Method and apparatus for blow molding parts with smooth surfaces

Claim 1

A mold for use in blow molding a heated parison into a finished part comprising: a base having a surface with the general contours of the part to be molded, said base including constant temperature cooling means, said base defining an aperture for surrounding a blow pin and a cut off means for pinching off the parison; an insulating layer attached to at least a portion of the contoured base for slowing the cooling of the parison during molding, said insulating layer comprising a compressible felt of thermally stable fibers with increased thermal conductivity when compressed; and a skin layer affixed to said insulating layer, said skin layer having a thermal conductivity greater than the insulating layer and said skin layer having the contour and surface characteristic corresponding to those desired of the finished part, said insulating layer with said skin layer affixed thereto situated in a portion of said base corresponding to the portion of the finished part where the surface characteristics of the skin layer, is desired.

Claim 4

A method of blow molding a heated parison into a finished part comprising the steps of: providing a mold having a base with constant temperature cooling means and an insulating layer of compressible felt attached to at least a portion of the base for slowing the cooling of the parison, the mold further having a skin layer affixed to the insulating layer, the skin layer having a thermal conductivity greater than the insulating layer and the contour and surface characteristics of the finished part; extruding a parison into the open mold; closing the mold, pinching the bottom of the parison closed; introducing a gas into the parison and expanding the parison against the interior of the mold, the portion of the parison in contact with the insulated skin layer not quenching thereby avoiding surface imperfections; and compressing the felt insulating layer, thereby increasing the thermal conductivity of the insulating layer to promote parison cooling.

Claim 5

A method of blow molding a heated parison into a finished part comprising the steps of: providing a mold having a base with constant temperature cooling means and an insulating layer of compressible felt attached to at least a portion of the base for slowing the cooling of the parison, the mold further having a skin layer affixed to the insulating layer, the skin layer having a thermal conductivity greater than the insulating layer and the contour and surface characteristics of the finished part; extruding a parison into the open mold; closing the mold, pinching the bottom of the parison closed; introducing a gas into the parison and expanding the parison against the interior of the mold, the portion of the parison in contact with the insulated skin layer not quenching thereby avoiding surface imperfections; and compressing the felt insulating layer, thereby increasing the thermal conductivity of the insulating layer to promote parison cooling.

Claim 6

A method of forming blow molded parts in a mold having a base including constant temperature cooling means, an insulating layer attached to at least a portion of the base, and a skin layer affixed to the insulating layer, the skin layer having a thermal conductivity greater than the insulating layer, said method comprising: extruding a parison in an open mold; closing the mold, pinching the bottom of the parison closed; introducing a gas into the parison, expanding the parison against the interior of the mold; opening the mold before the skin layer reaches the glass transition temperature of the resin of the part to be molded; removing and recycling the parison; extruding another parison in the mold while the skin layer is still hot; closing the mold, pinching the bottom of the parison closed; introducing gas into the parison expanding the parison against the interior of the mold, the portion of the parison contacting the skin layer not quenching thereby avoiding surface imperfections; opening the mold; and removing the finished part.

Claim 7

A method of forming blow molded parts in a mold having a base including constant temperature cooling means, an insulating layer attached to at least a portion of the base, and a skin layer affixed to the insulating layer, the skin layer having a thermal conductivity greater than the insulating layer, said method comprising: extruding a parison in an open mold; closing the mold, pinching the bottom of the parison closed; introducing a gas into the parison, expanding the parison against the interior of the mold; opening the mold before the skin layer reaches the glass transition temperature of the resin of the part to be molded; removing and recycling the parison; extruding another parison in the mold while the skin layer is still hot; closing the mold, pinching the bottom of the parison closed; introducing gas into the parison expanding the parison against the interior of the mold, the portion of the parison contacting the skin layer not quenching thereby avoiding surface imperfections; opening the mold; and removing the finished part.