BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the exemplary embodiments of the present invention (including alternatives and/or variations thereof) may be obtained with reference to the detailed description of the exemplary embodiments of the present invention along with the following drawings, in which:
FIG. 1 is a schematic representation of a solidified molded article according to a first exemplary embodiment (which is the preferred embodiment);
FIG. 2 is a schematic representation of reinforcement-forming systems used to form a reinforcement used in the solidified molded article of FIG. 1; and
FIG. 3 is a schematic representation of a molding system used to manufacture the solidified molded article of FIG. 1.
The drawings are not necessarily to scale and are sometimes illustrated by phantom lines, diagrammatic representations and fragmentary views. In certain instances, details that are not necessary for an understanding of the embodiments or that render other details difficult to perceive may have been omitted.
DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS
FIG. 1 is the schematic representation of a solidified molded article 100 according to the first exemplary embodiment. Generally, the solidified molded article 100 includes, possibly amongst other things (such as impurities, etc): (i) a solidified matrix 102, and (ii) an additive 104A, 104B, 104C (any one or more thereof either depicted or not depicted) embedded in the solidified matrix 102. The additive 104A includes two nodules. The additive 104B includes three nodules. The additive 104C includes one nodule. Generally, any one of the additives may include one or more nodules. The additive 104A, 104B, 104C includes, amongst other things, an additive body 106A, 106B, 106C. The additive body 106A, 106B, 106C has: (i) a length 108A, 108B, 108C, and (ii) a varying diameter 110A, 110B, 110C along the length 108A, 108B, 108C of the additive body 106A, 106B, 106C. A technical effect is that the varying diameter 110A, 110B, 110C improves mechanical properties of the solidified matrix 102, such as strength, etc. The presence of the additive 104A, 104B, 104C makes it more difficult to pull apart the solidified matrix 102. By way of example, the additive 104A, 104B, 104C may include any one of a fiber, a reinforcement, a particle, a polymer and any combination and permutation thereof. Preferably, the additive 104A, 104B, 104C substantially includes a glass fiber. By way of example, the solidified matrix 102 includes any one of a polypropylene material, a thermoplastic material, a plastic material, a polymer and any combination and permutation thereof. Preferably, the solidified matrix 102 substantially includes the polypropylene material. Preferably, the additive body 106A has an hour-glass shaped profile (which may be called a boned structure), formed at least in part along the length 108A. The additive body 106A includes a distal portion 112A and also includes a midpoint portion 114A that is offset from the distal portion 112A, and the midpoint portion 114A is smaller in diameter than the distal portion 112A.
FIG. 2 is a schematic representation of reinforcement-forming systems 1 and 3 (hereafter referred to as the “system 1, 3” respectively) used to form a reinforcement 8 used in the solidified molded article 100 of FIG. 1. The system 1, 3 includes, amongst other things: (i) a reinforcement-diameter varying mechanism 9 that is configured to vary the diameter 110 of the additive body 106 of the additive 8 along the length 108 of the additive body 106. With reference to FIG. 3, the additive body 106 is embeddable in a matrix 122 of a molding material 120 usable for molding a solidified molded article 100; a molding system 21 is used to mold or manufacture the solidified molded article 100. Preferably, the additive body 106A, 106B, 106C is inelastically deformable at least in part; and more specifically, the additive body 106A, 106B, 106C is inelastically deformable at least in part at a forming temperature and/or at a forming pressure.
Preferably, the system 1, 3 includes a former 7 that is configured to form the additive 8. The former 7 is cooperative with the reinforcement-diameter varying mechanism 9. The former 7 includes a furnace 4 that is configured to receive and melt a material 2 (such as glass for example). The former 7 includes a bushing 6 that is positionable relative to the furnace 7. The bushing 6 is configured to receive the material 2 melted by the furnace 4. The bushing 6 is also configured to permit drawing of the material 2 so as to form the additive 8 (preferably, gravity is used to draw the glass from the bushing 6). The reinforcement-diameter varying mechanism 9 includes a take-up reel 18 that is configured to rotate so as to impart a varying pulling force to the additive 8 (by pulling on the reinforcement or the fiber, the diameter of the reinforcement or the fiber is made to vary). The pulling force imparted to the additive 8 causes the additive to travel with a varying speed. Alternatively, the system 3 includes the reinforcement-diameter varying mechanism 9 that has a cam surface 20 that is placed against or abuts against the reinforcement, and then the cam surface 20 imparts, at least in part, a profile on the additive 8 (and the additive 8 may travel at either (i) a constant speed or (ii) a varying speed). A bath 16 is configured to place a coating, at least in part, on the additive 8. A spray nozzle 14 is configured to spray a coolant, at least in part, on the additive 8. Alternatively, the spray nozzle 14 is configured to spray a coating, at least in part, on the additive 8 (without having to use the bath 16).
FIG. 3 is a schematic representation of a molding system 21 used to manufacture the solidified molded article 100 of FIG. 1. The molding system 21, includes, amongst other things: an extruder 22 that is configured to process a molding material 120. The extruder 22 is configured to operate in an injection mode, a compression mode and any combination and permutation thereof. The molding material 120, includes, amongst other things: a molten matrix 122, and the additive 104A, 104B, 104C (any one or more thereof) embedded in the molten matrix 122. The system 21 also includes, amongst other things, (i) a machine nozzle 32, (ii) a stationary platen 34 and (iii) a movable platen 36. A mold 42 includes: (i) a stationary mold portion 38 (that is mounted to the stationary platen 34), and (ii) a movable mold portion 40 (that is mounted to the movable platen 36). The system 21 further includes, amongst other things, tangible subsystems, components, sub-assemblies, etc, that are known to persons skilled in the art. These items are not depicted and not described in detail since they are known. These other things may include (for example): (i) tie bars (not depicted) that operatively couple the platens 34, 36 together, and/or (ii) a clamping mechanism (not depicted) coupled to the tie bars and used to generate a clamping force that is transmitted to the platens 34, 26 via the tie bars (so that the mold 42 may be forced to remain together while a molding material is being injected in to the mold 42). These other things may include: (iii) a mold break force actuator (not depicted) coupled to the tie bars and used to generate a mold break force that is transmitted to the platens 34, 36 via the tie bars (so as top break apart the mold 42 once the molded article 100 has been molded in the mold 42), and/or (iv) a platen stroking actuator (not depicted) coupled to the movable platen 36 and is used to move the movable platen 36 away from the stationary platen 34 so that the molded article 100 may be removed from the mold 42, and (vi) hydraulic and/or electrical control equipment, etc. A screw 28 is disposed in the extruder 22 and the screw 28 is connected to a drive unit 30. A hopper 24 is operatively connected to the extruder 22 as to feed the matrix 102 into the extruder 22. An auxiliary hopper 26 is also attached to the extruder and is used to feed the reinforcement to 8 to the extruder 22.
The description of the exemplary embodiments provides examples of the present invention, and these examples do not limit the scope of the present invention. It is understood that the scope of the present invention is limited by the claims. The exemplary embodiments described above may be adapted for specific conditions and/or functions, and may be further extended to a variety of other applications that are within the scope of the present invention. Having thus described the exemplary embodiments, it will be apparent that modifications and enhancements are possible without departing from the concepts as described. It is to be understood that the exemplary embodiments illustrate the aspects of the invention. Reference herein to details of the illustrated embodiments is not intended to limit the scope of the claims. The claims themselves recite those features regarded as essential to the present invention. Preferable embodiments of the present invention are subject of the dependent claims. Therefore, what is to be protected by way of letters patent are limited only by the scope of the following claims:
Patent Application
20080075943
