US006254371B1

(12)

United States Patent

(10) Patent N0.: (45) Date of Patent:

McNally et al.

(54)

PRESS SYSTEM FOR URETHANE PARTS

(75) Inventors: Douglas J. McNally; Keith Wallace, both of Ontario (CA)

(73) Assignee: Konal Engineering and Equipment Inc., Blenheim (CA)

(*)

Notice:

Subject to any disclaimer, the term of this patent is extended or adjusted under 35

USC 154(b) by 0 days.

Filed:

FOREIGN PATENT DOCUMENTS 0 0 0 0 0

1 310 796 245 517A1 271 588A1 285 046A2 585 120A1 589 050A1

12/1992 11/1987 6/1988 10/1988 3/1994 3/1994

(CA) . (EP) . (EP) . (EP) . (EP) . (EP) .

* cited by examiner

Primary Examiner—James P. Mackey

(74) Attorney, Agent, or Firm—Flynn, Thiel, Boutell & Tanis, PC.

Mar. 12, 1998

(57)

Related US. Application Data

(63)

Continuation-in-part of application No. 08/915,621, ?led on Aug. 21, 1997, now abandoned.

(51) (52)

Int. Cl.7 .......................... .. B29C 33/20; B29C 44/34

(58)

Field of Search ............................... .. 425/451, 451.2,

US. Cl. ................. .. 425/214; 425/451.2; 425/451.7;

425/590

425/451.9, 450.1, 453, 451.7, 590, 409, 589, 214

ABSTRACT

The mold press includes a drive arrangement for controlling press movement and closure force. The drive arrangement includes a pair of generally identical drive units connected

betWeen upper and loWer press plates adjacent opposite longitudinal ends of the press. The drive units in a preferred embodiment each employ a ball-screW drive arrangement. The screW shaft extends vertically betWeen the top and bottom press plates. The screW shaft engages a ball nut

mounted on one press plate, typically the bottom press plate Which is disposed for movement toWard and aWay from the

top press plate. A?rst high speed drive arrangement employ ing a ?rst electric motor is coupled to the screW shafts for

References Cited

(56)

Jul. 3, 2001

Assistant Examiner—Emmanuel Luk

(21) Appl. No.: 09/041,068 (22)

US 6,254,371 B1

effecting high speed opening and closing of the bottom press plate. A second loW-speed driving arrangement including a

U.S. PATENT DOCUMENTS

second electric motor is drivingly connected to the ball-nut

3,262,158 *

7/1966 Reimer et al..

assemblies for permitting loW-speed but high-torque driving

4,008,026 * 4,828,475 *

2/1977 Engstrom . 5/1989 Kamiguchi ......................... .. 425/150

of the nut units for ?nal closing of the press and application of the desired press force. Each drive unit has the screW shaft

4,828,476 *

5/1989 Yoshiharu et al.

425/150

resiliently supported for limited axial displacement relative

4,944,669

7/1990

425/589

5,044,919 *

9/1991 Hama et al.

to the upper press plate so that, When the second drive system is activated to effect ?nal closure of the mold, one or the other of the screW shafts can be axially displaced a small amount if necessary so as to permit full closure betWeen the

5,091,124

2/1992

5,261,810

Zakich ............ .. Zakich ......... ..

11/1993 Kamp et al.

5,282,732

425/443 264/40.1

425/4519

2/1994 Eggert ...... ..

425/153

5,458,843 * 10/1995 Brown et al.

264/297.2

5,562,400

* 10/1996

Travis

.......... ..

5,741,528

4/1998 Amano et al

5,811,139 5,879,726 *

9/1998 3/1999

. 414/7453

425/29

Hehl ......... .. 425/590 Hsing .............................. .. 425/451.2

opposed upper and loWer mold parts even though irregu larities may cause one longitudinal end of the mold parts to

contact and close prior to the other longitudinal end.

11 Claims, 16 Drawing Sheets

U.S. Patent

Jul. 3, 2001

Sheet 1 0f 16

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U.S. Patent

Jul. 3, 2001

Sheet 2 0f 16

US 6,254,371 B1

U.S. Patent

Jul. 3, 2001

Sheet 3 0f 16

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U.S. Patent

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Sheet 4 0f 16

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US 6,254,371 B1 1

2

PRESS SYSTEM FOR URETHANE PARTS

hydraulic cylinders for creating the moving and pressing

CROSS REFERENCE TO RELATED APPLICATION

noise level associated With the ?uid cylinder system. Such

function of the press have also demonstrated an undesirable

systems also typically experience leakage of hydraulic ?uid, Which can create an undesired and sometimes potentially

This application is a continuation-in-part of application

haZardous condition around the press. The hydraulic sys tems also generate signi?cant and often undesired heat. Accordingly, it is an object of this invention to provide an

Ser. No. 08/915,621 ?led on Aug. 21, 1997, noW abandoned and entitled “PRESS SYSTEM FOR URETHANE PARTS”.

improved mold press Which is believed to overcome many

FIELD OF THE INVENTION

This invention relates to a press system for forming plastic parts, such as urethane parts, and more particularly to an improved press Which is preferably de?ned on a self propelled carrier associated With and suspended from an overhead transport system and Which includes an improved

of the disadvantages and inconveniences associated With knoWn mold presses, as brie?y summariZed above, and

Which is believed to provide for improved ef?ciency of operation, improved energy efficiency, and improved con venience of access and use. 15

More speci?cally, the improved mold press of this inven tion includes a drive arrangement for controlling the press

drive arrangement for effecting closure of the press.

movement and closure force Which is totally electric so as to

eliminate the use of hydraulic cylinders and the like, Whereby the overall energy ef?ciency of the press is signi? cantly improved, and at the same time, heat generation and

BACKGROUND OF THE INVENTION

It is conventional to form components Which are partially

or totally of plastic, particularly large components such as vehicle door panels and the like, in a reaction injection mold

oil leakage problems associated With conventional hydraulic

press (commonly referred to as a “rim” press) With the part

being formed in a mold cavity de?ned betWeen relatively movable upper and loWer mold parts. For forming a com ponent such as a vehicle door panel, various techniques can be utiliZed. For eXample, a vinyl sheet Which can be heated

25

and vacuumed formed, and possibly in conjunction With a ?berglass sheet, can be positioned in the mold cavity and

polyurethane deposited into the cavity to permit molding of the desired component Within the press. In some circum stances the vinyl is premolded or preshaped, or in other circumstances the molded component is formed Without a

shaft engaging a ball nut assembly Which is mounted on one

of the press plates, typically the bottom press plate Which is disposed for movement toWard and aWay from the top press plate. A ?rst high speed drive arrangement employing a ?rst

vinyl layer. The conventional mold presses for forming such compo

cylinder presses are eliminated. The improved mold press and speci?cally the drive arrangement includes a pair of generally identical drive units Which are associated With and connected betWeen the upper and loWer press plates adjacent opposite longitudinal ends of the press. The drive units in a preferred embodiment each employ a screW-nut drive arrangement, preferably a ball-screW arrangement. The screW shaft is an elongate member Which eXtends vertically betWeen the top and bottom press plates, With the screW

35

nents are often mounted on a turntable Which indeXes

electric motor is coupled to the screW shafts for effecting

high speed rotation and hence effecting high speed opening

through a plurality of stations formed along a circular Work

and closing movement of the bottom press plate. A second

path. While this arrangement does provide convenience With

loW-speed driving arrangement including a second electric

respect to ef?cient movement of multiple presses into and

motor is drivingly connected to the ball-nut assemblies of the tWo drive units for permitting a loW-speed but high torque driving of the nut units for ?nal closing of the press and application of the desired press force. Each drive unit

through spaced Workstations, nevertheless such turntable arrangement typically permits access to the press and spe ci?cally to the upper and loWer mold parts only from one side, and this greatly hinders and restricts the desired access

preferably has the screW shaft resiliently supported for limited aXial displacement relative to the upper press plate

to the press since Workers must access the press so as to not

only insert Whatever premold parts and components are necessary, but also to assist in removal of the molded part.

45

so that, When the second drive system is activated to effect

As an alternative, many of the knoWn mold presses are

?nal closure of the mold one or the other of the screW shafts can be axially displaced a small amount if necessary so as to

freestanding units. This increases Worker access by typically

permit full closure betWeen the opposed upper and loWer

permitting access to the press at least from opposite sides

mold parts even though irregularities may cause one longi tudinal end of the mold parts to contact and close prior to the

thereof. Nevertheless, the overall molding process associ ated With a single press involves several stages and hence requires signi?cant time, and thus ef?cient use of Workers accordingly normally requires that the Workers move back and forth so as to permit servicing of several adjacent freestanding presses. Such arrangement is less ef?cient than desired, and more fatiguing for Workers. With the knoWn mold presses, as brie?y discussed above,

other longitudinal end. In the improved mold press of this invention, as aforesaid, the ?rst and second drive systems are typically separately actuated in that only the ?rst drive system is activated so as 55

the opening and closing movement of the press, as Well as

the press closure force, is typically controlled by ?uid

to permit high speed movement of the loWer press plate during closure of the loWer mold part toWard the upper mold part until substantially reaching the closed position. At such time the ?rst drive system is deactivated, and preferably a locking device is actuated Which then engages and holds the screW shaft nonrotatable. The second drive system is then activated to effect rotation of the ball nut assemblies asso ciated With the loWer press plate to effect ?nal closure of the

pressure cylinders, normally hydraulic cylinders. Such press arrangements, hoWever, are generally energy inefficient since the use of hydraulic cylinders as the energiZing source,

and the overall support equipment necessary to provide and electrical energy Which is supplied so as to effect operation

mold and imposition of the desired mold pressure betWeen the upper and loWer mold parts. During activation of the second drive system, if one end of the mold parts contact and close prior to the other end, then the nut assembly associated

of the press ?uid system. In addition, presses employing

With said one end continues to drive, and the associated

supply pressuriZed hydraulic ?uid to the press cylinders, results in signi?cant energy loss in relationship to the

65

US 6,254,371 B1 3

4

screw shaft is axially displaced in opposition to the resilient

FIG. 3 is a further perspective vieW Which shoWs the same side of the press unit as FIG. 2, and Which illustrates the

structure associated thereWith until the drive unit associated With the other end of the mold parts senses proper closure, at Which time the second drive system is de-energiZed. The screW mechanisms associated With the drive units then effectively maintain the mold parts in a closed or locked

booking plate of the upper platen in a doWnWardly tilted access position. FIG. 4 is a diagrammatical side elevational vieW of the press unit. FIG. 5 is a diagrammatical end elevational vieW of the press unit of FIG. 4. FIG. 6 is an end vieW similar to FIG. 5.

position Whereby imposition of further driving force is not required, even though the mold parts remain in their closed

and effectively locked position. In accordance With the present invention, as aforesaid, the

10

mold press is preferably mounted on a self-propelled over head carrier associated With and driven along an overhead

rail system so that the mold press is suspended from the carrier and free of direct support from the underlying ?oor. The overall system preferably includes a plurality of carriers each mounting thereon a mold press, With the carriers being

15

sequentially moved through a plurality of spaced stations along the overhead track, the latter preferably de?ning a loop, to facilitate ef?cient use of the presses by permitting various functions to be carried out at spaced Workstations,

With the presses being ef?ciently transferred betWeen

Workstations, and With the actual molding operation being

controlling the tilting of the top booking plate.

carried out either as the carrier is transferred betWeen Workstations or is shuttled into an intermediate holding Zone

for sufficient duration to permit the desired molding of the

FIG. 12 is a side elevational vieW of the actuators for

controlling tilting of the loWer booking plate. 25

component. With the mold press mounted on a driven

movement through a series of Workstations. FIG. 14 is a top vieW similar to FIG. 10 but illustrating a

and loWer mold parts can be mounted on respective upper

modi?cation of the high-speed drive arrangement for driving

and loWer press plates Which vertically sWing into more convenient access positions, With the upper mold part sWinging into a position accessible from one side of the

the screW shafts.

FIG. 15 is an enlarged fragmentary elevational vieW, partially in cross section, of an upper portion of a modi?ed

press, and the loWer mold part sWinging into a position accessible from the opposite side of the press, Whereby tWo 35

screW shaft drive as associated With the press unit. FIG. 16 is a top vieW similar to FIG. 13 but illustrating a

further modi?ed high-speed drive arrangement for the screW shafts. FIG. 17 is a fragmentary side vieW of the modi?ed drive arrangement of FIG. 16.

In addition, the improved mold press of this invention includes a electric drive arrangement for controlling the opening and closing movement betWeen upper and loWer press plates. The drive arrangement includes a pair of generally parallel ball-screW drive units Which extend ver

tically and cooperate With the movable press plate for controlling opening and closing movement thereof. The

FIG. 13 is a diagrammatic top vieW of an overhead rail

system having plural press carriers associated thereWith for

overhead carrier, the press provides greatly increased access to the mold parts by Workers, and for example both the upper

Workers located on opposite sides of the press can readily and simultaneously access the respective upper and loWer mold parts to facilitate preparation of the mold. Other access positions or arrangements can also be provided.

FIG. 7 is an enlarged fragmentary vieW, partially in cross section, of the upper portion of the screW-type drive as associated With each end of the press unit. FIG. 8 is a diagrammatic sectional vieW shoWing the drive arrangement associated With the bottom platen of the press unit. FIG. 9 is a diagrammatical top vieW of the loW speed drive. FIG. 10 is a top vieW of the locking devices for the drive shafts. FIG. 11 is a top vieW illustrating the drive arrangement for

Certain terminology Will be used in the folloWing descrip tion for convenience in reference only, and Will not be

limiting. For example, the Words “upWardly”, “doWnWardly”, “rightWardly” and “leftWardly” Will refer to 45

press is mounted on a self-propelled overhead carrier asso

ciated With and driven along an overhead rail system so that the press can be sequentially moved betWeen the plurality of Working stations. The ball-screW drive units are driven from

directions in the draWings to Which reference is made. The Words “inWardly” and “outWardly” Will refer to directions toWard and aWay from, respectively, the geometric center of the press unit and designated parts thereof. Said terminology Will include the Words speci?cally mentioned, derivatives thereof, and Words of similar import.

an electric motor Which is mounted on and moves With the

DETAILED DESCRIPTION

carrier, With electrical poWer being supplied to the carrier in a conventional fashion from an electrical supply track Which

Referring to the draWings and speci?cally FIGS. 1—3,

extends along the overhead rail system. Other objects and purposes of the invention Will be apparent to persons familiar With assemblies of this general

there is illustrated a molding system 10 according to the present invention. The molding system 10 includes a plu 55

type upon reading the folloWing speci?cation and inspecting the accompanying draWings.

from an overhead rail system 12. The rail system 12 is

typically positioned in upWardly spaced relation from the

BRIEF DESCRIPTION OF THE DRAWINGS

?oor, such as adjacent a ceiling, and in the illustrated embodiment includes a pair of generally parallel and hori Zontally extending rails or beams 13 from Which individual carriers 11 are suspended. The rails 13 are typically formed

FIG. 1 is a perspective vieW taken from one side of an

overhead press arrangement according to the present invention, Which arrangement illustrates the loWer platen in

to de?ne a closed loop so that the carriers can be moved

an open position. FIG. 2 is a perspective vieW similar to FIG. 1 but taken

from the opposite side of the press arrangement, and illus

trating the booking plate of the loWer platen in an upWardly tilted access position.

rality of self-propelled carriers, only one carrier 11 being illustrated in FIGS. 1—3, supported in suspended relation

along a closed path into a plurality of Workstations de?ned 65

along the path. The carrier 11 includes a generally rigid frame 14 Which de?nes a top frame structure 15 disposed doWnWardly beloW

US 6,254,371 B1 5

6

and extending transversely between the pair of overhead

structure 26, and a bottom mold part 32 Which is ?xedly supported on and projects upWardly from the bottom press structure 27. The top and bottom mold parts 31 and 32 are

rails 13. The top frame structure 15 mounts thereon a

plurality of upwardly projecting cradles or yokes 16, With at

hence disposed generally in vertically aligned relation, and they respectively de?ne therein opposed mold cavity por

least tWo said yokes preferably being disposed adjacent each side of the frame adjacent front and trailing ends thereof.

tions Which cooperate to de?ne a mold cavity for forming the desired part When the bottom mold part has been moved up into a closed engaged relation With the upper mold part. The construction of the mold parts 31 and 32 is

Each cradle 16 in turn mounts thereon a plurality of rollers

17 Which effectively rollingly engage the upper surface of

the bottom ?ange of the respectively adjacent support rail 13. The support rail 13 in the illustrated and preferred embodiment is formed generally as an I-shaped beam so that

10

the rollers 17 effectively straddle the I-beam and rollingly engage the loWer ?ange thereof on opposite sides of the vertical Web of the I-beam. The top frame structure 15 also supports thereon at least one drive arrangement for the carrier, and in the illustrated embodiment a pair of drive rollers 18 are rotatably supported adjacent one side of the carrier and are disposed on opposite

believed unnecessary. The top press structure 26 preferably includes a top press 15

tudinally extending side edge thereof to the stationary upper

of the I-beam engaged therebetWeen. A suitable electrical

press structure 26 by a hinge structure 37 Which de?nes a

drive motor 19 is interconnected to one or both of the drive

generally horiZontally extending hinge axis 38, the latter extending generally in the longitudinal direction of the carrier and being disposed adjacent one side thereof. This hinge structure 37 permits the top booking plate 36 and the 25

The suspension of a carrier 11 from an overhead rail

arrangement, and the driving movement of the carrier along the overhead rails by means of a motoriZed drive roller arrangement mounted on the carrier, is conventional and

position, the upper mold part 31 is positioned so that the mold cavity thereof can be readily accessed by a Worker

standing adjacent one side of the press to permit perfor 35

vertically doWnWardly from the top frame in generally

shoWn in FIG. 6, a drive arrangement 41 is provided for

effecting movement of the top booking plate 36 betWeen the

extends vertically betWeen the end frames, but also trans

molding and access positions shoWn in FIGS. 5 and 6. The drive 41 includes a drive motor 42, preferably a pair of electric motors, mounted on the top frame structure 15. The

versely of the carrier (i.e., horiZontally sideWardly through the carrier relative to the longitudinal direction of movement of the carrier). The end frames 21 and 22 are substantially

motors 42 in turn rotatably drive a common drive shaft 43 45

Which in turn has drive pinions 44 secured thereto, the latter

being disposed in driving engagement With gear sectors 45. The gear sectors 45 extend through an angle of approxi

as associated With each side frame are rigidly joined to the top frame structure, and the loWer ends of the posts 23 as associated With each end frame are rigidly joined by a cross

mately 90°, and are ?xedly secured to and project upWardly from the top booking plate 36. EnergiZation of the motors 42, Which are preferably reversible electric drive motors,

rail 24 Which extends transversely therebetWeen. The frame 14 supports thereon a press 25 (i.e., a rim press) for forming parts Which are at least partially molded of a plastics material such as polyurethane. The parts are typi cally rather large in siZe and may comprise parts such as interior door panels for vehicles and the like. The press 25

mance of the necessary manual operations required relative to the upper mold part.

To effect movement of the top booking plate 36 betWeen the upper and generally horiZontal molding position shoWn in FIG. 5, and the vertically suspended access position

parallel relationship, and are cantilevered doWnWardly so as to de?ne a large open region therebetWeen Which not only

identical and each includes a pair of vertically elongate and substantially parallel support posts 23 Which are disposed in sideWardly spaced relation. The upper ends of the posts 23

top mold part 31 mounted thereon to be vertically sWung

doWnWardly about the axis 38 through an angle approaching 90° so that the top booking plate is thus suspended generally vertically doWnWardly betWeen the end frames 21 and 22 adjacent one side of the carrier, substantially as indicated by dotted lines in FIG. 6. When in this doWnWardly suspended

essary or desired.

further detailed description thereof is believed unnecessary. The frame 14 of the carrier 11 includes a pair of end frames 21 and 22 Which are disposed adjacent opposite longitudinal ends of the carrier, With the end frames 21 and 22 being rigidly ?xed to the top frame structure adjacent opposite ends thereof. The end frames 21 and 22 project

plate 36 Which de?nes thereon, in the normal operating position of the press, a generally horiZontally enlarged and doWnWardly facing surface to Which the upper mold part 31 is ?xedly secured. This top press plate 36, Which is often referred to as a booking plate, is secured along one longi

sides of one of the I-beam rails 13 so as to maintain the Web

rollers 18 to effect driving engagement With the support rail 13 When movement of the carrier 11 along the overhead rails is desired. While only one driving roller arrangement is illustrated in the draWings, it Will be appreciated that addi tional driving roller arrangements can be provided if nec

conventional, is designed in accordance With the speci?c part being formed, and further detailed description thereof is

causes driving of the gear sectors 45 to thus permit con

trolled sWinging movement of the top booking plate 36 betWeen the molding and access positions. The pair of drive motors 42 are preferably provided and drivingly connected 55

to the single drive shaft 43, and the motors 42 are also each

preferably provided With brake devices integrated thereon

as provided on the carrier 11 includes an upper press

Which engage Whenever the motors are de-energiZed. The

structure 26 Which in the preferred embodiment is ?xedly

provision of the pair of motors 42 for driving a single shaft

related to the top frame structure 15, and a loWer press

thus provide redundancy for safety purposes to accordingly

structure 27 Which is vertically movably supported on and betWeen the end frames 21 and 22. The bottom press structure 27 is vertically slidably guided on guides or gibs 28 Which are ?xed to and project vertically along the frame posts 23.

provide for control over the movement and positioning of

The press 25 is adapted to support thereon a mold Which

typically includes a top mold part 31 Which is ?xedly supported on and projects doWnWardly from the upper press

the top booking plate. The upper press structure 26 also includes a pair of

latching units 46 for positively holding the top booking plate 65

36 in its molding position. The pair of latch members 46 are provided on the upper press structure 26 adjacent the lon

gitudinally extending side thereof Which is opposite from the hinge axis 38, Whereby the latch units 46 are positioned for

Press system for urethane parts

Mar 12, 1998 - includes a pair of generally identical drive units connected. betWeen upper and loWer press plates adjacent opposite longitudinal ends of the ...

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