Molding apparatus to form a three dimensional product on a web material

Claim 2

Apparatus for the continuous production of a molded three-dimensional product comprising; a mold having a plurality of rows of spaced mold cavities therein, the rows being movable through a first station at which controlled charges of flowable thermoplastic material are simultaneously introduced only into each mold cavity of the row at said first station; a second station at which a web of a material which is permeable to the thermoplastic material is introduced into the open end of said mold cavities, one row at a time, and bonded to the spaced thermoplastic material charges therein; and a third station at which the molded thermoplastic material bonded to the web is removed from the mold; wherein the mold comprises a drum having angularly spaced rows of cavities therein, each cavity containing an insert which defines the shape and form of the thermoplastic material to be bonded to the web.

Claim 3

Apparatus as claimed in claim 1, further including a roller cooperable with said drum to define a nip and having at least one projection thereon to enter said mold cavity as it arrives at the nip to introduce said web into said mold cavity.

Claim 4

Apparatus as claimed in claim 2, in which the drum is hollow so as to be coolable by flowing cooling medium through the drum core.

Claim 5

Apparatus as claimed in claim 1 including an extruder for supplying molten polymer to an extruder block at the first station to introduce the thermoplastic material into said cavity located therebeneath.

Claim 6

Apparatus as claimed in claim 4, including means urging the extruder block into sealing engagement with the mold.

Claim 7

Apparatus for the continuous production of a molded three-dimensional product in the form of a preformed carrier web to which spaced molded thermoplastic projections are directly bonded, said apparatus comprising: a movable mold member having a series of spaced open-ended mold cavities defined in a surface thereof; extrusion means for selectively issuing flowable thermoplastic material from a predetermined location toward said mold surface; means for guiding a preformed web along at least a portion of said mold surface and over the open end of at least some of said cavities, said web being of a material which is permeable to said flowable thermoplastic material, said means for guiding being arranged to permit said web to be moved with said mold surface in response to movement of said mold member; drive means for moving said mold member to successively position at least one mold cavity at a time in place at said predetermined location to receive said flowable thermoplastic material from said injection means into the open end of the receiving mold cavity; and means for solidifying the thermoplastic material in said mold cavities to bond the thermoplastic material to said web; wherein said mold cavities are configured and spaced such that the solidified thermoplastic material from each cavity is completely separated along said web from the solidified thermoplastic material from all other cavities; wherein said mold comprises a rotatable drum having a plurality of said open-ended cavities defined in its periphery, said drum being indexed to stop at a plurality of specific positions wherein said cavities are aligned with respective work stations; and wherein said web is guided along said drum at a first work station so that flowable thermoplastic material enters the cavities at said first work station through the web, said web being movable with said drum to a second work station; and further comprising shaping means at said second work station arranged to enter cavities positioned thereat to shape and cool the thermoplastic material therein.

Claim 8

Apparatus for the continuous production of a molded three-dimensional product in the form of a preformed carrier web to which spaced molded thermoplastic projections are directly bonded, said apparatus comprising: a movable mold member having a series of spaced open-ended mold cavities defined in a surface thereof; extrusion means for selectively issuing flowable thermoplastic material from a predetermined location toward said mold surface; means for guiding a preformed web along at least a portion of said mold surface and over the open end of at least some of said cavities, said web being of a material which is permeable to said flowable thermoplastic material, said means for guiding being arranged to permit said web to be moved with said mold surface in response to movement of said mold member; drive means for moving said mold member to successively position at least one mold cavity at a time in place at said predetermined location to receive said flowable thermoplastic material from said injection means into the open end of the receiving mold cavity; and means for solidifying the thermoplastic material in said mold cavities to bond the thermoplastic material to said web; wherein said mold cavities are configured and spaced such that the solidified thermoplastic material from each cavity is completely separated along said web from the solidified thermoplastic material from all other cavities; wherein said mold comprises a rotatable drum having a plurality of said open-ended cavities defined in its periphery, said drum being indexed to stop at a plurality of specific positions wherein said cavities are aligned with respective work stations; and wherein said web is guided along said drum at a first work station so that flowable thermoplastic material enters the cavities at said first work station through the web, said web being movable with said drum to a second work station; and further comprising shaping means at said second work station arranged to enter cavities positioned thereat to shape and cool the thermoplastic material therein.

Claim 9

Apparatus for the continuous production of a molded three-dimensional product in the form of a preformed carrier web to which spaced molded thermoplastic projections are directly bonded, said apparatus comprising: a movable mold member having a series of spaced open-ended mold cavities defined in a surface thereof; extrusion means for selectively issuing flowable thermoplastic material from a predetermined location toward said mold surface; means for guiding a preformed web along at least a portion of said mold surface and over the open end of at least some of said cavities, said web being of a material which is permeable to said flowable thermoplastic material, said means for guiding being arranged to permit said web to be moved with said mold surface in response to movement of said mold member; drive means for moving said mold member to successively position at least one mold cavity at a time in place at said predetermined location to receive said flowable thermoplastic material from said injection means into the open end of the receiving mold cavity; and means for solidifying the thermoplastic material in said mold cavities to bond the thermoplastic material to said web; wherein said mold cavities are configured and spaced such that the solidified thermoplastic material from each cavity is completely separated along said web from the solidified thermoplastic material from all other cavities; wherein said mold comprises a rotatable drum having a plurality of said open-ended cavities defined in its periphery, said drum being indexed to stop at a plurality of specific positions wherein said cavities are aligned with respective work stations; and wherein said web is introduced onto said drum periphery adjacent cavities into which said flowable thermoplastic material has already been introduced.

Claim 10

Apparatus for the continuous production of a molded three-dimensional product in the form of a preformed carrier web to which spaced molded thermoplastic projections are directly bonded, said apparatus comprising: a movable mold member having a series of spaced open-ended mold cavities defined in a surface thereof; extrusion means for selectively issuing flowable thermoplastic material from a predetermined location toward said mold surface; means for guiding a preformed web along at least a portion of said mold surface and over the open end of at least some of said cavities, said web being of a material which is permeable to said flowable thermoplastic material, said means for guiding being arranged to permit said web to be moved with said mold surface in response to movement of said mold member; drive means for moving said mold member to successively position at least one mold cavity at a time in place at said predetermined location to receive said flowable thermoplastic material from said injection means into the open end of the receiving mold cavity; and means for solidifying the thermoplastic material in said mold cavities to bond the thermoplastic material to said web; wherein said mold cavities are configured and spaced such that the solidified thermoplastic material from each cavity is completely separated along said web from the solidified thermoplastic material from all other cavities; wherein said mold comprises a rotatable drum having a plurality of said open-ended cavities defined in its periphery, said drum being indexed to stop at a plurality of specific positions wherein said cavities are aligned with respective work stations; and wherein said web is introduced onto said drum periphery adjacent cavities into which said flowable thermoplastic material has already been introduced.

Claim 11

Apparatus for the continuous production of a molded three-dimensional product comprising: a mold having a plurality of mold cavities therein, each cavity being movable in turn step-by-step through a first station, means for introducing a measured charge of flowable thermoplastic material into the cavity at the first station; a second station; a shaping and cooling tool located at said second station and arranged to enter the charged cavity to shape and cool the thermoplastic material therein; a third station; means at said third station for removing the shaped and molded material from the cavity; means for stepping each cavity to said stations in sequence and for actuating the shaping and cooling tool when a cavity is stationary at the second station; and means for guiding a web of material, which is permeable to said thermoplastic material, into contact with the mold at the first station such that the thermoplastic material enters the cavity through the web; wherein the mold comprises: a rotatable drum having a plurality of angularly spaced rows of said mold cavities which may be each indexed in turn past said first station; an extruder at said first station; and a reciprocable press having a plurality of forming punches, one punch for each cavity in a row, said press being located at the second station.

Claim 12

Apparatus for the continuous production of a molded three-dimensional product comprising: a mold having a plurality of mold cavities therein, each cavity being movable in turn step-by-step through a first station, means for introducing a measured charge of flowable thermoplastic material into the cavity at the first station; a second station; a shaping and cooling tool located at said second station and arranged to enter the charged cavity to shape and cool the thermoplastic material therein; a third station; means at said third station for removing the shaped and molded material from the cavity; means for stepping each cavity to said stations in sequence and for actuating the shaping and cooling tool when a cavity is stationary at the second station; and means for guiding a web of material, which is permeable to said thermoplastic material, into contact with the mold at the first station such that the thermoplastic material enters the cavity through the web; wherein the mold comprises: a rotatable drum having a plurality of angularly spaced rows of said mold cavities which may be each indexed in turn past said first station; an extruder at said first station; and a reciprocable press having a plurality of forming punches, one punch for each cavity in a row, said press being located at the second station.