Compression molding using a self-aligning and activating mold system

Abstract

A compression molding system and method, including a mold set and one or more hydraulic cylinders that create a self-aligning and self-activating operating unit. The hydraulic cylinders can include a combination of activation and clamping cylinders. The mold set includes a first and second mold section and a source of heat is provided to heat the mold set. The mold sections are constructed of individual plates or bar stock, and machined to define a mold cavity. Reinforcement plates can be attached to the mold sections and add structure and integrity to the system. A computer control system interprets data from the activation hydraulic cylinders and monitors and controls hydraulic fluid flow into and out of each cylinder and a pumping system pumps hydraulic fluid into and out of the chambers within the activation and clamping cylinders.

1 . An apparatus for compression molding a charge of material into a work piece comprising:
 a mold set including a first mold section and a second mold section;   at least one activation cylinder mounted to one of said first and second mold sections, said at least one activation cylinder being adapted for extending and retracting a first cylinder rod, said cylinder rod slidably extending through an aperture in said one mold section and having an end attached to the other of said first and second mold sections; and   a source of heat for the mold set.   
   
   
       2 . The apparatus of  claim 1  wherein said at least one activation cylinder comprises a hydraulic cylinder having extension and retraction chambers each connected to a controllable source of pressurized hydraulic fluid. 
   
   
       3 . The apparatus of  claim 1 , wherein said source of heat for said mold set comprises steam. 
   
   
       4 . The apparatus of  claim 1 , wherein said source of heat for the mold set comprises hot oil. 
   
   
       5 . The apparatus of  claim 1 , wherein said source of heat for the mold set comprises resistance heat. 
   
   
       6 . The apparatus of  claim 1 , further comprising at least one clamping cylinder mounted to one of said first and second mold sections, said at least one clamping cylinder being adapted for extending and retracting a second cylinder rod having a second end releasably mounted to the other of said first and second mold sections. 
   
   
       7 . The apparatus of  claim 6  wherein said at least one clamping cylinder comprises a hydraulic cylinder having extension and retraction chambers each connected to a controllable source of pressurized hydraulic fluid. 
   
   
       8 . The apparatus of  claim 1 , further including a computer control system connected to the compression molding apparatus to control the mold process and insure that said first and second mold sections remain substantially parallel to each other during operation. 
   
   
       9 . The apparatus of  claim 8  further comprising linear transducers encased in said activation cylinders, wherein said transducers transmit continuous linear position data to said computer control system, and wherein said computer control system interprets incoming data from said at least one activation cylinder and monitors and controls hydraulic fluid flow into and out of said retraction and extension chambers. 
   
   
       10 . The apparatus of  claim 7  further comprising linear transducers encased in the activation cylinders, wherein said transducers transmit continuous linear position data to a computer control system, and wherein said computer control system interprets incoming data from said at least one activation cylinder and said at least one clamping cylinder and monitors and controls hydraulic fluid flow into and out of said retraction and extension chambers. 
   
   
       11 . The apparatus of  claim 1 , wherein said first and second mold sections are comprised of a plurality of individual plates connected together. 
   
   
       12 . The apparatus of  claim 1 , wherein said first and second mold sections are comprised of a plurality of solid steel bar-stock pieces connected together. 
   
   
       13 . The apparatus of  claim 6 , wherein said first and second mold sections are comprised of a plurality of individual plates connected together. 
   
   
       14 . The apparatus of  claim 6 , wherein said first and second mold sections are comprised of a plurality of bar-stock pieces connected with together. 
   
   
       15 . The apparatus of  claim 1 , wherein said first mold section and second mold section in a closed position have an interior surface that defines a mold cavity. 
   
   
       16 . The apparatus of  claim 1  further comprising support pillars affixed to one of said first and second mold sections. 
   
   
       17 . The apparatus of  claim 1 , wherein said at least one activation cylinder is arranged on a periphery of said mold set. 
   
   
       18 . The apparatus of  claim 1 , wherein said at least one activation cylinder is positioned substantially in the center of said mold set. 
   
   
       19 . The apparatus of  claim 6 , wherein said at least one activation cylinder and said at least one clamping cylinder are arranged on a periphery of said mold set. 
   
   
       20 . The apparatus of  claim 19 , wherein said at least one activation cylinder and said at least one clamping cylinder are arranged in opposing orientation to each other. 
   
   
       21 . The apparatus of  claim 19 , wherein said at least one activation cylinder and said at least one clamping cylinder are arranged in an alternating layout. 
   
   
       22 . The apparatus of  claim 1 , wherein one of said first and second mold sections includes a plurality of stopping blocks. 
   
   
       23 . The apparatus of  claim 1 , wherein the charge of material is molded at a force of 75 to 350 psi. 
   
   
       24 . The apparatus of  claim 1 , wherein said mold set includes reinforcement plates attached along an exterior surface of said mold set. 
   
   
       25 . The apparatus of  claim 6 , wherein said mold set includes reinforcement plates attached along an exterior surface of said mold set.