core between the bodies (622). The hollow core may be filled with elastomer. The grid (624) may form an outer shell around the passage (627) with elastomer. The structure and formation of the above grid (624) are substantially similar to the structure and formation of the above grid (24) described in detail above in relation to the gasket (10).

[0073] When the grid (624) is positioned over the shank (606), a mold is placed over the shank (606) and the grid (624). Next, an elastomer flows through and around the grid (624) and the shank (606) into the cavity of the mold to form an elastomer section (630) of the handle (610). The elastomer is mechanically attached to the grid (624) to improve the durability of the handle (610). Additionally, the grid (624) can reinforce the elastomer section (630) to improve retention and fixation to the shank (606).

[0074] Although various embodiments of the present invention are illustrated in the drawings, the invention is not intended to be limited thereto, but is intended to be interpreted broadly to the extent permitted in the art, and the specification is likewise intended to be interpreted. Furthermore, any combination of the above embodiments is anticipated and falls within the scope of the appended claims. Accordingly, the above detailed description should not be interpreted restrictively, but merely as illustrative of specific embodiments. Those skilled in the art will anticipate other modifications within the scope of the appended claims.

Claims

Claim 1 A composite article comprising: a grid structure formed by an additive manufacturing method and including a plurality of members forming the frame that defines a plurality of voids between adjacent members of an open mesh frame; an elastomer section formed of an elastomer disposed at least partially around the grid structure and within the voids of the grid structure; and a body monolithically formed with the grid structure, wherein a portion of the body extends from the grid structure and a portion of the body is disposed outside the elastomer section. Claim 2 A composite article according to claim 1, wherein the lattice structure is formed monolithically. Claim 3 A composite article according to claim 1, wherein each of the plurality of voids has a size in the range of 0.05 mm to 5 mm. Claim 4 A composite article according to claim 1, wherein the elastomer section comprises a thermosetting elastomer. Claim 5 In claim 4, the thermosetting elastomer is a composite article comprising silicone. Claim 6 A composite article according to claim 1, wherein the elastomer section comprises a thermoplastic elastomer. Claim 7 A composite article according to claim 6, wherein the elastomer section comprises a block polymer of styrene-isobutylene-styrene or polyurethane. Claim 8 A composite article according to claim 1, wherein the main body forms a ring and the lattice structure extends inwardly from the inner surface of the ring. Claim 9 A composite article according to claim 8, wherein the elastomer section comprises a flange extending inwardly from the lattice structure. Claim 10 A composite article according to claim 9, wherein the elastomer section comprises a rib having a thickness greater than that of the flange, and the rib is disposed between the flange and the main body. Claim 11 A composite article in claim 8, wherein the main body comprises one or more grips extending in a direction away from its surface. Claim 12 In claim 1, the article is a composite article selected from the group consisting of a circular gasket, a gasket having a grip, a rectangular gasket, a container cap, a flask stand, and a handle for a hand tool. Claim 13 A composite article comprising: a grid structure including a plurality of members forming a frame that defines a plurality of voids between adjacent members of an open mesh frame; an elastomer section formed of an elastomer disposed around the grid structure and within the voids of the grid structure; and a body monolithically formed with the grid structure, wherein a portion of the body extends from the grid structure and a portion of the body is disposed outside the elastomer section. Claim 14 A composite article according to claim 13, wherein each of the plurality of voids has a size ranging from 0.05 mm to 5 mm. Claim 15 In claim 13, the lattice structure is a composite article formed monolithically. Claim 16 In claim 13, the elastomer of the elastomer section is disposed around the entire lattice structure, a composite article. Claim 17 In claim 13, the above-mentioned elastomer section comprises a thermosetting elastomer or a thermoplastic elastomer, a composite article. Claim 18 A composite article according to claim 13, wherein the main body forms a ring and the lattice structure extends inwardly from the inner surface of the ring. Claim 19 A composite article in claim 18, wherein the elastomer section comprises a flange extending inwardly from the lattice structure. Claim 20 A composite article according to claim 19, wherein the elastomer section comprises a rib having a thickness greater than that of the flange, and the rib is disposed between the flange and the main body. Claim 21 In claim 18, the elastomer section is a composite article extending over the main body. Claim 22 A composite article in claim 18, wherein the main body comprises one or more grips extending in a direction away from its surface. Claim 23 In claim 13, the article is a composite article selected from the group consisting of a round gasket, a gasket having a grip, a rectangular gasket, a container cap, a flask stand, and a handle for a hand tool. Claim 24 delete Claim 25 delete Claim 26 delete

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