Patent US5356580A successfully refreshed from Google Patents.
US5356580A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of using a vented mold
Assignee: Woodbridge Foam Corp
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Filing: 1992-09-02
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Granted: 1994-10-18
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Expires: 2012-09-02
Abstract
Abstract A novel method of molding an article includes providing a mold with a vent of a pre-determined size such that, due to the difference in viscosities, gases to be vented from the mold may easily pass through the vent while the material to be molded cannot quickly pass through the vent. In fact, the vent is designed such that the material to be molded which enters the vent, does not exit the end of the vent. In the most preferred embodiment, the vent is in the form of a thin ribbon-like groove so that the material to be molded which does enter the vent forms a thin ribbon of extruded material which need not be removed prior to a finish cover being applied to the molded article.
Inventors
- 👤 Leslie E. Clark
- 👤 Craig A. Hunter
- 👤 Robert B. Magee
- 👤 Gerry V Wetering
- 👤 Wilfred W. T. Cheng
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 21:47
CPC Classifications
B; B29; B29C; B29C44/00; B29C44/34; B29C44/58; B29C44/588; B29C33/00; B29C33/10; B29K; B29K2105/00; B29K2105/04; Y; Y10; Y10S; Y10S425/00; Y10S425/812
Claims Analysis
Total Claims: 32
Claim 1
Independent Claim
222 words
A method of producing an article in a mold comprising an upper mold and a lower mold defining a mold cavity, the process comprising the steps of: dispensing a liquid foamable polymeric composition into the mold cavity; allowing the liquid foamable polymeric composition to expand to substantially fill the mold cavity; venting gases in the mold cavity through at least one vent in the mold to allow the gases to exit from the mold, the vent comprising a passageway between an interior of the mold and an exterior of the mold; selecting the size of each vent such that movement of the liquid foamable polymeric composition in the vent is restricted; at least partially curing the liquid foamable polymeric composition in the vent, slowing the movement of the composition therein; preventing the liquid foamable polymeric composition from exiting from the vent; and wherein the size of each vent is also selected such that the at least partially cured polymeric composition, which is extruded into said vent passageway: (i) does not exit the vent passageway to the exterior of the mold, and (ii) is a ribbon of foam material which, when folded back against said article, may be covered with a cover material to produce a covered article of acceptable appearance and texture without the need to remove said ribbon from said article.
Claim 2
Independent Claim
222 words
A method of producing an article in a mold comprising an upper mold and a lower mold defining a mold cavity, the process comprising the steps of: dispensing a liquid foamable polymeric composition into the mold cavity; allowing the liquid foamable polymeric composition to expand to substantially fill the mold cavity; venting gases in the mold cavity through at least one vent in the mold to allow the gases to exit from the mold, the vent comprising a passageway between an interior of the mold and an exterior of the mold; selecting the size of each vent such that movement of the liquid foamable polymeric composition in the vent is restricted; at least partially curing the liquid foamable polymeric composition in the vent, slowing the movement of the composition therein; preventing the liquid foamable polymeric composition from exiting from the vent; and wherein the size of each vent is also selected such that the at least partially cured polymeric composition, which is extruded into said vent passageway: (i) does not exit the vent passageway to the exterior of the mold, and (ii) is a ribbon of foam material which, when folded back against said article, may be covered with a cover material to produce a covered article of acceptable appearance and texture without the need to remove said ribbon from said article.
Claim 3
Dependent Claim
24 words
The method of claim 1 wherein said at least one vent is located at the part-line between said upper mold and said lower mold.
Claim 4
Dependent Claim
23 words
The method of claim 2 wherein the size of each vent comprises a thickness of from about 0.002 inches to about 0.030 inches.
Claim 5
Dependent Claim
23 words
The method of claim 2 wherein the size of each vent comprises a thickness of from about 0.005 inches to about 0.020 inches.
Claim 6
Dependent Claim
44 words
The method of claim 1, further comprising the step of venting gases from the mold cavity through a differential vent having a thickness of less than about 0.002 of an inch to inhibit substantially entry of said liquid foamable polymeric composition into said vent.
Claim 7
Dependent Claim
33 words
The method of claim 2 wherein each vent is substantially rectangular in cross-section and said liquid foamable polymeric composition entering said vent results in a ribbon of polymeric material attached to said article.
Claim 8
Dependent Claim
42 words
The method of claim 6 further comprising the steps of folding back said ribbon of polymeric material against said article and applying a finish cover to said article so that said ribbon is folded flat between said article and said finish cover.
Claim 9
Dependent Claim
33 words
The method of claim 3 wherein each vent is substantially rectangular in cross-section and said liquid foamable polymeric composition entering said vent results in a ribbon of polymeric material attached to said article.
Claim 10
Dependent Claim
42 words
The method of claim 8 further comprising the steps of folding back said ribbon of polymeric material against said article and applying a finish cover to said article so that said ribbon is folded flat between said article and said finish cover.
Claim 11
Dependent Claim
41 words
A method according to claim 1, wherein said selecting step includes the step of selecting a plurality of substantially rectangular cross-shaped vents, and wherein said liquid foamable polymeric composition forms a plurality of ribbons of polymeric material attached to said article.
Claim 12
Independent Claim
155 words
A method of producing an article in a mold comprising an upper mold and a lower mold defining a mold cavity, the process comprising the steps of: dispensing a liquid foamable polymeric composition into the mold cavity; allowing the liquid foamable polymeric composition to expand to substantially fill the mold cavity; venting gases in the mold cavity through at least one vent in the mold to allow the gases to exist from the mold, the size of each vent being selected such that movement of the liquid foamable polymeric composition into the vent is restricted to substantially prevent exist thereof from the vent, said liquid foamable polymeric material entering into said vent forming a ribbon of polymeric material attached to said article; and folding back said ribbon of polymeric material against said article and applying a finish cover to said article so that said ribbon is folded flat between said article and said finish cover.
Claim 13
Independent Claim
155 words
A method of producing an article in a mold comprising an upper mold and a lower mold defining a mold cavity, the process comprising the steps of: dispensing a liquid foamable polymeric composition into the mold cavity; allowing the liquid foamable polymeric composition to expand to substantially fill the mold cavity; venting gases in the mold cavity through at least one vent in the mold to allow the gases to exist from the mold, the size of each vent being selected such that movement of the liquid foamable polymeric composition into the vent is restricted to substantially prevent exist thereof from the vent, said liquid foamable polymeric material entering into said vent forming a ribbon of polymeric material attached to said article; and folding back said ribbon of polymeric material against said article and applying a finish cover to said article so that said ribbon is folded flat between said article and said finish cover.
Claim 14
Independent Claim
256 words
A method of producing an article in a mold comprising an upper mold and a lower mold defining a mold cavity, the process comprising the steps of: dispensing a liquid foamable polymeric composition into the mold cavity; allowing the liquid foamable polymeric composition to expand to substantially fill the mold cavity; venting gases in the mold cavity through at least one vent in the mold to allow gases to exit from the mold; and selecting the size of said at least one vent such that movement of the liquid foamable polymeric composition in the vent is restricted, and such that said vent extends between an interior of the mold an exterior of the mold; at least partially curing the liquid foamable polymeric composition in the vent, slowing the movement of the composition therein; causing the liquid foamable polymeric composition to enter the vent and preventing the liquid foamable polymeric composition from exiting from the vent to the exterior of the mold, wherein the size of each vent is also selected (i) such that the at least partially cured polymeric composition, which is extruded into said vent, does not exit from the vent to the exterior of the mold, and (ii) such that the polymeric composition which cures within said vent forms a flexible extrusion capable of being folded back against said article when a finished cover is applied over both said article and said folded-back flexible extrusion, such that a covered article may be produced without the necessity of removing said flexible extrusion from said article.
Claim 15
Independent Claim
256 words
A method of producing an article in a mold comprising an upper mold and a lower mold defining a mold cavity, the process comprising the steps of: dispensing a liquid foamable polymeric composition into the mold cavity; allowing the liquid foamable polymeric composition to expand to substantially fill the mold cavity; venting gases in the mold cavity through at least one vent in the mold to allow gases to exit from the mold; and selecting the size of said at least one vent such that movement of the liquid foamable polymeric composition in the vent is restricted, and such that said vent extends between an interior of the mold an exterior of the mold; at least partially curing the liquid foamable polymeric composition in the vent, slowing the movement of the composition therein; causing the liquid foamable polymeric composition to enter the vent and preventing the liquid foamable polymeric composition from exiting from the vent to the exterior of the mold, wherein the size of each vent is also selected (i) such that the at least partially cured polymeric composition, which is extruded into said vent, does not exit from the vent to the exterior of the mold, and (ii) such that the polymeric composition which cures within said vent forms a flexible extrusion capable of being folded back against said article when a finished cover is applied over both said article and said folded-back flexible extrusion, such that a covered article may be produced without the necessity of removing said flexible extrusion from said article.
Claim 16
Dependent Claim
24 words
The method of claim 12, wherein said at least one vent is located at the part-line between said upper mold and said lower mold.
Claim 17
Dependent Claim
23 words
The method of claim 13, wherein the size of each vent comprises a thickness of from about 0.002 inches to about 0.030 inches.
Claim 18
Dependent Claim
23 words
The method of claim 13, wherein the size of each vent comprises a thickness of from about 0.005 inches to about 0.020 inches.
Claim 19
Dependent Claim
44 words
The method of claim 12, further comprising the step of venting gases from the mold cavity through a differential vent having a thickness of less than about 0.002 of an inch to inhibit substantially entry of said liquid foamable polymeric composition into said vent.
Claim 20
Dependent Claim
33 words
The method of claim 13, wherein each vent is substantially rectangular in cross-section and said liquid foamable polymeric composition entering said vent results in a ribbon of polymeric material attached to said article.
Claim 21
Dependent Claim
42 words
The method of claim 17, further comprising the steps of folding back said ribbon of polymeric material against said article and applying a finish cover to said article so that said ribbon is folded flat between said article and said finish cover.
Claim 22
Dependent Claim
33 words
The method of claim 14, wherein each vent is substantially rectangular in cross-section and said liquid foamable polymeric composition entering said vent results in a ribbon of polymeric material attached to said article.
Claim 23
Dependent Claim
42 words
The method of claim 19, further comprising the steps of folding back said ribbon of polymeric material against said article and applying a finished cover to said article so that said ribbon is folded flat between said article and said finish cover.
Claim 24
Independent Claim
219 words
A method of producing an article in a mold comprising an upper mold and a lower mold defining a mold cavity, the process comprising the steps of: dispensing a liquid foamable polymeric composition into the mold cavity; allowing the liquid foamable polymeric composition to expand to substantially fill the mold cavity; venting gases in the mold cavity through at least one vent in the mold to allow gases to exit from the mold; selecting a vent having a passageway and an obstruction in said passageway, said obstruction and said passageway combining to form an opening having a shape which causes movement of the liquid foamable polymeric composition in the vent to be restricted, said vent passageway extending between an interior of the mold and an exterior of the mold; at least partially curing the liquid foamable polymeric composition in the vent, slowing the movement of the composition therein; preventing the liquid foamable polymeric composition from exiting from the vent, wherein the size of each is also selected such that the at least partially cured polymeric composition, which is extruded into said vent passageway, does not exit from the vent passageway to the exterior of the mold; and moving said obstruction axially inside said passageway to expel the at least partially cured liquid foamable polymeric composition from the vent passageway.
Claim 25
Independent Claim
219 words
A method of producing an article in a mold comprising an upper mold and a lower mold defining a mold cavity, the process comprising the steps of: dispensing a liquid foamable polymeric composition into the mold cavity; allowing the liquid foamable polymeric composition to expand to substantially fill the mold cavity; venting gases in the mold cavity through at least one vent in the mold to allow gases to exit from the mold; selecting a vent having a passageway and an obstruction in said passageway, said obstruction and said passageway combining to form an opening having a shape which causes movement of the liquid foamable polymeric composition in the vent to be restricted, said vent passageway extending between an interior of the mold and an exterior of the mold; at least partially curing the liquid foamable polymeric composition in the vent, slowing the movement of the composition therein; preventing the liquid foamable polymeric composition from exiting from the vent, wherein the size of each is also selected such that the at least partially cured polymeric composition, which is extruded into said vent passageway, does not exit from the vent passageway to the exterior of the mold; and moving said obstruction axially inside said passageway to expel the at least partially cured liquid foamable polymeric composition from the vent passageway.
Claim 26
Dependent Claim
17 words
The method of claim 21 wherein said at least one vent is located in said upper mold.
Claim 27
Dependent Claim
12 words
The method of claim 22 wherein each vent is segmental in cross-section.
Claim 28
Dependent Claim
23 words
The method of claim 22 wherein the size of each vent comprises a thickness of from about 0.002 inches to about 0.015 inches.
Claim 29
Dependent Claim
23 words
The method of claim 22 wherein the size of each vent comprises a thickness of from about 0.003 inches to about 0.010 inches.
Claim 30
Dependent Claim
55 words
A method according to claim 21, wherein said selecting step comprises the step of selecting a vent having a passageway and an obstruction in said passageway, said obstruction and said passageway combining to form an opening having a shape which causes the movement of the liquid foamable polymeric composition in the vent to be restricted.
Claim 31
Dependent Claim
48 words
A method according to claim 21, wherein said selecting step includes the step of selecting a passageway and an obstruction combining to form a plurality of openings between the obstruction and a wall of said passageway to cause the liquid foamable polymeric composition to move through said openings.
Claim 32
Dependent Claim
29 words
A method according to claim 27, wherein said venting step includes the step of venting the gases through a port which is in communication with said plurality of openings.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1997-10-17 | 1998-04-18 | 1998-10-18 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2001-10-17 | 2002-04-18 | 2002-10-18 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2005-10-17 | 2006-04-18 | 2006-10-18 | $7700.00 | Window Closed / Lapsed |