US5637329A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Plasticator and system for molding parts
Assignee: Composite Technologies Co LLC
•
Filing: 1995-06-07
•
Granted: 1997-06-10
•
Expires: 2015-06-07
Abstract
Abstract A system is disclosed for molding parts. The system comprises a plasticator and press. The plasticator is capable of receiving a plurality of molding materials comprising a predetermined amount of a polyester, at least one other carbocylic and reinforcing fiber, such as glass fiber. The plasticator is characterized in that it is capable of simultaneously receiving contaminated molding materials and relatively long glass fibers and molding them into a billet wherein the fibers remain substantially undamaged. The billet is subsequently in a compression molding press where other materials may be molded or applied to its surface. The system is further characterized in that a single thermal rise is used to plasticate the molding materials. The system comprises a plasticator having a screw, a screw drive system, a plurality of heaters and control system to control the pressure and temperature in a barrel of the plasticator so as to create a billet having certain predetermined billet characteristics (such as a desired volume and/or density).
Inventors
- 👤 Fredric L. Abrams
- 👤 Robert F. Freund
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 13:33
CPC Classifications
B; B29; B29B; B29B7/00; B29B7/80; B29B7/88; B29B7/90; B29B11/00; B29B11/06; B29B11/10; B29B17/00; B29B17/0026; B29B7/02; B29B7/06; B29B7/10; B29B7/12; B29B7/14; B29B7/22; B29B7/28; B29B7/283; B29B7/30; B29B7/34; B29B7/38; B29B7/40; B29B7/42; B29B7/428; B29B7/429; B29B7/58; B29B7/72; B29B7/728; B29B7/82; B29B7/823; B29B7/826; B29C; B29C48/00; B29C48/001; B29C48/0011; B29C48/022; B29C48/25; B29C48/285; B29C48/286; B29C48/287; B29C48/297; B29C48/36; B29C48/395; B29C48/45; B29C48/78; B29C48/793; B29C48/80; B29C48/83; B29C48/832; B29C48/84; B29C48/845; B29C48/86; B29C48/865; B29C48/92; B29B7/24; B29B7/242; B29B7/244; B29B7/60; B29C2948/00; B29C2948/92; B29C2948/92504; B29C2948/92514; B29C2948/92704; B29C2948/92819; B29C2948/92857; B29C2948/92876; B29C2948/92895; B29C43/00; B29C48/03; B29K; B29K2023/00; B29K2023/04; B29K2023/06; B29K2023/08; B29K2023/083; B29K2023/10; B29K2023/12; B29K2105/00; B29K2105/06; B29K2105/12; Y; Y02; Y02W; Y02W30/00; Y02W30/50; Y02W30/62; Y10; Y10S; Y10S264/00; Y10S264/65; Y10S264/911; Y10S264/913; Y10S264/921
Claims Analysis
Total Claims: 49
Claim 1
Independent Claim
185 words
A plasticator for creating a billet of moldable material comprising: a feeder for receiving a plurality of molding materials comprising a predetermined amount of a thermoplastic and reinforcing fibers; and a barrel coupled to said feeder for receiving said plurality of molding materials from said feeder; a screw situated in said barrel, said screw being rotatably driveable to create a molten suspension in a storage area of said barrel while leaving a substantial number of said reinforcing fibers intact; a heater associated with said barrel to heat said barrel to facilitate creating said molten suspension; a driver for rotatably driving said screw to create said molten suspension in said storage area, said driver also being capable of axially driving said screw to force said molten suspension out of an extrusion end of said barrel after a predetermined pressure is applied to said billet; and a cutter associated with said extrusion end to close said extrusion end to facilitate defining said storage area of said barrel such that when said cutter is actuated to a closed position, said molten suspension is severed to provide said billet.
Claim 2
Dependent Claim
185 words
A plasticator for creating a billet of moldable material comprising: a feeder for receiving a plurality of molding materials comprising a predetermined amount of a thermoplastic and reinforcing fibers; and a barrel coupled to said feeder for receiving said plurality of molding materials from said feeder; a screw situated in said barrel, said screw being rotatably driveable to create a molten suspension in a storage area of said barrel while leaving a substantial number of said reinforcing fibers intact; a heater associated with said barrel to heat said barrel to facilitate creating said molten suspension; a driver for rotatably driving said screw to create said molten suspension in said storage area, said driver also being capable of axially driving said screw to force said molten suspension out of an extrusion end of said barrel after a predetermined pressure is applied to said billet; and a cutter associated with said extrusion end to close said extrusion end to facilitate defining said storage area of said barrel such that when said cutter is actuated to a closed position, said molten suspension is severed to provide said billet.
Claim 3
Dependent Claim
29 words
The plasticator as recited in claim 1 wherein said barrel comprises a heating portion, a blending portion and an extruding portion; said screw being rotatably mounted in said barrel.
Claim 4
Dependent Claim
35 words
The plasticator as recited in claim 1 wherein said cutter comprises a knife associated with said end of said barrel such that it engages and closes said extrusion end to facilitate defining said storage area.
Claim 5
Dependent Claim
22 words
The plasticator as recited in claim 3 wherein said heater comprises a plurality of heaters associated with said feeder and said barrel.
Claim 6
Dependent Claim
52 words
The plasticator as recited in claim 3 wherein said barrel comprises a heating portion, a blending portion and an extruding portion, said heater comprising a barrel heater capable of heating said heating portion, said blending portion and said extruding portion to a first temperature, a second temperature and a third temperature, respectively.
Claim 7
Dependent Claim
20 words
The plasticator as recited in claim 1 wherein said heater comprises a plurality of resistance bands located around said barrel.
Claim 8
Dependent Claim
41 words
The plasticator as recited in claim 5 wherein said first, second and third temperatures fall within a range of approximately 475°-575° F. when the molding materials include a thermoplastic polyester and 375°-475° F. when the molding materials are primarily thermoplastic polyolefin.
Claim 9
Dependent Claim
44 words
The plasticator as recited in claim 5 wherein said heater comprises a heater controller for sensing the actual temperature at said feeding, blending and extruding portions of said barrel and also for adjusting the heater to maintain approximately said first, second and third temperatures.
Claim 10
Dependent Claim
75 words
The plasticator as recited in claim 2 wherein said screw comprises a feeding section, a blending section and an extruding section; said feeding section comprising a first plurality of threads having a feeding thread depth, said blending section comprising a second plurality of threads having a blending thread depth, and said extruding section having a third plurality of threads having an extruding thread depth; said feeding thread depth being greater than said extruding thread depth.
Claim 11
Dependent Claim
100 words
The plasticator as recited in claim 1 wherein said screw comprises a feeding section, a blending section and an extruding section associated with said heating portion, blending portion and said extruding portion, respectively, of said barrel; said feeding section comprising a first plurality of threads having a feeding thread depth, said blending section comprising a second plurality of threads having a blending thread depth, and said extruding section having a third plurality of threads having an extruding thread depth; said second plurality of threads having a pitch which is generally smaller than the pitch of said first plurality of threads.
Claim 12
Dependent Claim
47 words
The plasticator as recited in claim 1 wherein said screw comprises a feeding end, an extruding end and a core which is generally tapered such that the depth of threads located at said feeding end are greater than the depth of threads located at said extruding end.
Claim 13
Dependent Claim
14 words
The plasticator as recited in claim 11 wherein said cutter includes a knife blade.
Claim 14
Dependent Claim
22 words
The plasticator as recited in claim 12 wherein said knife blade comprises a knife heater associated therewith for heating said knife blade.
Claim 15
Dependent Claim
47 words
The plasticator as recited in claim 1 wherein said driver permits said screw to axially retract from said barrel when said billet achieves a characteristic, said driver comprises a sensor for causing said screw to extrude said billet upon the occurrence of at least one preselected condition.
Claim 16
Dependent Claim
56 words
The plasticator as recited in claim 14 wherein said barrel is mounted to a stationary block, said driver comprising a slidable drive motor coupled to the screw for driving the screw in and out of the barrel, said sensor further comprises a distance sensor for measuring the distance said screw has axially traveled in said barrel.
Claim 17
Dependent Claim
42 words
The plasticator as recited in claim 1 wherein said driver comprises a drive motor coupled to the screw and a cylinder associated with the drive motor for axially driving the drive motor to cause the screw to move axially in the barrel.
Claim 18
Dependent Claim
55 words
The plasticator as recited in claim 16 wherein the drive motor and cylinder are hydraulic, said plasticator further comprising a power system for driving said cylinder and drive motor; said power system comprising a cylinder pressure regulator and a drive motor pressure regulator for regulating the pressure delivered to said cylinder and drive motor, respectively.
Claim 19
Dependent Claim
40 words
The plasticator as recited in claim 17 wherein said driver comprises a plurality of pressure valves operatively coupled to said power system and said cylinder and hydraulic motor for controlling the fluid being delivered to the cylinder and drive motor.
Claim 20
Dependent Claim
72 words
The plasticator as recited in claim 1 wherein said plasticator further comprises: a cutter driver coupled to said cutter for driving said cutter from an open to a closed position; a controller capable of energizing said cutter driver to drive said cutter to an open position, and also being capable of energizing said cutter driver to drive said cutter to a closed position, thereby separating said molten suspension to provide the billet.
Claim 21
Dependent Claim
39 words
The plasticator as recited in claim 3 wherein said feeder comprises a feed hopper for receiving said plurality of molding materials; said heater further comprises a preheater for preheating said molding materials to a temperature in said feed hopper.
Claim 22
Dependent Claim
36 words
The plasticator as recited in claim 1 wherein said feeder comprises an agitator and an agitator driver coupled to the agitator for rotatably driving said agitator to agitate said plurality of molding materials in said feeder.
Claim 23
Dependent Claim
23 words
The plasticator as recited in claim 1 wherein said plasticator further comprises a conveyance system for facilitating positioning the billet in a press.
Claim 24
Dependent Claim
12 words
The plasticator as recited in claim 1 wherein said thermoplastic is contaminated.
Claim 25
Dependent Claim
16 words
The plasticator as recited in claim 1 wherein said thermoplastic comprises an olefinic which is contaminated.
Claim 26
Dependent Claim
16 words
The plasticator as recited in claim 23 wherein said thermoplastic comprises an olefinic which is contaminated.
Claim 27
Dependent Claim
25 words
The plasticator as recited in claim 1 wherein said long reinforcing fibers are glass fibers which generally comprise a length of at least 2 inches.
Claim 28
Dependent Claim
17 words
The plasticator as recited in claim 1 wherein said molding materials further comprises a compatibility enhancing agent.
Claim 29
Dependent Claim
23 words
The plasticator as recited in claim 27 wherein said compatibility enhancing agent comprises a polypropylene coupling agent having at least 6% acrylic acid.
Claim 30
Dependent Claim
204 words
A plasticator for creating a billet from a plurality of molding materials, including long fibers, said plasticator comprising: barrel means coupled to a feeder for receiving said plurality of molding materials from said feeder; screw means rotatably mounted in said barrel means for mixing said plurality of molding materials to create a molten suspension in said barrel means while leaving a substantial number of said long fibers substantially undamaged; heating means associated with said barrel for heating said barrel means to create said molten suspension; drive means for rotatably driving said screw means to create said molten suspension in a storage area created by axial retraction of said screw means and also for axially driving said screw means to force said molten suspension out of an extrusion end of said barrel means after a predetermined pressure is applied to said billet; control means for controlling and coordinating the operation of the plasticator in order to facilitate plasticating the billet and extruding the billet upon the occurrence of at least a preselected condition; knife means associated with said extrusion end of said barrel means for closing said barrel means to facilitate defining said storage area and for severing said molten suspension to provide said billet.
Claim 31
Dependent Claim
204 words
A plasticator for creating a billet from a plurality of molding materials, including long fibers, said plasticator comprising: barrel means coupled to a feeder for receiving said plurality of molding materials from said feeder; screw means rotatably mounted in said barrel means for mixing said plurality of molding materials to create a molten suspension in said barrel means while leaving a substantial number of said long fibers substantially undamaged; heating means associated with said barrel for heating said barrel means to create said molten suspension; drive means for rotatably driving said screw means to create said molten suspension in a storage area created by axial retraction of said screw means and also for axially driving said screw means to force said molten suspension out of an extrusion end of said barrel means after a predetermined pressure is applied to said billet; control means for controlling and coordinating the operation of the plasticator in order to facilitate plasticating the billet and extruding the billet upon the occurrence of at least a preselected condition; knife means associated with said extrusion end of said barrel means for closing said barrel means to facilitate defining said storage area and for severing said molten suspension to provide said billet.
Claim 32
Dependent Claim
29 words
The plasticator as recited in claim 29 wherein said screw means comprises a screw dimensioned to facilitate mixing said molding materials such that said long fibers remain generally intact.
Claim 33
Dependent Claim
25 words
The plasticator as recited in claim 29 wherein said screw means comprises a screw comprising a plurality of threads having a plurality of pitch distances.
Claim 34
Dependent Claim
25 words
The plasticator as recited in claim 29 wherein said screw means comprises a screw comprising a plurality of threads having a plurality of thread depths.
Claim 35
Dependent Claim
25 words
The plasticator as recited in claim 29 wherein said screw means comprises a screw comprising a plurality of threads having a plurality of thread depths.
Claim 36
Dependent Claim
34 words
The plasticator as recited in claim 29 wherein the control means comprises a controller for controlling and coordinating the operation of the plasticator in order to facilitate plasticating the billet to have the characteristic.
Claim 37
Dependent Claim
29 words
The plasticator as recited in claim 29 wherein said plasticator comprises control means coupled to said heating means for controlling the heat applied to said plurality of molding materials.
Claim 38
Dependent Claim
86 words
The plasticator as recited in claim 29 wherein said barrel means comprises a feeding end and an extruding end, said feeding end having a feed hopper associated therewith and said extruding end having said knife means associated therewith, said heating means comprising a plurality of heaters associated with said feed hopper, said barrel and said knife, said control means being capable of controlling the plurality of heaters in order to apply a plurality of temperatures to the molding materials as they are plasticated in the plasticator.
Claim 39
Dependent Claim
20 words
The plasticator as recited in claim 36 wherein at least one of said plurality of heaters is a resistance band.
Claim 40
Dependent Claim
27 words
The plasticator as recited in claim 29 wherein said plasticator comprises a controller capable of selectively energizing said drive means to rotatably and axially drive said screw.
Claim 41
Dependent Claim
76 words
The plasticator as recited in claim 38 wherein said drive means comprises a drive motor coupled to the screw means, at least one cylinder associated with the drive motor for driving the drive means and screw means to move axially, and a power system coupled to the controller for energizing said drive means and said cylinder; said controller being capable of selectively energizing said power system to actuate said at least one cylinder and drive means.
Claim 42
Dependent Claim
43 words
The plasticator as recited in claim 39 wherein said cylinder, drive motor and power system are hydraulic; said control means further comprising at least one variable pressure regulator for controlling the pressure delivered by the power system to the drive motor and cylinder.
Claim 43
Dependent Claim
49 words
The plasticator as recited in claim 29 wherein said knife means further comprises a hydraulic knife cylinder coupled to a knife blade thereto, said plasticator further comprising a controller coupled to said knife means for energizing said knife means to actuate said hydraulic knife cylinder to said closed position.
Claim 44
Dependent Claim
21 words
The plasticator as recited in claim 29 wherein the molding materials comprise an amount of a thermoplastic and said long fibers.
Claim 45
Dependent Claim
30 words
The plasticator as recited in claim 42 wherein said long fibers are glass fibers, said molding materials being provided in approximately the following proportions: 60% thermoplastic and 40% glass fibers.
Claim 46
Dependent Claim
16 words
The plasticator as recited in claim 43 wherein the molding materials comprise a compatibility enhancing agent.
Claim 47
Dependent Claim
18 words
The plasticator as recited in claim 43 wherein the compatibility enhancing agent comprises at least 6% acrylic acid.
Claim 48
Dependent Claim
12 words
The plasticator as recited in claim 44 wherein said thermoplastic is contaminated.
Claim 49
Dependent Claim
24 words
The plasticator as recited in claim 46 wherein said contamination comprises a contaminant from a contamination group, including HDPE, PP, EVA, paper and aluminum.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 2000-06-09 | 2000-12-09 | 2001-06-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2004-06-09 | 2004-12-09 | 2005-06-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2008-06-09 | 2008-12-09 | 2009-06-10 | $7700.00 | Window Closed / Lapsed |