METHOD FOR MOLDING MULTICOLORED SILICONE RUBBER ARTICLES

Abstract: Simultaneous molding of multicolored articles is accom­ plished by filling the cavities of an open mold with a plurality of differently colored, pumpable silicone rubber compositions us­ ing a single injector. The mold is then assembled and heated to cure the silicone rubber composition contained in the mold cavities and in a connecting clearance formed above the mold cavities when the mold is assembled.

Description: METHOD FOR MOLDING MULTICOLORED SILICONE RUBBER ARTICLES The present invention relates to a method for molding a multicolored silicone rubber article using a single molding operation. Generally, the key tops for calculators or computer keyboards are colored according to the function of the keystroke. In accordance with prior art teaching, molding of color-classified key tops from silicone rubber compounds is accomplished by separately milling a number of different colored paste-type silicone rubber compositions together with a curing catalyst to obtain a homogeneous composition, manually filling each of these compositions into the mold cavities of the lower section of metal mold, assembling the upper and lower mold sections and heating the mold to cure the contents. The shortcoming of this manufacturing method is that it not only requires time to mill the curing catalyst uniformly into the composition, but also requires a relatively long time to manually fill each mold cavity. Acreover, if each mold cavity is not filled with extreme care, the reject rate may be greatly increased, resulting in reduced productivity. Also, manually filling mold cavities with differently colored compositions is prone to error. It is known to prepare multicolored molded artIcles by simultaneously introducing two or more different colored molten thermoplastic organic polymer compositions into adjoining sections of a mold cavity and subsequently cooling the compositions to yield o unitarv article One disadvantage of such a method is the high probability of adhesive failure at the interfaces between the variously colored sections of the the article. The goal of the present invention is to provide a rapid method for manufacturing unitary, multicolored silicone rubber moldings such as key tops, while simultaneously reducing the reject rate and improving productivity relative to prior art methods. Unitary, molded silicone rubber articles comprising a plurality of differently colored objects joined together by a silicone rubber layer are prepared by filling a plurality of cavities simultaneously in the lower section of a disassembled metal mold with differently colored, pumpable, heat curable silicone rubber compositions. The filling is accomplished using an injector containing a separate compartment for each colored composition, said compartment having a plurality of outlet nozzles. The mold is then assembled and heated to cure the composition. The assembled mold contains a common chamber connecting together all of the mold cavities. The chamber is filled with at least one of said silicone rubber composItions. In the cured form, the contents of the chamber provide the silicone rubber layer that unites all of the molded objects to form said unitary article. This invention provides a method for manufacturing silicone rubber articles consisting essentially of a plurality of differently colored molded objects joined by a silicone rubber layer to form a unitary article, said method comprising the following sequence of steps: filling a plurality of mold cavities simultaneously in the lower section of an open metal mold with a plurality of differently colored pumpable silicone rubber compositions supplied by an ijcto, where each mold cavity is filled with single composition, said mold when assembled contains a connecting clarance above said mold cavities that roles access to all of said cavities, and where the amount of said compositions is sufficient to fill each of sala mold cavities and said connecting clearance following assembly of the mold; assemblIng the upper and lower sections of said mold and heating the silicone rubber compositions sufficiently to produce a unitary, cured silicone rubber article; and disassembling the mold and removing said cured article therefrom. Figure 1 illustrates the manufacturing method of the present invention. Figure 2 is a cross section, taken along line II-IT of Figure 3, of a prospective view of a typical mold useful in connection with the present method. Figure 3 is a top view of Figure 2 along imaginary surface from the direction indicated b arrow III. Figure 4 is a partially cut-away prospective view of the injector used in the present invention The individual moldings that together constitute the unitary articles formed in accordance with the present method are formed using two or more differently colored versions of the same silicone rubber composition. Each molding can be formed from a single color or a mixture of two or more differently colored compositions. The marble silicone rubber composition used to prepare the articles of the invention is a liquid at room temperature and is composed of a liquid, curable polyorganosiloxane, a filler, a crosslinking agent, and optionally, a curing catalyst as principal components. The composition cures to a rubber at room temperature or by heatin. During injectiDn into the mold cavities of the mold, the viscosity of the composition is preferably from 0.05 to 30 Pa s, measured using a BH-type rotary viscometer equipped with a number ? spindle. Curing of the silicone rubber composi-lon can occur bv means c an addition reaction, a condensation reaction, or a reaction catalyzed by an organic peroxide. From the viewpoints of curing rate and uniformity of curing, an addition reaction type of curing or a curing catalyzed by an organoperoxide is preferred. Color is imparted to the liquid silicone rubber composition by addition of a filler, a pigment or a combination of filler and pigment. Two or more liquid silicone rubber compositions are fed into the mold cavities in the metal mold by means of an injector. This injector distributes the compositions to all mold cavities simultaneously and is internally divided into one chamber for each color. Output nozzles corresponding to the location of each mold-cavity are located in the floor of the chambers. The liquid silicone composition is temporarily stored in these chambers and metered into the mold cavities through the output nozzles. Transfer of the liquid silicone rubber composition into the injector can be accomplished by gravity with the aid of a hydraulically or pneumatically activated piston or by utilizing pumps such as gear pumps. The metal molds are divided at least into a top and bottom section and the required number of mold cavities are present in the lower metal mold section. The metal mold can be disassembled into two or more sections as necessary. The mold cavities In the assembled metal mold are connected together by a connecting clearance located along the plane defined by the parting surfaces of the assembled mold. The quantity of liquid silicone rubber injected into each mold cavity can be equalized by means of this connecting clearance. This connecting clearance may be present as a depression in either upper or lower mold section or in both sections. When present in the upper metal mold section, the upper surface of the depression is preferably planar. Separation and/or assembly of the metal mold can be performed manually in small scale production, while mechanical operations are preferred in large-scale production. 4 practIcal application of the present invention is explained below with the aid of figures. Figure 1 (I), (tri) and (III) shows a process during which differently colored key tops are molded from a liquid silicone rubber composition. la and lb are the upper and lower sections of the divided metal mold. 2a, 2b and 2c are containers in which differently colored liquid silicone rubber compositions A, B and C are stored. 3a, 3b and 3c are gear pumps which supply injector 4 with silicone rubber compositions A, B and C from containers 2a, 2b and 2c. The structure of the divided metal mold composed of upper metal mold section la and lower metal mold section lb is shown In Figures 2 and 3. Both metal mold sections have several holes 5 and 6 for the insertion of cartridge heaters. A layer of thermal insulation material 7 and 8, such as asbestos, is applied to the top and bottom surfaces. Several mold cavities 9 are formed in the upper region of the lower metal mold section lb. A shallow, flat depression is formed in the parting surface of upper metal mold section la assembled with lower metal mold section lb. The depression 10 in upper metal mold section la assembled with lower metal mold section lb. The depression 10 in upper metal mold section la corresponds with area occupied by the open ends of the several mold cavities 9 in the lower metal mold section lb, and thus forms connecting clearance or chamber connecting these mold cavities 9 when the mold is assembled. A similar depression can be located in the lower metal mold section ib along wiTh the old cavities 9 or both the upper and lower metal mold sections la and lb may contain depressions similar to 10. Lower metal mold section lb can be further divided along imaginary surface F which intersects the bottom surfaces of mold cavities 9 and divides the metal mold into 3 sections. Upper and lower metal mold sections la and lb are held tightly in place by hook 11. However, because the weight of the metal mold itself also contributes to a tight assembly, hook 11 is not always necessary. The injector 4 comprises a main case 12 which is divided into 3 chambers, 12a, 12b and 12c, for storing three differently colored liquid silicone rubber compositions, A, B and C. Several output nozzles 13 are installed facing downward along the bottom surfaces of chambers 12a, 12b and 12c. Each output nozzle 13 is located above a mold cavity 9 into which the liquid silicone rubber composition is to be dispensed. When multicolored key tops are molded, the upper and lower metal mold sections la, 1b are first separated as shown in Figure 1, exposing the upper ends of the mold cavities. One output nozzle 13 is located above each mold cavity 9. Gear pumps 3a, 3b and 3c are then operated, transferring liquid silicone rubber compositions A, B and C from containers 2a, 2b and 2c into chambers i2a, 12b and 12c of injector 4 and simultaneously dIstributing the compositions to each mold cavity 9 through output nozzles 13. At least a portion of the cavities are filled above the plane defined by the upper surface of the lower mold section. After compositions A, B and C have been simultaneously fed into mold cavities 9, upper and lower metal mold sections la and 1b are tightly pressed together as shown In process Ii. at the momentwe upper metal mold section la presses against lower metal mold section 1b, part of the liquid silicone rubber composition filled into mold cavities 9 estates into the connecting clearance defined by depression 10, thereby equalizing the quantIties of composition present In adjacent mold cavities. Preferably a sufficient amount of composition is present to completely fill the space defined by the connecting clearance. The cartridge heaters inserted in insertion holes 5 and 6 then heat and cure the liquid silicone rubber composition. Jpon completion of curing, the upper and lower metal mold sections 1. and 1b are separated as shown in Figure 1 (III) to release molding M. Molding M consists of a single molding of several key tops molded in mold cavities 9 connected by a layer of silicone rubber formed In the connecting clearance formed by depression 10. The above example discloses the molding of key tops. By changing the shape of the mold cavities of the metal mold, the present method can be applied to fabricating other multicolored silicone rubber moldings. As mentioned above, due to the high flowability of the startIng silicone rubber composition in the present invention's method for manufacturing multicolor silicone rubber holdings, the time consuming roll kneading operation of the prior art is no longer necessary since the mold cavities can be rapidly filled. The high flowability also makes possible the molding of complicated shapes as well as high precision molding and reduces the reject rate. Moreover, because the mold cavities are filled by an injector device, sbmultaneous filling of multiple mold cavities is possible. The inefficiency resulting from filling a pasty ilicone rubber compositlcn into one mold cavity at a tIme is eliminated. Furthermore, by connecting each mold cavity at the metal mold parting surface by means of a connecting clearance, the amounts of lIquid silicone rubber composition in each mold cavity can be equalized. Since the mold cavities are fed by the output nozzle of an injector, a better quantitatIve control is exercised. Accordingly, the molding reject rate, particularly for small parts molding, can be significantly reduced.

Claims: CLAIMS 1. A method for manufacturing silicone rubber articles consisting essentially of a plurality of differently colored molded objects joined by a silicone rubber layer to form a unitary article, said method being characterised by sequentially (i) filling a plurality of mold cavities simultaneously in the lower section of an open metal mold with a plurality of differently colored pumpable silicone rubber compositions supplied by an injector, where each mold cavity is filled with a single composition, said mold when assembled contains a connecting clearance above said mold cavities that provides access to all of said cavities, and where the amount of said compositions is sufficient to fill each of said mold cavities and said connecting clearance following assembly of the mold ; (li) assembling the upper and lower sections of said mold and heating the silicone rubber compositions sufficiently to produce a unitary, cured silicone rubber article ; and (iii) disassembling the mold nd removing said cured article therefrom. 2. A method according to claim 1 where the interior portion of said Injector contains separate chambers for each color of liquid silicone rubber composition and each chamber is in communication with a plurality of outlet nozzles corresponding to at least a portion of the total number of said mold cavities. 3. A method accordIng to claim 1 where said liquid silicone rubber compositions are cured using an addition reaction or one catalyzed by an organoperoxide.

Inventors: HAMADA, MITSUO, SHIMIZU, KOJI
Applicants: TORAY SILICONE COMPANY LIMITED
Application year: 1984
Main classification: B29C31
IPC codes: B29K83, B29C39, B29L19, B29C31, B29C33