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Патент USA US2360201

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Filed oct. 2a, 1941
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Oct., l0, 1944c
Filed Oct. 28, 1941
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Filed Oct. 28, 1941
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Patented‘oct. 10, i944 `
' 2,360,201
1 -mural) '” STATI-:s- PATENT OFFICE
william J. clama and .mm r. schon, Mish- A
awaka, Ind., assignors to United States Rubber
Company, New York, N. Y., a corporation of ~
New Jersey
Application 'oculta 23,1941, serai No. 416,792 »
1 Claim. (cl. 1li-39)'
object of the invention to provide a íoraminous
invention relates'to the fabrication of
top-plate structural element for such molds in
shaped heat-treated articles, especially to the
which the openings are oi' suitable dimensions to
manufacture `_of such articles by setting foamable
material into solid shapes, and' is oi particular
permit the foam to rise into a multiplicity of the
openings so that the top-plate will support the
foam so engaged preparatory to vulcanization,
but when vulcanized the resulting sponge rubber
use when employed in the fabrication of latex
roam into' vulcanized sponge rubber cushions `forV
automobiles, or into vulcanized sponge rubber
.mattresses valthough the invention may be uti
article and the foraminous top-»plate may be
` neatly separated by a conventional stripping op
nature of our improvements.
_ . 10 eration. _ The construction is preferably such that
the top plate will aiîord maximum support for '
' For a long time it has been'recognized that
lized in any iield for which it is adapted by the
-the weight of the sponge mass without causing
the sponge massto tear where the top plate is
none ofthe present formulae for latex foam
sponge can be used to produce in an open mold
light density sponge which has a low and uniform
vertical shrinkage.. In order to overcome this
' pulled loose therefrom.
Other features and objects of the present in
vention will appear as progress is made in the .
dliliculty it is well understood that some-form of
a top plate must be used..
description of the accompanying drawings, illus-_
trative of a now preferred form of structure in
Other workers in this fleld have found that
solid plates, cr plates with holes, cored plates, 20 the. making of which the ypresent invention has
been carried into eiïect.
and wire screens, could be used as top plates for
In the accompanying drawings-like characters
latex- foam molds. ` Each of these types 'or top ,
of reference> have been applied to similar parts
plates can be used to produce sponge units which
throughout the various ñgures which make up
are satisfactory in general, but each such -form
the drawings, in which:
oi' ,top‘ plate has one or more` disadvantages.
Fig.- 1 is a view in longitudinal sectional ele- _
'Some of the most important of these expedients asv vation
of a molding apparatus in the construction
are listed below.
the present invention has been em
'A. Solid plateau-The bottoms-of the sponge l
- units which are produced in a mold with a solid
top plate, are found to be covered with small
cavities caused by entrapment of air. V(In most
cases sponge units are molded in inverted molds,
and therefore the plate covers what is to b'e
' come the bottom side of the unit.)
ities are reduced but not eliminated by using top
duced is a cored stock rather than a solid mate
' rial. The cost of coredplates is another dis-`
Accordingly, an object of the present inven- ’
tion is to provide top plates for loam sponge 45
molds which shall be free from the disadvantages'
and inconveniences encounteredin the us'e of - ~
fabrication of such foam’sponge articles, but
will result _in an increasedand more economical '
production of a more satisiactory'product.
with the invention;
Fig. 5 is a view in vertical sectional elevation
on an enlarged scale of a portion of the struc-4
ture as shown at the left hand end of Fig. 1, illus
`trating the manner in which the latex foam
under treatment reacts under application of the
advantage in theirëuse.
which will not only increase the convenience of '
ever the grid utilized as a top plate in accordance
have in addition many advantages in loperation
Fig. 1 with the vulcanizing hood omitted;
Fig. 4 is a view‘similar to Fig. 3, showing how-.
C. Corellil platea-cored plates can be used to
prevent excess vertical ridges but the stock pro
earlier forms of top plates but will retain the
proved advantages of _those top plates and will
._ Fig. 3 is a plan view of the apparatus shown in V
plates which contain a large number ot vent
ao in vertical section;
' B. Solid .plates with hoZes.-The aforesaid cav-_
Fig. 2 is a view taken on tlie line 2-2 of Fig. l
top plate constituting the present invention;
Fig. 6 is a fragmentary detail view in vertical
sectional elevation of one _of the elements of the
perforated top plate illustrated in Fig. 5 and in
Fig. l; and
Fig. 'l is a fragmentary detail view, Vtaken in
.front elevation, of a part of ascraper used in
forming a crowned surface'upon the latex'foam
preparatory toits vulcanlzation in the apparatus
of Fig.
Referring now to the drawings, Ill designates
generally a vulcanizlng unit in whichja mold
frame H is made to receive afsuitable _quantity
of latex foam which is the material that in this
:Ancillary to the above general object, it is'an 55 instance is to be treated. The mold frame com
prises uprightwalls I2, bolted at I3 to a mold
bottom plate I4 which is in turn supported by 'a
the upstanding foam, the latter preferably occu
pies substantially the position indicated by full
metal plate I5 mounted upon a foundation I6
which may be made of concrete or cement, or
lines in Fig. 5, and after its heat-treatment, such
other suitable material.
as Vulcanization, the foam may rise to approxi
5 mately the height 4I indicated by dotted lines
in Fig. 5, taking the form of a multiplicity of small
cushion-like elements which present somewhat
The foam I1 to be treated occupies the central
cavity enclosed by the walls I2 and'bottom I4
of the mold, and provision is made for a suitable
source of heat, such as the pipes I8 leading from
the appearance of square loaves.
After vulcanization in the conventional or other ,
10 suitable manner, the grid may be lifted from
a steam line I9 having a control valve 20.
the contiguous surface made up of these sponge
For the purpose of introducing water, a supply
pipe 2| is illustrated, _having a control valve 22
and preferably leading to a spray .pipe 23 which
may desirably be disposed in a recess 24 formed
in the concrete base I6, this -recess being adapted 15
to serve also as a sump from which liquid may
be withdrawn through a drain pipe 25, controlled Y
rubber subdivisions of the main surface, which
are found to clear themselves neatly from the
circumjacent partitions 36, leaving the latter with
few accretions, which can be readily washed,
brushed or scraped ofi’ preparatory to the next ~
use of the grid.
From the foregoing disclosure, it is clear that
An oven 2l of conventional or other suitable
‘ we have provided a structural top-plate element
by a valve 26.
form and material, such as sheet metal, may be 20 of a foraminous character which is constructed
raised and lowered by the Kbridle 28 and cable 29, > and arranged to carry into effect the stated ob
jects of the instant invention, particularly in
and when in use is shown as resting at 30 upon
the important respects that the walls of the open
a steel plate 3| supported upon the base I6. ,
ings 34 are adapted to support the foam, which
In pursuance of the invention, provision is
made of a top plate 33, taking the form of a. 25 rises to a suitable distance into the openings 34
but does not penetrate far enough to run together
foraxninous structural element adapted to be' dis- v
- posed above the foam-filled cavity I'I, resting
above the top of the plate, so that there is no
tendencyfor the resulting sponge rubber unit.
to be torn when the plate is stripped; and the
This element may be of any construction adapt- '
ed to afford á. multiplicity of deep openings, as 30 foraminous grate is further serviceable in the
important respect that it does not clog readily,
34, into which the foam I 'I may extend in the form
upon the upper edges 32 of the side walls I2.
of upright projections 35, (see Fig. 5) separated
and may be easily kept clean. '
from each other by' grooves or slots which are "
Having thusdescribed our invention, what we
claim and desire to protect by Letters Patent‘is:
made by the vertical'partitions 36 that define
the openings 34. These openings are of uniform
In a mold of the class intended for use in the
fabrication of shaped articles from latex foam and
like moldable material adapted to be set in solid
form, and in combination with a bottom wall andl
ping of the grill without tearing the molded mate
side wal1s.designed to confine vsaid material, a.
In the instance illustrated rectangular aper-` 40 rigid open grid adapted to cover the foam and
formed of fiat partition strips having their ñat
tures 34 are constituted by the upright metal
faces in upright position and arranged to define
partition members 36 which are notched at 31
a multiplicity of openings having deep surround
and interfit to form a grid, being fastened to a
ing straight walls so disposed as _to receive the
peripheral metal frame 38 by suitable fittings
such as the hook-bolts 39 illustrated in Fig. 5.
45 upper surface of the foam and to support the
same in an. elevated position during the operation
In the operation of the mold,'the space I‘I is
filled with foam to a height which may desirably ,
of setting the foam into solid form; whereby the
extend approximately a quarter of an inch above
foam can rise a substantial amount in said open
the upper edges of the surrounding walls I2, and
ings in the form of straight-sided, loaf-like pro
then this upper zone or stratum, as best seen 50 jections without reaching the upper ends thereof
in Fig. 5, receives a crowned shape, which is im
so as to support the weight of the foam mass and permit said solid foam to be stripped in sub
parted to it by means of a suitable scraper, such
stantially intact condition from the grid.
as that shown at 4I!I in Fig. 7, the scraper being
drawn over the upper edges 32 of the side walls
I2 from end to end.
When the grid is lowered into contact with
, cross section throughout their height. This pre-v
` vents clogging of the grill and facilitates strip-‘
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