Method of making a two-component piston

Abstract

A method of making a two-component piston, the two-component piston including a piston cover as the first component and a piston body as the second component. The piston cover is arranged adjacent to the piston body and is configured to be moved relative to the piston body.

Claims

1. A method of making a two-component piston, the two-component piston comprising a piston cover as a first component and a piston body as a second component, the piston cover arranged adjacent to the piston body and configured to be moved relative to the piston body, the method comprising: forming the piston cover; and subsequently forming the piston body at the piston cover such that the piston body is non-releasably formed at the piston cover by a non-releasable connection present between the piston body and the piston cover, and the non-releasable connection is produced by a part of the piston body that is formed to extend through an attachment portion of the piston cover.

2. The method in accordance with claim 1, wherein the piston cover comprises an aperture, and the piston body comprises a web of material formed while forming the piston body at the piston cover such that the web of material of the piston body extends through the aperture.

3. The method in accordance with claim 1, wherein the piston cover has a front side and a rear side, the rear side being arranged adjacent to the piston body, and the piston cover is formed starting from a position present at the front side of the piston cover.

4. The method in accordance with claim 3, wherein the piston cover has a central region and the piston cover is formed starting from a position present at the central region.

5. The method in accordance with claim 1, wherein the piston body has a first side, a second side and a wall peripherally extending around the piston body between the first side and the second side, and the piston body is formed starting from a position present at the wall.

6. The method in accordance with claim 5, wherein the wall has a recess and the piston body is formed starting from a position present at the recess.

7. The method in accordance with claim 1, wherein the attachment portion is at least partly received in the piston body after the forming the piston body has been completed.

8. The method in accordance with claim 1, wherein the part of the piston body that extends through the attachment portion is formed by a web of material that extends through the attachment portion.

9. The method in accordance with claim 8, wherein the web of material extends through an aperture of the attachment portion, with the web of material being non-releasably connected to two sections of the piston body.

10. The method in accordance with claim 1, wherein the piston cover and the piston body are formed in an injection molding process.

11. The method in accordance with claim 1, wherein the piston body and the piston cover are formed from different materials.

12. The method in accordance with claim 10, wherein the piston cover and the piston body are formed in an injection mold by the injection molding process, and the forming the piston cover includes form the piston cover in a first mold of the injection mold, and further comprising removing parts of the first mold specific to a rear side of the piston cover from the injection mold after at least partly curing the piston cover; and using the piston cover as a part of a second mold for the piston body.

13. The method in accordance with claim 12, the method further comprising: maintaining the piston cover in the injection mold as part of the second mold; or introducing the piston cover into the second mold; introducing further parts of the second mold specific to the piston body; arranging the further parts of the second mold specific to the piston body relative to the piston cover; forming the piston body in the second mold; at least partly curing the piston body in the second mold; and removing the two-component piston from the second mold.

14. The method in accordance with claim 12, wherein a first point of injection for injection molding material for the piston cover is present at a part of the first mold configured to mold a front side of the piston cover.

15. The method in accordance with claim 14, wherein the piston cover is formed to have a central region at the front side and the first point of injection is present at a part of the first mold configured to mold a crown of the central region.

16. The method in accordance with claim 13, wherein the piston body is formed to have an outer wall extending from a first side of the piston to a second side of the piston, the second mold comprising a second point of injection for injection molding material for the piston body present in a region of a part of the second mold configured for the outer wall of the piston body.

17. The method in accordance with claim 16, wherein the outer wall of the piston body comprises a recess, and the second point of injection is present in a vicinity of the part of the second mold, which is configured for the recess.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The invention will be explained in more detail hereinafter with reference to the drawings.

(2) FIG. 1 is an exploded view of components of an embodiment of a cartridge;

(3) FIG. 2 is a further exploded view of components of a further embodiment of a cartridge;

(4) FIG. 3 is a view of an embodiment of a piston;

(5) FIG. 4 a section through the piston of FIG. 3;

(6) FIG. 5A is a first side view of a piston cover;

(7) FIG. 5B is a second side view of the piston cover of FIG. 5A;

(8) FIG. 5C is a view from above of the piston cover of FIG. 5A;

(9) FIG. 6A a schematic section through a first mold of an injection molding tool; and

(10) FIG. 6B a schematic section through a second mold of the injection molding tool.

DETAILED DESCRIPTION OF THE EMBODIMENTS

(11) Features which have the same or a similar function will be described in the following using the same reference numeral. It is also understood that the description given with respect to reference numerals used in one embodiment also applies to the same reference numerals in connection with other embodiments unless something is stated to the contrary.

(12) FIG. 1 shows a first embodiment of a cartridge 10. The cartridge 10 comprises an outlet 12, two chambers 14a, 14b and two pistons 16a, 16b. The outlet 12 of the cartridge 10 is sealed through the use of a cap mechanism 18. The cap mechanism 18 comprises a cap 20 which is secured to the cartridge 10 by a circlip 22 engaging a sealing plug 24. The outlets 12 are sealed through the use of the sealing plug 24. The cartridge 10 shown in FIG. 1 is a so-called 1:1 cartridge 10.

(13) FIG. 2 shows a further embodiment of a cartridge 10. In contrast to the embodiment of FIG. 1 the cartridge 10 of FIG. 2 shows a so-called 4:1 cartridge 10. This means that a volume of material M that can be stored in the first chamber 14b is four times a volume of material M′ that can be stored in the second chamber 14a. A further difference between the cartridges 10 of FIG. 1 and FIG. 2 is the closure cap 26. The closure cap 26 of FIG. 2 is secured at the cartridge 10 by a so-called bayonet means or device 27 as is well known in the art. Other kinds of closure caps (not shown) can also be used to seal off the outlet 12 from the cartridge 10.

(14) The closure cap 26, the cap mechanism 18 and the ratios of cartridges 10 shown in FIG. 1 and FIG. 2 can be arbitrarily combined, depending on the specific use of the cartridge 10 and/or of the materials to be dispensed using said cartridge 10. Since the volume of the chambers 14a, 14b of the cartridge of FIG. 2 is different, the outer diameter, i.e. the size of the pistons 16a, 16b employed in the chambers 14a, 14b is also different as is clear from FIG. 2.

(15) FIG. 3 shows a schematic view of a piston 16. The piston 16 comprises a generally cylindrically shaped piston body 28 and a piston cover 30. The piston cover 30 covers at least a substantial part of a first side 32 of the piston 16. The piston body 28 further comprises a centering portion 34 in the form of a circumferentially extending chamfered lip 34a at the first side 32. The lip 34a has three venting slots 36 disposed therein as venting means or system 36a in order to permit venting of air present between the lip 34a and a chamber wall of the cartridge (not shown) once the piston 16 is installed in the cartridge 10 and the venting process is carried out.

(16) A sealing lip 38 is disposed beneath the chamfered lip 34a as a sealing means or device 38a. The selling lip 38 is provided to ensure a seal between the cartridge 10 and the piston 16 in order to prevent air or the like from entering or exiting the cartridge 10 via the sealing lip 38. As can be seen the sealing lip 38 is adjacent to the centering portion 34.

(17) Moreover, a boundary of the venting slots 36 is preferably directly adjacent to a boundary of the sealing lip 38 which is adjacent to the centering portion 34. This ensures that the venting means 36a are positioned such that air can be reliably vented from the space between the centering lip 34 and the cartridge wall. In the Figure shown, the venting slots 36 have the form of a generally U-shaped valley in a cross-section thereof. Naturally speaking any other kind of shape can be selected for the venting slots 36, such as a V-shaped valley or a simple through bore extending through the centering portion.

(18) On insertion of the piston 16 into the cartridge 10 the centering portion 34 not only functions as a centering aid to protect the sealing lip 38 from becoming damaged on insertion of the piston 16 into the cartridge and thus aids in avoiding leaks, but also as a scraper and thereby helps to clear material and any particles present at the cartridge wall from the area close to the cartridge wall (this is naturally only the case when the materials include particles).

(19) In this connection it should be noted that the piston cover 30 is typically made from a material different from that of the piston body 28. The material of the piston cover 30 can e.g. comprise PE or PBT; that of the piston body 28 can e.g. comprise PA (polyamide) or HDPE. In a preferred embodiment of the two-component piston 16, the piston cover 30 comprises PBT and the piston body 28 comprises HDPE.

(20) The piston cover 30 has a concavely shaped central region 42 which can be considered to have the shape of a plate. Venting grooves (not shown) can be disposed at a front side 50 of the piston cover 30 to facilitate the air removal from the concavely shaped central region 42. Such venting grooves could extend from the central region 42 of the piston cover 30, and also project downwardly along a peripherally extending side portion 44 of the piston cover 30 into a groove 46 formed within the piston body 28. The venting grooves could extend into the groove 46 over a complete height of the side portion 44.

(21) FIG. 4 shows a section through the piston 16 of FIG. 3 along the sectional line A-A of FIG. 3 that coincides with a longitudinal axis A of the piston 16. The piston cover 30 extends into the peripherally extending groove 46 of the piston body 28. Moreover, the piston cover 30 has the front side 50 at the first side 32 and a rear side 48. The rear side 48 has a shape which is complementary to a substantial part of the shape of the first side 32 of the piston body 28. The piston cover 30 also has a so-called valve pin 52 which forms part of a valve 54 arranged between the piston cover 30 and the piston body 28. The center of the valve pin 52 coincides with the longitudinal axis A of the piston 16. At the first side 32, the piston body 28 comprises an inner wall 33 having a top end 40′, an outer surface 40 and a valve surface 40″. Parts of the rear side 48 the piston cover 30 are supported at the inner wall 33 in a non-venting state of the piston 16.

(22) On installation of the piston 16 into the cartridge 10, the valve pin 52 can be actuated. Thereby the piston cover 30 is lifted off from the piston body 28 and permits an air flow in a venting channel (not shown) then present between the rear side 50 of the piston cover 30 and the wall 33 of the piston body 28, i.e. between the piston cover and the top end 40′, the outer surface 40 and the valve surface 40″. This then permits a venting of residual are present at the first side 32 of the piston 16 from the front side 50 of the piston cover via the valve 54.

(23) On actuating the valve pin 52 from the second side 68, the valve pin 52 is moved along the longitudinal axis A in the direction of the piston cover 30 causing the concavely shaped central region 42 to deflect and to become less concave or in some instances even convex. Thereby forming the venting channel (not shown) between the rear side 50 of the piston cover 30 and the piston body 28 in the region of the top end 40′, the outer surface 40 as well as the valve surface 40″.

(24) The longer a length of the valve pin 52 selected, the further the piston cover 30 can be lifted from the piston body 28. Thereby, a space of the venting channel provided for air to be vented from the cartridge 10 via the piston 16 is enlarged. Rather than using the valve pin 52 shown in the Figures other forms of valve members 52a, such as a hollow cylindrical member (not shown) can be used. The valve member 52a has two functions, namely to cooperate with a plunger for venting and with the valve surface 40″ of the piston body to form the valve 54.

(25) The piston 16 has an outer peripheral surface 56 formed by a peripherally extending outer wall 57, with the annular groove 46 being formed between the outer wall 57 and the inner wall 33.

(26) The outer peripheral surface 56 respectively the outer wall 57 of FIG. 4 has a substantially cylindrical outer shape and has the chamfered centering lip 34 at the first side 32. Following an outer contour of the outer peripheral surface 56 from the first side 32 to a second side 68 of the piston 16, the piston body 28 comprises the centering lip 34, the sealing lip 38, a first recess 58 and a stabilizing projection 60 formed at the second side 68. The first recess 58 is arranged between the sealing lip 38 and the stabilizing projection 60.

(27) The stabilizing projection 60 is disposed on the piston 16 in order to stabilize the piston 16 as it travels along the cartridge wall during a dispensing action. This ensures that the piston 16 travels along the cartridge wall in an as uniform as possible manner.

(28) Moreover, a sprue mark 78 is present in the first recess 58, indicating that the piston body 28 is formed in an injection molding process and that the point of injection of the molding material at the corresponding mold 96 (see FIG. 6B) is present in a region of the mold designed to form the outer wall 57.

(29) The second side 68 of the piston 16 further comprises a central recess 70 into which a plunger (not shown) can be introduced in order to actuate the valve pin 52. The second side 68 can further be actuated to move the piston 16 in the cartridge to dispense a material M, M′ present in the cartridge 10 via the outlet 12.

(30) The plunger is designed such that it does not engage the valve 54 during a dispensing action, as otherwise a component present in the cartridge 10 could leak out of the cartridge 10 via the central recess 70 on dispensing.

(31) The piston body 28 can comprise an O-ring (not shown) arranged at the outer peripheral surface 56. Such sealing O-rings are advantageously used, in order to ensure a continuous seal of cartridges that are not only used for one application, but for many applications spaced apart in time.

(32) The piston cover 30 is non-releasably connected to the piston body 28. The non-releasable connection is formed by a part 62 of the piston body 28 extending through an attachment portion 64 of the piston cover 30. The piston cover 30 comprises at least two attachment portions 64 for the non-releasable connection between the piston cover 30 and the piston body 28. The piston body 28 comprises two parts 62 that each respectively extend through a respective attachment portion 64. The attachment portions 64 are arranged such that they face one another on opposite sides of the longitudinal axis A. The attachment portion 64 projects from the piston cover 30 at least generally in the direction of the second side 68.

(33) Each attachment portion 64 comprises an aperture 64′ (see also FIGS. 5A to 5C) and the part 62 of the piston body 28 that extends through the attachment portion 64 at least substantially completely fills an internal space of the aperture 64′.

(34) In the present example the part 62 of the piston body 28 that extends through the attachment portion 64 is formed by a web 62′ of material that extends through the attachment portion 64. The web of material is non-releasably connected to two sections of the piston body 28 disposed on either side of the attachment portion 64. The web 62′ is formed from the same material as the piston body. Similarly the attachment portion 64 is formed from the same material as the piston cover 30.

(35) The attachment portion 64 is integrally formed with the piston cover and projects from the piston cover 30 at a region of a base 66 of the groove 46 of the piston body 28 in the direction of the second side 68. The attachment portion 64 is completely received in the piston body. To this end the base 66 of the groove 46 comprises an attachment portion recess 65. The piston body 28 is formed around the attachment portion 64 and adjacent to the piston cover 30.

(36) The central region 42 of the piston cover comprises a crown 74. A sprue mark 76 is present at the center of the crown 74. This sprue mark 76 indicates that the piston cover 30 was injection molded and that the point of injection of the molding material at a corresponding mold 92 (see FIG. 6A) is present in the region of the crown 74.

(37) FIGS. 5A to 5C show various views of the piston cover 30. As can be seen the aperture 64′ has an at least generally rectangular shape. The dimensions of the aperture 64′ are chosen such that the lower frame 84 of the aperture 64′ (i.e. the part which is completely embedded in the second plastic) is located roughly at equal distances to the surrounding exterior surfaces of the piston body 28, i.e. the outer wall 57 and a wall of the recess 70. The lower frame 84 is connected to the upper frame 86 of the attachment portion 64 via two arms 88. In the drawing shown a width of the arms 88 is greater than a height of the lower frame 84. The height of the lower frame could also be more than a width of the arms 88 or equivalent thereto. The upper frame 86 is integrally formed at a lower side 89 of the piston cover 30 and thus projects from the piston cover 30 at the lower side 89 thereof.

(38) The side portion 44 of the piston cover has an undulated shape indicated by two recesses 80, 80′ and two peaks 82, 82′. These features are present in order to ensure a gripping of the piston cover 30 during a forming of the piston body 28 as will be discussed in the following.

(39) FIG. 6A shows a schematic section of an injection mold 90 for the two-component piston 16 discussed in the foregoing. The injection mold 90 comprises a first mold 92 for the piston cover 30. The first mold has a first injection channel 94 forming a first point of injection for the injection molding material for the piston cover 30. The first injection channel 94 is present at a part of the first mold 92 for molding the front side 50 of the piston cover 30.

(40) The injection molding material is introduced into the first mold 92 at the respective temperatures and pressures typically used for the material of the piston cover 30 via the first injection channel 94. On molding the piston cover 30 the sprue mark 76 will be present at the crown 74.

(41) As shown in FIG. 6B, the injection mold 90 further comprises a second mold 96 for the piston body 28. On injection molding the piston 16, the piston cover is initially molded in the first mold 92 and subsequently forms a part of the second mold 96.

(42) The second mold 96 comprises a second injection channel 98 forming a second point of injection used for the injection of molding material for the piston body 28. The second point of injection is present in a region of a part of the second mold 96 for an outer peripheral wall 57 of the piston body 28.

(43) Thus, in the method of manufacturing the two-component piston, the sprue marks for the piston cover 30 and for the piston body 28 are moved in comparison to prior art molds. In the prior art processes, the plastic was injected from the bottom of the pin which is also the position where the valve is operated (by pressing the pin in the direction of the material side). In order to minimize the size of the sprue mark formed there good care needed to be taken to keep the sprue mark under control. This necessitated the use of a needle valve for the hot runner which is rather expensive.

(44) Moving the sprue mark to the front side of the piston cover in the new method, the position of the sprue mark is less critical with respect to any local residual resin. Thus a cheaper runner system can be used. In this connection it should be noted that the position of the sprue needs to be close to the axis of symmetry for the formation of the piston cover 30.

(45) Also the sprue mark 78 for the piston body has been moved from the second side 68 to the outer wall 57 in comparison to prior art molds. This also simplifies the method of manufacture of the piston body 28.

(46) On making a piston the following method of making the two-component piston 16 is carried out: In a first step the piston cover 30 is formed by injecting injection molding material via the first injection channel 94 into the first mold 92. Subsequently in a second step the piston body 28 is formed at the piston cover 30 in the second mold 96.

(47) During the first step the piston cover 30 is formed starting from a position present at the front side 50 of the piston cover 30, more specifically at a position representing the center of the crown 74 of the central region 42. This starting position is later defined by the sprue mark 76 present at the piston cover 30. Once the piston cover 30 has been allowed to cure for a certain period of time either completely or partially, parts of the first mold 92 specific to the rear side 48 of the piston cover 30 are removed from the injection mold 90.

(48) The piston cover 30 is then used as a part of a second mold 96 for the piston body 28. This can be conducted in a further injection mold 90 or in the same injection mold 90 in which the piston cover 30 was formed.

(49) During the second step the piston body 28 is formed starting from a position present at the outer wall 57, more specifically, at a position present at the recess 58 of the outer wall 57 via the second injection channel 98. This second injection channel 98 forms the second point of injection that causes the sprue mark 78 to be formed in the recess 58.

(50) Once the position of the piston cover 30 has been ensured in the second mold 96 the remaining parts of the second mold 96 specific to the piston body 28 are introduced into the injection mold 90. Thereafter, the piston body 28 is formed by introducing injection molding material into the second mold 96 at the respective temperatures and pressures typically used for the material of the piston body 28 via the second point of injection 96. Thereafter, the piston body is allowed to at least partly, preferably completely, cure in the second mold 96, before the final two-component piston 16 is removed from the second mold 96 and made available for assembly with the cartridge 10.