Other

LeRoy Payne

Peter H Markusch

Ralf Guether

The present invention is directed to a method for impregnating at least one geofabric with a liquid solidifiable polyurethane composition, conforming at least one polyurethane-impregnated geofabric to a surface (such as to the surface of a canal, ditch and/or pipe) and allowing the liquid solidifiable polyurethane composition to cure and form a polyurethane/geofabric composite. The liquid solidifiable polyurethane composition is the reaction product of COMPONENT A, COMPONENT B and COMPONENT C, as defined herein. COMPONENT C has the same equivalent weight as COMPONENT B and contains catalyst. One advantage of the present invention is that the ratio of COMPONENT B to COMPONENT C can be adjusted during processing without changing the isocyanate index. As a result, geltimes of liquid solidifiable polyurethane compositions of the present invention can be adjusted to accommodate changes in outdoor application temperature.

Method for producing a polyurethane/geofabric composite

A method of forming a continuous composite structure includes encapsulating solid additive particles with a first reactive liquid resin forming material and migrating part of the mixture through a porous blanket to form a continuous resin matrix within the blanket with adhesive outer surfaces. A thin coating of a second preselected resin forming material which substantially cures immediately upon application is applied over one major adhesive upper surface of the matrix/blanket while allowing an area of the adhesive surface to remain exposed along one edge of the upper surface thereof. A plurality of preselected flexible lengths of the coated matrix/blanket are individually positioned successively in an overlapping orientation with the exposed adhesive area of the upper surface of the adjoining positioned length tightly affixed to the adhesive lower surface of the succeeding length to form a continuous composite structure. Also, the composite structure and apparatus for producing same.

Structure forming method, apparatus and product

A method of continuously forming integrally molded structures includes the steps of rotating a plurality of independently movable multisection mold assemblies about a plurality of axes, successively flowing a plurality of polymerizable mixtures over surfaces of each enclosed mold cavity while selectively heating mold sections thereof in a preselected heating profile and monitoring the flowing of each mixture, the heating of the mold sections and the formation of resins therefrom. The monitored mixture flowing, the mold section heating and the formation of each resin are coordinated with each monitored axis rotation. The molded structure is removed after it has achieved structural integrity within the mold cavity, and the steps are repeated to form a multiplicity of the integrally molded structures on a continuing basis. Also, multiaxis molding apparatus for conducting the above method.

Multiaxis rotational molding method and apparatus

A method of forming a continuous tubular structure includes preselecting a liquid reactive resin forming material, a particulate solid additive material, a porous tubular blanket and an inflatable bladder member disposed within the blanket. The additive particles are mixed with the liquid resin forming material substantially continuously to form a substantially uniform mixture thereof. Substantially all of the additive particles are encapsulated with the resin forming material. The tubular blanket/bladder combination is advanced through the liquid resin/additive mixture, part of which migrates through the blanket substantially uniformly to form a continuous resin matrix therein. The mixture-treated blanket is advanced along a preselected path, while the bladder therein is inflated to form a tubular structure of a preselected cross section. The structure is placed into a preselected final configuration while it is flexible and has an adhesive outer surface. Apparatus for conducting the above method.

A multiaxis rotational molding apparatus includes a support portion, a molding portion and a control portion. The support portion includes an upstanding arcuate frame section. The molding portion includes an upstanding arcuate mold supporting assembly disposed within and spaced from the arcuate frame section. A mold assembly includes separable mold sections forming a substantially enclosed mold cavity carried within the mold supporting assembly. The control portion includes drive assemblies arranged in a preselected configuration adjacent the arcuate frame section selectively energized in coordination with adjacent drive assemblies for movement of the mold supporting assembly in a selected profile. Programmable memory stores preselected operating parameters. Monitors sense operating information form control components. Circuitry transmits signals from the monitors to a coordinator comparing the operating information with operating parameters stored in the memory to control rotation of the mold supporting assembly in a preselected rotational profile.

Multiaxis rotational molding apparatus and method

Multiaxis rotational molding apparatus (,) includes a plurality of spaced generally horizontally oriented arm members (,) each having one end (,) extending from an upstanding frame section (,) with one mold assembly (,) rotatably mounted adjacent a free end thereof. Each mold assembly includes a plurality of separable mold sections (,) including plate sections (,). A plurality of movable elongated mixing chambers (,), each including a plurality of adjacent axially aligned rotatable driven mixing sections (,). A control portion (,) includes an indexing mechanism (,) sequentially orienting a dispenser of each mixing chamber with each mold assembly to control formation of molded structures continuously in a preselected multiaxis molding profile. Also, a method of forming molded structures with the molding apparatus is disclosed.

Multiaxis rotational molding method, apparatus and structure

A method of and apparatus for forming a continuous structure includes the steps of preselecting a liquid reactive resin forming material, a particulate solid additive material and a porous blanket, mixing and encapsulating the additive particles with the liquid resin forming material while tumbling the materials along a cylindrical mixing chamber. The leading edge of the structure is grasped with a gripping device along its entire length and advanced over a horizontal supporting surface. Once a desired length has been formed a cutting device cuts the structure and the cut portion is placed into a final configuration while flexible and adhesive.

Structure forming method and apparatus

A method of continuously forming an integrally molded structure in a multiaxis rotational molding operation includes the steps of rotating a multisection mold assembly about at least three axes. A first freshly formed polymerizable mixture is flowed over surfaces of an enclosed mold cavity within the multisection mold assembly. The flowing of the first mixture over the mold cavity surfaces and formation of a first resin therefrom is monitored. A second freshly formed polymerizable mixture is flowed under pressure through an orifice into the mold cavity. A liquid stream of the second mixture is formed. The liquid stream is gelled as it advances through the mold cavity to form a continuous filament with structural integrity. The filament is contacted with the first resin formed within the mold cavity. The filament is distributed over the first resin in a preselected pattern. A third freshly formed polymerizable mixture is flowed over the filament pattern formed within the mold cavity with the second mixture. The flowing of the third mixture and formation of a third resin therefrom is monitored. The rotation of the multisection mold assembly is continued throughout the steps of the continuous molding operation while monitoring individually each axis rotation of the multisection mold assembly. The monitored flowing of each mixture and the monitored formation of each resin with each monitored axis rotation is coordinated in a preselected profile to form the integrally molded structure of the first, second and third resins. Also, apparatus forming the structure is included.

Multiaxis rotational molding apparatus

A method of forming a continuous structure includes the steps of flowing a first liquid reactive resin forming material over a base surface, forming a first thin substantially uniform layer thereof and gelling the first layer. A second liquid resin forming material is flowed through an orifice under pressure forming a liquid stream thereof. The liquid stream is gelled to form a continuous filament with structural integrity as it advances toward the first gelled layer. The filament is contacted with the first layer and distributed thereover in a preselected pattern forming a porous non-woven filament blanket. A particulate solid material is distributed substantially uniformly over the filament blanket. A third liquid resin forming material is flowed over the blanket forming a second thin substantially uniform layer of the third liquid resin forming material and the layer is gelled. The resulting freshly formed structure is compressed and positioned in a final configuration while the structure is flexible and adhesive after which curing is completed. Also, apparatus forming the structure as well as the structure itself.

Continuous structure forming apparatus

A method of forming a continuous structure includes the steps of preselecting a liquid reactive resin forming material, a particulate solid additive material and a porous blanket. The additive particles are mixed with the liquid resin forming material substantially continuously in a proportion significantly greater than that of the liquid resin forming material. Substantially all of the additive particles are encapsulated with the liquid resin forming material to a preselected thickness. A pool of the resulting mixture is formed on the blanket. The blanket is advanced at a rate sufficient to create movement of the additive particles within the pool and maintain the additive particles in suspension. Part of the liquid resin forming material is migrated through the blanket substantially uniformly prior to gelling of the liquid resin forming material to form a continuous resin matrix within the blanket. Also, apparatus forming the structure as well as the structure itself.

Method for continuously forming structure from resin, particles, and

Continuous structure forming method

Multiaxis rotational molding apparatus includes a support portion, a molding portion, a mixing portion and a control portion. The support portion includes an arm member disposed in a generally horizontal orientation and having one end extending from an upstanding supporting section. The molding portion includes a mold supporting assembly pivotally connected to a free end of the arm member and an independently rotatable mold connector section. The mold supporting assembly includes a central passage therethrough from a pivotal connection with the arm member and through the mold connector section. A mold assembly includes at least two separable mold sections forming a substantially enclosed cavity. The mixing portion includes an elongated section extending axially within the central passage through the mold supporting assembly adjacent the mold connector section. The mixing section includes a plurality of deflector sections disposed along the length thereof. A plurality of inlet conduits extends along the arm member and is operatively connected to an inlet end of the mixing section. A hollow probe member extends from an outlet end of the mixing section into the cavity of the mold assembly. The control portion includes actuators rotating the mold connector section and the mold assembly affixed thereto and actuators pivoting the mold supporting assembly and the mold assembly affixed thereto with respect to the arm member, a programmable memory, a coordinator, monitors and circuitry.

Rotational molding apparatus

A method of continuously forming an integrally molded structure in a multiaxis rotational molding operation includes the steps of rotating a multisection mold assembly about at least three axes. A first freshly formed polymerizable mixture is flowed over surfaces of an enclosed mold cavity within the multisection mold assembly. The flowing of the first mixture over the mold cavity surfaces and formation of a first resin therefrom is monitored. A second freshly formed polymerizable mixture is flowed under pressure through an orifice into the mold cavity. A liquid stream of the second mixture is formed. The liquid stream is gelled as it advances through the mold cavity to form a continuous filament with structural integrity. The filament is contacted with the first resin formed within the mold cavity. The filament is distributed over the first resin in a preselected pattern. A third freshly formed polymerizable mixture is flowed over the filament pattern formed within the mold cavity with the second mixture. The flowing of the third mixture and formation of a third resin therefrom is monitored. The rotation of the multisection mold assembly is continued throughout the steps of the continuous molding operation while monitoring individually each axis rotation of the multisection mold assembly. The monitored flowing of each mixture and the monitored formation of each resin with each monitored axis rotation is coordinated in a preselected profile to form the integrally molded structure of the first, second and third resins. Also, apparatus forming the structure.

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Molt, MT, United States of America

LeRoy Payne