Abstract:
A mold device includes a mold member having a mold cavity for receiving a melted foamable material to form an object, and a pressure applying device for applying a pressure to the melted foamable material, and to limit a foaming of the melted foamable material, and for preventing orifices from being formed in an outer peripheral portion of the object, and for forming a smooth and shiny or sparkling outer appearance to the object. A mold piece is movably received in the mold cavity, and an actuator may force the mold piece to force against the melted foamable material. A pumping device may pump the hydraulic fluid into and out of the actuator.

Description:
BACKGROUND OF THE INVENTION  
       [0001]     1. Field of the Invention  
         [0002]     The present invention relates to a mold device, and more particularly to a mold device having a structure arranged for pressurizing foamable materials, and for preventing the foamable materials from being over foamed, and for preventing perforations or orifices from being formed in the outer peripheral portion of the objects to be formed or made with the foamable materials.  
         [0003]     2. Description of the Prior Art  
         [0004]     Typical mold devices comprise one or more mold pieces including one or more mold cavities formed or provided therein, for receiving injected plastic or foamable materials therein, and for forming various objects, such as shoes, board or sheet members, or other objects.  
         [0005]     For example, U.S. Pat. No. 4,309,376 to Ueno et al., and U.S. Pat. No. 4,605,455 to Lai, and U.S. Pat. No. 5,667,737 to Wittmann disclose three of the typical mold devices each also comprising one or more mold cavities formed or provided therein and defined by one or more mold pieces, for receiving various injected or molded plastic or foamable materials therein, and to form various objects.  
         [0006]     Normally, the mold cavities of the mold devices are emptied to receive the injected or molded plastic or foamable materials therein, and the typical mold devices may not apply any forces to or against the plastic or foamable materials that are filled or injected into the mold cavities of the mold devices, and may only let the plastic or foamable materials to foam or to expand without being limited, such that the plastic or foamable materials may be over foamed or may be over expanded in some circumstances.  
         [0007]     For example, when the plastic or foamable materials are heated to make or to form various objects, and when the plastic or foamable materials may be over foamed or may be over expanded, some of the air bubbles generated within the plastic or foamable materials, during the foaming procedures, may be broken to form perforations or holes or orifices or cavities in the outer peripheral surfaces of the objects, and may spoil the outer appearances of the objects, particularly when the objects are required to have a smooth and shiny or sparkling outer appearance.  
         [0008]     The present invention has arisen to mitigate and/or obviate the afore-described disadvantages of the conventional mold devices.  
       SUMMARY OF THE INVENTION  
       [0009]     The primary objective of the present invention is to provide a mold device including a structure arranged for pressurizing foamable materials, and for preventing the foamable materials from being over foamed, and for preventing perforations or orifices from being formed in the outer peripheral portion of the objects to be formed or made with the foamable materials.  
         [0010]     In accordance with one aspect of the invention, there is provided a mold device comprising a mold member including a mold cavity formed therein for receiving a melted foamable material therein to form an object, and a pressure applying device for applying a pressure to the melted foamable material, and to limit a foaming of the melted foamable material, and for preventing orifices from being formed in an outer peripheral portion of the object, and for forming a smooth and shiny or sparkling outer appearance to the object.  
         [0011]     The pressure applying device includes a mold piece movably received in the mold cavity of the mold member, to form a chamber between the mold member and the mold piece, and for receiving the melted foamable material therein.  
         [0012]     The mold member includes a pouring passage formed therein and communicating with the chamber formed between the mold member and the mold piece, and having a pouring spout provided therein for receiving and filling the melted foamable material into the chamber formed between the mold member and the mold piece.  
         [0013]     The pressure applying device includes an actuator engageable with the mold piece, for forcing the mold piece to force against the melted foamable material. The actuator includes a housing having a compartment formed therein for receiving a hydraulic fluid therein, and a shank slidably received in the compartment of the housing and engageable with the mold piece, for forcing against the mold piece, and then onto the melted foamable material.  
         [0014]     The pressure applying device includes a pumping device coupled to the compartment of the housing, for pumping the hydraulic fluid into and out of the compartment of the housing. The pumping device includes a receptacle having a space formed therein and coupled to the compartment of the housing via a conduit, for receiving the hydraulic fluid therein, and a piston slidably received in the space of the receptacle, to pump the hydraulic fluid to the actuator.  
         [0015]     The pumping device includes a motorized device coupled to the piston, to move the piston relative to the receptacle, and to pump the hydraulic fluid between the space of the receptacle and the compartment of the housing. A coupler is coupled to the conduit, and includes a port provided thereon, for filling the hydraulic fluid into the conduit and then into the space of the receptacle and the compartment of the housing.  
         [0016]     A pressure gauge may further be provided and coupled to the coupler, for detecting and watching a pressure within the conduit and the space of the receptacle and the compartment of the housing. A pressure regulator valve may further be provided and coupled to the coupler, for regulating a pressure within the conduit and the space of the receptacle and the compartment of the housing.  
         [0017]     The pressure applying device includes a passage formed in the mold member and communicating with the mold cavity, and a pneumatic device coupled to the passage via a hose, for supplying a pressurized air to the mold cavity, and for forcing against the melted foamable material.  
         [0018]     Further objectives and advantages of the present invention will become apparent from a careful reading of the detailed description provided hereinbelow, with appropriate reference to the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0019]      FIG. 1  is a plan schematic view of a mold device in accordance with the present invention;  
         [0020]      FIG. 2  is a partial cross sectional view of the mold device;  
         [0021]      FIG. 3  is another partial cross sectional view of the mold device, similar to  FIG. 2 , illustrating the operation of the mold device; and  
         [0022]      FIG. 4  is a further partial cross sectional view illustrating the other arrangement of the mold device. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0023]     Referring to the drawings, and initially to  FIGS. 1 and 2 , a mold device  10  in accordance with the present invention comprises a lower or mother or first or female mold member  20  which may be formed or made of, for example, two or more mold elements  21 ,  22 ,  23 , with such as fasteners or latches (not shown), or the like, and which includes one or more mold cavities  24  formed therein, each provided for slidably receiving a movable or slidable mold piece  25  therein.  
         [0024]     The mold device  10  further includes an upper or daughter or second or male mold member  30  which may also be formed or made of two or more mold elements  31 ,  32 , with such as fasteners or latches (not shown), or the like, in which the mold piece  25  is movable or slidable relative to the second or male mold member  30 , to partially expose the mold cavity  24  or to form a chamber  33  between the mold members  20 ,  30  and the movable or slidable mold piece  25 . The mold members  20 ,  30  may also be solidly secured or formed integral together to form a one-integral single piece mold member.  
         [0025]     The upper or daughter or second or male mold member  30  includes a pouring passage  34  formed therein and communicating with the chamber  33  formed or defined between the mold members  20 ,  30  and the movable or slidable mold piece  25 , and having a pouring gate or spout  35  provided therein for receiving the melted plastic or foamable materials, and for allowing the melted plastic or foamable materials to be filled or injected into the chamber  33 , or into the mold cavity  24  of the mold member  20 .  
         [0026]     The mold device  10  further includes a pressurizing means or device  4  for applying a force or compression pressure onto or against the melted plastic or foamable materials filled or injected into the chamber  33  defined between the mold members  20 ,  30  and the mold piece  25 , or into the mold cavity  24  of the mold member  20 . For example, the pressurizing means or device  4  includes an actuator  40  for applying the force or compression pressure onto or against the melted plastic or foamable materials.  
         [0027]     As shown in  FIGS. 2 and 3 , the actuator  40  includes a housing  41  having a chamber or compartment  42  formed therein for receiving hydraulic oil or fluid therein, and a shank  43  slidably received in the chamber or compartment  42  of the housing  41  and contactable or engageable with the movable or slidable mold piece  25 , for applying the force or compression pressure onto or against the mold piece  25 , and then onto the melted plastic or foamable materials.  
         [0028]     The pressurizing means or device  4  further includes a forcing or pumping means or device  5  coupled to the actuator  40 , for forcing or pumping the hydraulic oil or fluid into the chamber or compartment  42  of the housing  41 , and for allowing the hydraulic oil or fluid to flow back from the chamber or compartment  42  of the housing  41  toward the forcing or pumping means or device  5 . For example, the forcing or pumping means or device  5  includes a receptacle  50  having a chamber or space  51  formed therein for receiving the hydraulic oil or fluid therein, and a piston  52  slidably received in the space  51  of the receptacle  50 , to force or to pump the hydraulic oil or fluid to the pressurizing device  4 .  
         [0029]     For example, the piston  52  of the forcing or pumping device  5  includes a piston rod  53  extended therefrom, for coupling to a motor, or various motorized devices  80 , which may be used to move the piston  52  relative to the receptacle  50 , in order to force or to pump the hydraulic oil or fluid to the pressurizing device  4 , or to draw the hydraulic oil or fluid backward from the space  51  of the receptacle  50  to the chamber or compartment  42  of the housing  41  of the pressurizing device  4 . The pressurizing device  4  and the forcing or pumping device  5  may be disposed in or out of the mold members  20 ,  30 .  
         [0030]     As shown in  FIG. 1 , a manifold or conduit  54  may be formed or provided or coupled between the chamber or compartment  42  of the housing  41  and the space  51  of the receptacle  50 , for allowing the hydraulic oil or fluid to flow between the space  51  of the receptacle  50  and the chamber or compartment  42  of the housing  41  of the pressurizing device  4 . An elbow  55  may be coupled to the space  51  of the receptacle  50 , two U-shaped couplers  56 ,  58  and a T-shaped coupler  57  may be coupled between the elbow  55  and the chamber or compartment  42  of the housing  41 , for forming or coupling the manifold or conduit  54  between the housing  41  and the receptacle  50 .  
         [0031]     The U-shaped coupler  58  may include a port  59  provided thereon, for filling the hydraulic oil or fluid into the manifold or conduit  54  and then into the space  51  of the receptacle  50  and the chamber or compartment  42  of the housing  41 . A pressure gauge  60  may be coupled to the T-shaped coupler  57 , for detecting or watching the pressure within the manifold or conduit  54  and/or within the space  51  of the receptacle  50  and/or within the chamber or compartment  42  of the housing  41 .  
         [0032]     A pressure regulator valve  61  may be coupled to the U-shaped coupler  56 , for adjusting or regulating the pressure within the manifold or conduit  54  and/or within the space  51  of the receptacle  50  and/or within the chamber or compartment  42  of the housing  41 . The pressure regulator valve  61  and the motor or motorized devices  80  may thus be used to regulate or to adjust the actuator  40  to applied the predetermined force or pressure to or against the mold piece  25  and thus the melted plastic or foamable materials.  
         [0033]     Alternatively, as shown in  FIG. 4 , the pressurizing device  4  may include a passage  70  formed in both the mold member  20  and the mold piece  25 , and communicating with the chamber  33  formed or defined between the mold members  20 ,  30  and the mold piece  25 , or between the mold member  30  and the mold piece  25 , and coupled to a pressurized air supplying reservoir or device or a pneumatic device  71  via a hose  72 , for allowing the pressurized air to be supplied into the chamber  33 , to apply the force or compression pressure onto or against the melted plastic or foamable materials filled or injected within the chamber  33  formed between the mold member  30  and the mold piece  25 .  
         [0034]     In operation, as shown in  FIG. 2 , the forcing or pumping device  5  may force the hydraulic oil or fluid to the chamber or compartment  42  of the housing  41 , and to force the shank  43  to act onto the movable or slidable mold piece  25 , and to apply the force or compression pressure, such as 70 bars, onto or against the mold piece  25 , and then to apply the force or compression pressure onto the melted plastic or foamable materials, to force the melted plastic or foamable materials to be foamed and to generate micro bubbles, and to prevent the bubbles from being broken, and to prevent the perforations or orifices from being formed in the outer peripheral portion of the objects to be formed or made with the foamable materials. The stiffness of the objects may also be increased or facilitated.  
         [0035]     Accordingly, the mold device in accordance with the present invention includes a structure arranged for pressurizing foamable materials, and for preventing the foamable materials from being over foamed, and for preventing perforations or orifices from being formed in the outer peripheral portion of the objects to be formed or made with the foamable materials.  
         [0036]     Although this invention has been described with a certain degree of particularity, it is to be understood that the present disclosure has been made by way of example only and that numerous changes in the detailed construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention as hereinafter claimed.