A method of moulding plastics

Abstract: A method of moulding plastics by rotary moulding in which the plastics is subjected to a pressure differential, preferably by introducing gas under pressure to the mould cavity during its rotation. The pressure differential being applied no earlier than a stage at which all of the plastics has melted in the cavity and no later than the stage at which the plastics commences to solidify during cooling of the mould. Said pressure differential being maintained at least until all of the plastics in the cavity has solidified to the moulded product.

Description: TECHNICAL FIELD AND BACKGROUND ART The present invention relates to a method of moulding plastics and, more particularly, to rotational moulding in which the plastics material in the moulding tool is subjected to a pressure differential to improve the quality of the moulded product. The formation of thermoplastics articles by rotational fusion moulding is a well known process. Such a process is disclosed in International Patent Publication WO-A-91/05647 where temperature within the mould tool is monitored to determine, relative to moulding time, when all of the plastics material has been melted, when the plastics moulding has achieved its optimum properties and when the moulding can be removed from the tool so that the moulding process can be controlled for a particular plastics material. It is also known to introduce into the mould tool during its rotation, a gaseous medium, at pressure, for maintaining the plastics material against the face of the cavity in the tool and alleviating the formation of bubbles or voids in the plastics moulding. Patent Specification US-A-3,514,508 (which provides the basis for the preamble to claim 1 hereof) discloses the circulation of an inert gas under pressure through the mould tool, such gas conveniently serving to cool the interior surface of the plastics moulding. However subjecting the plastics material to a pressure differential as aforementioned, indiscriminately or without strict monitoring, can cause any bubbles that are formed in the plastics moulded product to be pressurised, which would weaken the moulded structure and provide an unacceptable finish to the product. It is an object of the present invention to provide an improved method of moulding plastics by rotational moulding which alleviates the disadvantages of the prior proposals, particularly by alleviating the formation of bubbles or voids in the moulded product, in a simple, economical and efficient manner. STATEMENT OF INVENTION According to the present invention there is provided a method of moulding plastics which comprises charging a cavity of a rotary mould with plastics powder or granules; rotating the mould to tumble the powder or granules in the cavity and heating the powder or granules successively through a first heating phase during which the powder or granules is progressively melted and at the end of which all of the plastics has melted to a layer on an internal surface of the rotating mould and a second heating phase during which the molten plastics layer attains a predetermined maximum temperature; cooling the plastics layer from said maximum temperature successively through a first cooling phase to a transition phase at the commencement of which the molten plastics layer commences to solidify and at the termination of which the plastics layer forms a substantially solid plastics moulding, and in which the molten plastics layer is subjected to a pressure differential with pressure on the face of said layer adjacent to the internal surface of the mould being less than pressure on the face of the layer remote from said internal surface, CHARACTERISED IN THAT the molten plastics layer is subjected to the pressure differential subsequent to the first heating phase and prior to the commencement of the transition phase and said pressure differential is maintained at least until the termination of the transition phase. Preferably, the pressure differential will be applied at the commencement of the second heating phase and will usually be removed at the termination of the transition phase. Subsequent to the termination of the transition phase the solid plastics moulding will usually be further cooled prior to its removal from the mould cavity. FIGURES A method of rotation moulding in accordance with the present invention will now be described, by way of example only, with reference to the accompanying Figures, in which:- FIGURE 1 is a graph showing internal mould temperature (°C) against time (Minutes) for rotational moulding of a Polyethylene product; and FIGURE 2 is a graph showing internal mould temperature (°C) against time (Minutes) for rotational moulding of a Polypropylene product. DETAILED DESCRIPTION WITH REFERENCE TO THE FIGURES The rotational moulding of thermoplastics material is carried out by charging a cavity of a rotary moulding tool with the plastics material, such as polyethylene, in the form of granules or as a powder and heating this plastics material as the mould is rotated. As its temperature rises the plastics material gradually melts and, due to the centrifugal forces to which it is subjected by the rotating tool, the plastics forms a layer on the internal surface of the tool in the mould cavity. The plastics material is then heated to a maximum temperature, ensuring all the material is completely melted, before being allowed to cool and solidify, as the moulding tool continues its rotation, until the moulded plastics product is obtained. The plastics material is subjected to a pressure differential, preferaby by increasing the internal pressure of the mould cavity during the moulding process; this may be achieved by injection of compressed air, or other gas at high pressure into the mould cavity. This pressure differential serves two purposes, it helps hold the molten plastics material against the surface of the moulding tool during the cooling stage and it has been shown to reduce the formation of bubbles or voids within the plastics material, which bubbles could adversely affect the strength of the moulded structure and mar the finish of the exterior surface of the moulded article. However, care must be taken with the use of gas under pressure in the mould cavity. Such pressure if applied incorrectly may be ineffective and indeed may prove to have a detrimental effect on the final article, especially if it causes pressurized gas bubbles to develop within the plastics material. Our research has indicated that the aforementioned gas pressure differential, especially the introduction of gas under pressure to the tool cavity, should only be applied when the plastics material is completely melted if the aforementioned gas bubbles are to be avoided and a satisfactory external surface finish for the moulded product is to be achieved. Our studies of the variation of temperature of thermoplastics during rotary moulding against time during the moulding process (known as a "Rotolog Trace") have revealed that for most thermoplastics materials the temperature follows a standard pattern, as is illustrated in the graphs of Figures 1 and 2 which are typical for polyethylene and polypropylene respectively. In typical cases of polyethylene and polypropylene it can be seen from Figures 1 and 2 that at the start of the moulding process, as the mould is heated uniformly, the temperature of the plastics rises steadily to point A and the plastics material remains in a solid form, tumbling within the rotating mould. At point A the plastics material begins to melt and adhere to the surface of the cavity in the mould, and the rate of temperature increase of the plastics within the mould decreases as extra energy (latent heat) is absorbed by the plastics material to cause it to melt. At point B all of the plastics material has melted and the temperature of the plastics again continues to rise steadily to a maximum, controlled temperature at point C. The mould is then allowed to cool until region D in the graph where the curve flattens out , the first timed inflexion point D' of region D indicating where the plastics material begins to solidify (which may result from crystallisation of the material releasing latent heat, thus maintaining the temperature of the mould at this time) and the second timed inflexion point D'' of region D indicating that the plastics material has completely solidified, the mould then cools further until the plastics moulded product may be removed at point E. Thus, from studies of the temperature of the mould (the Rotolog Trace) and the plastics material it is possible to determine closely the time region at which the plastics material has completely melted, (point B in the Figures) and also the time region at which the molten plastics begins to solidify (the first timed inflexion point D' of region D in the Figures). Our research has indicated that to alleviate bubble formation or voids in, and to provide an efficient external surface finish for, the moulded product, and in accordance with the present invention, the plastics material has to be subjected to the pressure differential, preferably by introducing gas under pressure into the cavity of the moulding tool, no earlier than point B and no later than the first timed inflexion point D' as shown in the Figures. Preferably the pressure differential is applied at point B. The period for which the pressure differential is maintained is variable up to the moment of demoulding (point E) but this period has to extend until plastics material has solidified as indicated at the second timed inflexion point D'' in the Figures. Usually the pressure differential will be removed at the termination of the transition phase D (that is at the inflexion point D'').

Claims: A method of moulding plastics which comprises charging a cavity of a rotary mould with plastics powder or granules; rotating the mould to tumble the powder or granules in the cavity and heating the powder or granules successively through a first heating phase during which the powder or granules is progressively melted and at the end of which all of the plastics has melted to a layer on an internal surface of the rotating mould and a second heating phase during which the molten plastics layer attains a predetermined maximum temperature; cooling the plastics layer from said maximum temperature successively through a first cooling phase to a transition phase at the commencement of which the molten plastics layer commences to solidify and at the termination of which the plastics layer forms a substantially solid plastics moulding, and in which the molten plastics layer is subjected to a pressure differential with pressure on the face of said layer adjacent to the internal surface of the mould being less than pressure on the face of the layer remote from said internal surface, CHARACTERISED IN THAT the molten plastics layer is subjected to the pressure differential subsequent to the first heating phase and prior to the commencement of the transition phase and said pressure differential is maintained at least until the termination of the transition phase. The method of claim 1 in which the pressure differential is applied at the commencement of the second heating phase. The method as claimed in either claim 1 or claim 2 in which the pressure differential is removed at the termination of the transition phase. The method as claimed in any one of the preceding claims in which subsequent to termination of the transition phase the solid plastics moulding is further cooled prior to its removal from the mould cavity. The method as claimed in any one of the preceding claims in which the pressure differential is applied by introducing air or other gas under pressure into the cavity of the rotating mould.

Inventors: CRAWFORD R J PROFESSOR, SPENCE A, CRAWFORD, R.J., PROFESSOR, SPENCE, A.
Applicants: LIN PAC MOULDINGS, LIN PAC MOULDINGS LIMITED
Application year: 1993
Main classification: B29C41
IPC codes: B29C41