Patent EA-001287-B1 (EA)
Title: Injection moulding process and apparatus for making articles from two components
Inventor: KRAMER HANS
IPC: B29C45/14
Filed: 1998-02-11
Abstract: 1. A process for making a moulded article which comprises the steps of:  forming by injection moulding of a plastics material a body part having an internal body cavity corresponding substantially to the shape of the first core and having apertures passing through the body from the said body cavity to the outer surface of the body corresponding substantially to the shape and position of the member(s); separating the formed body from the first mould cavity and removing the first core from the body cavity; enclosing the formed body in a second mould cavity, and inserting a second internal core into the body cavity, between the second core and the inner surface of the body cavity there being one or more channels in communication with the said apertures when the second core is in place in the body cavity; injecting a fluid mouldable settable material into the said channels such that the material flows along the channels and into the apertures and then sets; separating the so-formed article from the second mould cavity and the second core from the body cavity. 2. A process according to claim 1 wherein the moulded article made by the process is a toothbrush body comprising a grip handle and a head all arranged along a longitudinal toothbrush axis, with the body cavity within the grip handle. 3. A process according to claim 1 or claim 2 wherein the first mould cavity and the second mould cavity are made in a multi-part mould construction, each part defining a respective part of the mould cavity thereby allowing the mould cavity to be opened to allow the body to be separated from the mould. 4. A process according to any one of claims 1, 2 or 3 wherein the one or more internal members are located on the inner wall surface of the first mould cavity. 5. A process according to any one of claims 1 to 4 wherein the members taper, narrowing in dimension from their outer end toward their inner end. 6. A process according to any one of claims 1 to 5 wherein between the inner wall of the second mould cavity and the body there are hollows in communication with the said apertures and channels, allowing the second material to flow into these hollows and form areas of second material exposed at the surface of the formed article. 7. A process according to any one of the preceding claims wherein when the second core has been removed from the body cavity the body cavity is closed by a closure.  8. A first mould cavity adapted for use in a process according to any one of the preceding claims. 9. A first mould for use in a process according to any one of claims 1 to 7, and incorporating a first mould cavity. 10. A first internal core adapted for use in a process according to any one of claims 1 to 7. 11. A second mould cavity adapted for use in a process according to any one of claims 1 to 7. 12. A second mould adapted for use in a process according to any one of claims 1 to 7 and incorporating a second mould cavity. 13. A second internal core adapted for use in a process according to any one of claims 1 to 7. 14. A process in which a mould as claimed in claim 9 or 12 is made. 15. A moulded article, particularly a toothbrush body, made by the process according to any one of claims 1 to 7. 16. A toothbrush body comprising a bristle-bearing head and a hollow moulded grip handle body having a body wall made of plastics material, having apertures passing through its plastics material body wall from an internal body cavity to the outer surface, the apertures being filled with a moulded second material, the second material in the cavities being linked by residual second material in moulding channels in, or residual second material on, the inner surface of the body cavity.