System and Method for Complex Objects Molding

Abstract

A molding system and method, allowing for the repeated use of the same molding insert for purposes of elaborate objects molding is described. The proposed method allows for multiple moldings of intricate shapes and curvatures improving the mass production of the jewelry moldings. During the process, the raw molding material is squeezed through the narrow opening inside the mold form under pressure. As the molding material enters the mold form, it is coated with a coating fluid. After the curing, the molding material could be easily removed through a narrow cavity opening, promptly reassembling back to the shape of the insert for continuous use in the next steps of the molding procedure.

Claims

1. A method of molding complex objects, said method comprising the steps of: providing a hollow cavity having an opening having a cross-sectional area; providing a dispensing container having an opening having a cross-sectional area, wherein the cross-sectional area of the dispensing container opening is smaller than the cross-sectional area of the hollow cavity opening; providing an elastomer in the dispensing container, said elastomer being pliable enough to be protruded from the dispensing container opening to enter the hollow cavity opening; said elastomer further having a property to change into a more rigid physical state under an outside influence; providing a fluid that remains unchanged under said outside influence; applying a pressure to the dispensing container thereby protruding a thread of the elastomer from the opening of the dispensing container to enter the hollow cavity through the opening, while said fluid spreads on the said elastomer's surface, preventing said elastomer from binding with itself and other surfaces; coating the thread of said elastomer with said fluid, whereby an unmixable combination is formed from the elastomer and the fluid; protruding the coated thread of said elastomer into the hollow cavity via the opening of the hollow cavity until the hollow cavity is completely filled with the unmixable combination of the elastomer and the fluid; cutting the elastomer thread coated with the fluid after the hollow cavity is completely filled with the elastomer coated with the fluid, allowing an end of the thread to protrude from the hollow cavity's opening; subjecting the hollow cavity filled up with the unmixable combination of the elastomer and the fluid to the outside influence whereby the elastomer is changed to a more rigid physical state; pulling the protruding end of the continuous thread away from the hollow cavity thereby removing the more rigid solid material thread from the hollow cavity; reassembling the pulled-out more rigid solid material thread into a shape of the hollow cavity form for a continuous use in a repeated molding.

2. The method of claim 1, wherein said elastomer is selected from the group consisting of high temperature vulcanizing silicone (HTV), mold making rubber, natural rubber, room temperature vulcanization (RTV) silicone putty, thermoplastic rubbers (also known as thermoplastic elastomers, or TPE), and reactoplastic polymers.

3. The method of claim 1, wherein said fluid is selected from the group consisting of mineral oil, organic oil, siloxanes, and Mold Release liquids.

4. The method of claim 1, wherein said fluid is further mixed with a filler powder selected from the group consisting of metal powders, metal oxide powders, silicate powders, calcium carbonate powders, granite powders, synthetic filler powders and sand powders.

5. The method of claim 1, wherein said fluid is placed inside said hollow cavity, prior to the elastomer being protruded into the hollow cavity, to assure the coating of the elastomer by the fluid.

6. The method of claim 1, where said elastomer and said fluid are combined prior to filling said hollow cavity.

7. The method of claim 1, wherein said outside influence is selected from the group consisting of ultraviolet, ultrasound, chemical, electrical and thermal treatment.

8. The method of claim 1, wherein said elastomer is stored in a container, said container opening's shape and diameter determining the shape and diameter of said thread.

9. The method of claim 1, wherein said hollow cavity has multiple openings that could be filled with said elastomer coated with said fluid to complete filling of said hollow cavity from said multiple openings.

10. The method of claim 1, wherein said method is used for a molding process selected from a group consisting of jewelry molding, dental implants molding, hearing aids molding, high-precision industrial molding.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] The detailed description particularly refers to the accompanying figures in which:

[0040] FIG. 1 is a prospective view of a complex molding form being injected through an opening cavity with a raw molding material by means of syringe;

[0041] FIG. 2 is a prospective view of a molding form completely filled with the raw molding material coated with coating fluid and cut from the syringe;

[0042] FIG. 3 is a schematic representation of a curing step when the molding form filled with the raw molding material coated with fluid undergoes curing;

[0043] FIG. 4 is a view of a step of a cured molding material removal through the opening cavity in the molding form;

[0044] FIG. 5 is a prospective view of the cured molding material removed from the molding form in an unwrapped configuration.

[0045] FIG. 6 is a prospective view of a step when the cured molding material wraps back together to restore itself into the shape of the insert mold.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0046] For the purposes of promoting and understanding the principles of the invention, reference will now be made to one or more illustrative embodiments illustrated in the drawings and specific language will be used to describe the same.

[0047] Referring to FIG. 1, a step of filling the mold form 1 with a raw molding material 4 via syringe 2 is depicted. The open end of the syringe is inserted into the opening of the cavity 3 in the molding form. The inside of the cavity of the molding form 1 is hollow and in the depicted embodiment is filled with a coating fluid 5 completely or partially prior to being filled with the raw molding material. As the syringe is squeezed, the narrow thread of the raw molding material 4 is being protruded inside the mold form. As the molding material fills the mold form, it is evenly coated with the coating fluid, replacing the coating fluid inside the mold form.

[0048] As could be seen from FIG. 2, as soon as the mold form is completely filled with the raw molding material coated with the coating fluid, the thread is cut off from the syringe. At this point, the coated raw molding material is tightly packed inside the mold form 1, with the cut-off end protruding from the opening of the cavity entrance.

[0049] FIG. 3 provides a schematic view of the curing step. During the curing step, the entire mold form with the coated raw molding material inside is subjected to chemical, thermal, electrical, ultraviolet or any other vulcanization treatment. During this step, the raw molding material undergoes chemical changes, forming internal bonds between the polymer links, turning into a more solid and rigid form. Due to the even coating with the coating fluid, there is no bonding between the threads of the molding material. To reduce the likelihood of such bonding, the coating fluid is usually selected from chemically inert liquids like mineral oils, organic oils, or combination of such oils with different powder fillers.

[0050] FIG. 4 demonstrates removal of the cured molding material from the cavity opening by means of tweezers. During this step, the entire uninterrupted line of the rigid vulcanized material is pulled through the narrow cavity opening layer by layer, in order to free the mold form. This process is a reverse of steps described in FIG. 1 and FIG. 2. The cured molding material is more rigid than previously injected soft raw molding material, allowing for the removal of the entire thread without tearing. Similar to a squeezed memory foam, the removed cured molding material strives to return to the shape of the mold form as soon as it is completely removed from the mold form.

[0051] FIG. 5 depicts the unwrapped form of the vulcanized molding material after being pulled from the mold form. This configuration of the cured molding material is strained due to the deformation after being pulled from the mold form. Due to rigidity, the cured molding material strives to resume the shape of the mold form.

[0052] FIG. 6 depicts the process of the cured molding material assuming the shape of the mold form or the insert. The thread, reassembled in the shape of the mold form, is ready to be used in the next step of the molding process. Due to the improved rigidity and resistance of the cured molding material, the next step of molding could be repeated many times before wear-and-tear causes the breaking of the insert.

[0053] Figures provide preferred embodiment of the invention. However, the invention is not limited to the disclosed configuration. Number of different materials could be used in place of the raw molding material and in place of the coating liquid. The mold form could be of any configuration, and could be filled from many different openings.

[0054] While the invention has been illustrated and described in detail in the foregoing drawings and description, the same is to be considered as illustrative and not restrictive in character, it being understood that only illustrative embodiments thereof have been shown and described and that all changes and modifications that come within the sprit and scope of the invention as defined in the following claims are desired to be protected.