Method of making a molded article from two or more different formable materials in a single heating cycle

Abstract

A composition for forming a molded article comprises a first formable material capable of flowing when heated to a first molding temperature, a second formable material capable of flowing when heated to a second molding temperature, and an additive mixed with the second formable material. The additive is provided in an amount determined by: (a) calculating a molding time for the first formable material to reach the first molding temperature; (b) calculating a required power factor for the second formable material that will allow the second formable material to reach the second molding temperature in the molding time of the first formable material; and (c) calculating the amount of the additive to be mixed with the second formable material to obtain the required power factor. A method of forming the composition is also disclosed.

1 . A composition for forming a molded article, comprising:
 a first formable material having a first molding temperature;   a second formable material having a second molding temperature; and   an additive mixed with the second formable material, wherein the additive is provided in an amount determined by: (a) calculating a molding time for the first formable material to reach the first molding temperature; (b) calculating a required power factor for the second formable material that will allow the second formable material to reach the second molding temperature in the molding time of the first formable material; and (c) calculating the amount of the additive to be mixed with the second formable material to obtain the required power factor.   
     
     
         2 . The composition of  claim 1 , wherein the first formable material and the second formable material with the additive are provided in two distinct layers. 
     
     
         3 . The composition of  claim 1 , wherein the first formable material and the second formable material with the additive are blended together. 
     
     
         4 . The composition of  claim 1 , wherein each of the first and second formable materials is independently selected from the group consisting of thermoplastics and thermosets. 
     
     
         5 . The composition of  claim 1 , wherein at least one of the first and second formable materials is a thermoplastic selected from the group consisting of acrylonitrile butadiene styrene, methylacrylate, polyamide, polycarbonate, polyester, ethylene vinyl acetate, ethylene vinyl alcohol, ethylene methyl acrylate, polyvinyl chloride, plastisol, polyvinylidene fluoride, surlyn ionomeror, thermoplastic urethane, and thermoplastic olefin. 
     
     
         6 . The composition of  claim 1 , wherein at least one of the first and second formable materials is a thermoset selected from the group consisting of polyester, melamine formaldehyde, and rubber: 
     
     
         7 . The composition of  claim 1 , wherein at least one of the first and second formable materials is a foam material. 
     
     
         8 . The composition of  claim 7 , further comprising one or both of a blowing agent and a cross-linker. 
     
     
         9 . The composition of  claim 1 , wherein at least one of the first and second formable materials is a foam material selected from the group consisting of cross-linked polyethylene-ethyl vinyl acetate foam, polyvinyl chloride foam, vinyl nitrile foam, and neoprene foam. 
     
     
         10 . The composition of  claim 1 , wherein at least one of the first and second formable materials comprises a blend of two or more materials. 
     
     
         11 . The composition of  claim 1 , further comprising a polar additive mixed with at least one of the first and second formable materials. 
     
     
         12 . A composition for forming a molded article, comprising:
 a first formable material having a first molding temperature;   a second formable material having a second molding temperature; and   an additive mixed with the second formable material, wherein the additive is provided in an amount that results in the second formable material with the additive having a molding time that is substantially the same as a molding time of the first formable material.   
     
     
         13 . The composition of  claim 12 , wherein the second formable material without the additive has a molding time that is different than the molding time of the first formable material. 
     
     
         14 . The composition of  claim 12 , wherein the first formable material and the second formable material with the additive are provided in two distinct layers. 
     
     
         15 . The composition of  claim 12 , wherein the first formable material and the second formable material with the additive are blended together. 
     
     
         16 . The composition of  claim 12 , wherein each of the first and second formable materials is independently selected from the group consisting of thermoplastics and thermosets. 
     
     
         17 . The composition of  claim 12 , wherein at least one of the first and second formable materials is a thermoplastic selected from the group consisting of acrylonitrile butadiene styrene, methylacrylate, polyamide, polycarbonate, polyester, ethylene vinyl acetate, ethylene vinyl alcohol, ethylene methyl acrylate, polyvinyl chloride, plastisol, polyvinylidene fluoride, surlyn ionomeror, thermoplastic urethane, and thermoplastic olefin. 
     
     
         18 . The composition of  claim 12 , wherein at least one of the first and second formable materials is a thermoset selected from the group consisting of polyester, melamine formaldehyde, and rubber: 
     
     
         19 . The composition of  claim 12 , wherein at least one of the first and second formable materials is a foam material. 
     
     
         20 . The composition of  claim 19 , further comprising one or both of a blowing agent and a cross-linker. 
     
     
         21 . The composition of  claim 12 , wherein at least one of the first and second formable materials is a foam material selected from the group consisting of cross-linked polyethylene-ethyl vinyl acetate foam, polyvinyl chloride foam, vinyl nitrile foam, and neoprene foam. 
     
     
         22 . The composition of  claim 12 , wherein at least one of the first and second formable materials comprises a blend of two or more materials. 
     
     
         23 . The composition of  claim 12 , further comprising a polar additive mixed with at least one of the first and second formable materials. 
     
     
         24 . A method of forming a composition, comprising
 providing a first formable material having a first molding temperature;   providing a second formable material having a second molding temperature;   calculating a molding time for the first formable material to reach the first molding temperature;   calculating a required power factor for the second formable material that will allow the second formable material to reach the second molding temperature in the molding time of the first formable material;   calculating an amount of an additive to be mixed with the second formable material to obtain the required power factor; and   mixing the calculated amount of the additive with the second formable material.   
     
     
         25 . The method of  claim 24 , wherein the calculating steps are performed by programming a computer to calculate the molding time for the first formable material, the required power factor for the second formable material, and the amount of the additive to be mixed with the second formable material. 
     
     
         26 . The method of  claim 24 , wherein the first formable material and the second formable material with the additive are provided in two distinct layers. 
     
     
         27 . The method of  claim 24 , wherein the first formable material and the second formable material with the additive are blended together. 
     
     
         28 . The method of  claim 24 , wherein each of the first and second formable materials is independently selected from the group consisting of thermoplastics and thermosets. 
     
     
         29 . The method of  claim 24 , wherein at least one of the first and second formable materials is a thermoplastic selected from the group consisting of acrylonitrile butadiene styrene, methylacrylate, polyamide, polycarbonate, polyester, ethylene vinyl acetate, ethylene vinyl alcohol, ethylene methyl acrylate, polyvinyl chloride, plastisol, polyvinylidene fluoride, surlyn ionomeror, thermoplastic urethane, and thermoplastic olefin. 
     
     
         30 . The method of  claim 24 , wherein at least one of the first and second formable materials is a thermoset selected from the group consisting of polyester, melamine formaldehyde, and rubber: 
     
     
         31 . The method of  claim 24 , wherein at least one of the first and second formable materials is a foam material. 
     
     
         32 . The method of  claim 31 , further comprising mixing one or both of a blowing agent and a cross-linker with at least one of the first and second formable materials. 
     
     
         33 . The method of  claim 24 , wherein at least one of the first and second formable materials is a foam material selected from the group consisting of cross-linked polyethylene-ethyl vinyl acetate foam, polyvinyl chloride foam, vinyl nitrile foam, and neoprene foam. 
     
     
         34 . The method of  claim 24 , wherein at least one of the first and second formable materials comprises a blend of two or more materials. 
     
     
         35 . The method of  claim 24 , further comprising mixing a polar additive with at least one of the first and second formable materials. 
     
     
         36 . A method of forming a composition, comprising
 providing a plurality of formable materials each of which has a molding temperature;   calculating a molding time for each of the formable materials to reach their respective molding temperatures;   selecting the one of the formable materials with the shortest molding time as a reference material whereby the remaining formable materials each comprise a non-reference material;   for each non-reference material: (i) calculating a required power factor that will allow the non-reference material to reach its molding temperature in the molding time of the reference material; (ii) calculating an amount of an additive to be mixed with the non-reference material to obtain the required power factor; and (ii) mixing the calculated amount of the additive with the non-reference material.   
     
     
         37 . The method of  claim 36 , wherein the calculating steps are performed by programming a computer to calculate the molding time for each of the formable materials, the required power factor for each of the non-reference materials, and the amount of the additive to be mixed with each of the non-reference materials. 
     
     
         38 . The method of  claim 36 , wherein the reference material and each non-reference material with the additive are provided in distinct layers. 
     
     
         39 . The method of  claim 36 , wherein the reference material and each non-reference material with the additive are blended together. 
     
     
         40 . The method of  claim 36 , wherein each of the formable materials is independently selected from the group consisting of thermoplastics and thermosets. 
     
     
         41 . The method of  claim 36 , wherein at least one of the formable materials is a thermoplastic selected from the group consisting of acrylonitrile butadiene styrene, methylacrylate, polyamide, polycarbonate, polyester, ethylene vinyl acetate, ethylene vinyl alcohol, ethylene methyl acrylate, polyvinyl chloride, plastisol, polyvinylidene fluoride, surlyn ionomeror, thermoplastic urethane, and thermoplastic olefin. 
     
     
         42 . The method of  claim 36 , wherein at least one of the formable materials is a thermoset selected from the group consisting of polyester, melamine formaldehyde, and rubber: 
     
     
         43 . The method of  claim 36 , wherein at least one of the formable materials is a foam material. 
     
     
         44 . The method of  claim 43 , further comprising mixing one or both of a blowing agent and a cross-linker with at least one of the formable materials. 
     
     
         45 . The method of  claim 36 , wherein at least one of the formable materials is a foam material selected from the group consisting of cross-linked polyethylene-ethyl vinyl acetate foam, polyvinyl chloride foam, vinyl nitrile foam, and neoprene foam. 
     
     
         46 . The method of  claim 36 , wherein at least one of the formable materials comprises a blend of two or more materials. 
     
     
         47 . The method of  claim 36 , further comprising mixing a polar additive with at least one of the formable materials. 
     
     
         48 . A method of forming a composition, comprising
 providing a first formable material having a first molding temperature;   providing a second formable material having a second molding temperature;   mixing an additive with the second formable material, wherein the additive is provided in an amount that results in the second formable material with the additive having a molding time that is substantially the same as a molding time of the first formable material.   
     
     
         49 . The method of  claim 48 , wherein the first formable material and the second formable material with the additive are provided in two distinct layers. 
     
     
         50 . The method of  claim 48 , wherein the first formable material and the second formable material with the additive are blended together. 
     
     
         51 . The method of  claim 48 , wherein each of the first and second formable materials is independently selected from the group consisting of thermoplastics and thermosets. 
     
     
         52 . The method of  claim 48 , wherein at least one of the first and second formable materials is a thermoplastic selected from the group consisting of acrylonitrile butadiene styrene, methylacrylate, polyamide, polycarbonate, polyester, ethylene vinyl acetate, ethylene vinyl alcohol, ethylene methyl acrylate, polyvinyl chloride, plastisol, polyvinylidene fluoride, surlyn ionomeror, thermoplastic urethane, and thermoplastic olefin. 
     
     
         53 . The method of  claim 48 , wherein at least one of the first and second formable materials is a thermoset selected from the group consisting of polyester, melamine formaldehyde, and rubber: 
     
     
         54 . The method of  claim 48 , wherein at least one of the first and second formable materials is a foam material. 
     
     
         55 . The method of  claim 54 , further comprising mixing one or both of a blowing agent and a cross-linker with at least one of the first and second formable materials. 
     
     
         56 . The method of  claim 48 , wherein at least one of the first and second formable materials is a foam material selected from the group consisting of cross-linked polyethylene-ethyl vinyl acetate foam, polyvinyl chloride foam, vinyl nitrile foam, and neoprene foam. 
     
     
         57 . The method of  claim 48 , wherein at least one of the first and second formable materials comprises a blend of two or more materials. 
     
     
         58 . The method of  claim 48 , further comprising mixing a polar additive with at least one of the first and second formable materials.