FORM-2
THE PATENTS ACT,1970
(39 of 1970)
&
THE PATENTS RULES, 2006
COMPLETE
Specification
(See Section 10 and Rule 13)
AN INJECTION MOULDING APPARATUS AND PROCESS
NILKAMAL LIMITED,
an Indian Company,
of Survey No.354/2 & 354(3),Near Rakholi Bridge,
Silvassa-Khanvel Road,Village Vasona ,
Silvassa(D & NH), India.
THE FOLLOWING SPECIFICATION PARTICULARLY DESCRIBES THE INVENTION AND THE MANNER IN WHICH IT IS TO BE PERFORMED

FIELD OF INVENTION
The invention relates to an injection moulding machine and the method of manufacturing an article by using the same.
BACKGROUND OF THE INVENTION
Plastic moulded articles/ product are generally manufactured by injection moulding. Injection moulding is a manufacturing process for producing parts from both thermoplastic materials. Typically, material is fed into a heated barrel where they are melted and mixed and forced into a mould cavity so as to cool and harden to the configuration of the mould cavity.
The use of plastic articles/ product has been increasing as they are light in weight. However, presently the plastic article/ product are generally manufactured of single colour. This is achieved by mixing colour to the raw material in a blender and thereafter the blended material is injected into a mould by means of a screw barrel, a shut off nozzle and a machine nozzle.
In order to manufacture plastic moulded article/ product of more than one colour, separate injection barrel is connected after the shut off nozzle. This is carried out in a double barrel injection moulding machine. However, using this technology the plastic moulded article/ product contain thick bands/ patches of distinct colours.
Thus, the prior art helps in manufacturing plastic moulded article/ product of single colour or having patches of distinct colours. They cannot be used to produce plastic moulded article/ product having finishing of natural

materials like wood, marble, granite, stone and the like. Hence, there was felt a need for a moulding machine and method which can produce a plastic moulded article/ product having finishing of natural materials.
OBJECT OF THE INVENTION
An object of the present invention is to provide an injection moulding machine which is capable of producing plastic moulded article/ product having finishing of natural materials.
Another object of the present invention is to provide plastic moulded article/ product having better aesthetic appearance.
Yet another object of the present is to provide an injection moulding machine which is simple in construction.
Still another object of the present invention is to provide an injection moulding machine which is efficient.
An added object of the present invention is to provide an injection moulding machine which is cost effective.
An additional object of the present invention is to provide an injection moulding machine which is easy to install.
SUMMARY OF THE INVENTION
In accordance with the present invention there is provided an injection moulding apparatus for moulding an article from a molten raw material, the apparatus comprising:
injection unit having a first hopper and a second hopper;

a first screw and barrel assembly and a second screw and barrel
assembly cooperating with the first hopper and the second
hopper respectively, each of the screw and barrel assemblies
being provided with a nozzle; and
a clamping unit cooperating with the injection unit, the
clamping unit having a hot runner manifold adapted to receive
molten raw material from the nozzle and injecting the molten
raw material into a mould.
Typically, each of the screw and barrel assemblies and the hoppers are controlled by means of at least one electronic controller.
Alternatively, each of the screw and barrel assemblies and the hoppers are hydraulically operated.
Typically, the clamping unit is hydraulically operated.
Typically, the first screw and barrel assembly and the second screw and barrel assembly are adapted to mix the molten raw material with a first colour and a second colour respectively, the molten raw material being selected from the group comprising Filled Polpropylene (FPP), Polpropylene Homo Polymer (PPHP), Polpropylene Co Polymer (PPCP) and a combination thereof.
Typically, the first screw and barrel assembly and the second screw and barrel assembly cooperate with the nozzle via a die head.
Typically, the clamping unit is provided with an ejector cylinder for removal of the article from the mould.

Typically, the mould is attached to a fixed platen and is closed by means of a moving platen, the moving platen is moved to a predetermined position by means of a plurality of tie bars and at least one toggle plate.
Typically, the clamping unit is provided with at least one door for inspection.
Typically, the hot runner manifold is provided with a plurality of tubes having a coil heater, the hot runner manifold further provided with a tubular heater.
Typically, the hot runner manifold is adapted to receive molten raw material from the nozzle through a gate.
In accordance with the present invention there is provided a method for moulding an article from a molten raw material, the method comprising the steps of:
blending a group of raw material to form a molten raw material;
pouring the molten raw material through a first hopper and a
second hopper and causing the molten raw material to pass
through a first screw and barrel assembly and a second screw
and barrel assembly respectively;
mixing the molten raw material with a first colour and a second
colour in the first screw and barrel assembly and the second
screw and barrel assembly respectively;
injecting the molten raw material to flow into a mould to form
the article; and

cooling the article in the mould and withdrawing the article from the mould.
Typically, the step of injecting the molten raw material is controlled by means of at least one electronic controller.
BRIEF DESCRIPTION OF THE FIGURES
Other aspects of the invention will become apparent by consideration of the accompanying drawing and their description stated below, which is merely illustrative of a preferred embodiment of the invention and does not limit in any way the nature and scope of the invention.
Figure 1 illustrates a side view of the clamping unit of the moulding machine of the present invention;
Figure 2 illustrates the top view of the clamping unit of the moulding machine of the present invention;
Figure 3a illustrates a top view of the hot runner manifold of the moulding machine of the present invention;
Figure 3b illustrates a side view of the hot runner manifold of the moulding machine of the present invention;
Figure 4 illustrates a side view of the injection unit of the moulding machine of the present invention;

Figure 5 illustrates the front view of the injection unit of the moulding machine of the present invention;
Figure 6 illustrates the top view of the injection unit of the moulding machine of the present invention; and
Figure 7 illustrates the flow of the molten raw material to the mould through the injection unit.
DETAILED DESCRIPTION
The invention will now be described with reference to the accompanying drawings which do not limit the scope and ambit of the invention. The description provided is purely by way of example and illustration,
The process of moulding of the present invention is carried out in the injection moulding machine having a clamping unit (10), shown in figure 1 and figure 2, and an injection unit (40), shown in figure 4, figure 5 and figure 6.
The clamping unit (10), shown in figure 1 and figure 2, is mounted on a clamping unit base (11) and comprises at least one hydraulic cylinder (12), at least four tie bars (14) each having two tie bar nuts (16), a moving platen (18), a fixed platen (20), a toggle plate (22), at least one toggle (24), an hot runner (HR) manifold (32), shown in figure 3a and figure 3b, with a HR bushing (35) and a mould (33). The mould (33) is attached to the fixed platen (20) on one side and is closed by means of the moving platen (18). The moving platen (18) is moved from a mould closing position to a mould

opening position by means of the tie bars (14) and the toggle plate (22). The clamping unit (10) is further provided with a front door (26) and a rear door (28) to facilitate in maintenance work. An ejector cylinder (30) is provided to help in ejecting the moulded article from the mould (33). A locating ring (38) is provided for precisely locating the injection unit (40) with respect to the clamping unit (10).
The Hot Runner manifold (32), shown in figure 3a and figure 3b, comprises a plurality of tubes (48) adapted to receive a molten raw material from the injection unit (40). The molten raw material is formed from a blend of raw materials selected from the group comprising Filled Polpropylene (FPP), Polpropylene Homo Polymer (PPHP), Polpropylene Co Polymer (PPCP) and the a combination thereof. The Hot Runner (HR) Manifold (32) is further provided with tubular heater (41). Each of the tubes (48) is provided with a coil heater (50). The plurality of tubes (48) at one end opens into the mould (33) while at the other end the plurality of tubes (48) communicates with at least two passages/gates (52). which receives molten raw material from the nozzle (43) of the screw and barrel (Bl) and the screw and barrel (B2) of the injection unit (40). The Hot Runner manifold (32) is further provided with a spacer (54) and plug (56).
The injection unit (40), shown in figure 4, figure 5 and figure 6, is mounted on an injection unit base (42) and comprises a first hopper (HI) communicating with a screw and barrel (Bl) and a second hopper (H2) communicating with a screw and barrel (B2). The first hopper (HI) and the second hopper (H2) are each provided with hopper pipe (45). The screw and barrel (Bl) and the screw and barrel (B2) further communicate with a die

head (41) cooperating with a nozzle (43). The first hopper (H1) and the second hopper (H2) are individually provided with a heater (44). The first hopper (H1) with the barrel (Bl) and the second hopper (H2) with the barrel (B2) are each provided with a hydraulic cylinder (46) controlled by a controller (not shown in figure). The nozzle (43) of the screw and barrel (Bl) and the screw and barrel (B2) of the injection unit (40) cooperates with the gate (52) of the Hot Runner manifold (32) to supply the molten raw material.
The operation of the screw and barrel (B1) and the screw and barrel (B2) are controlled by an electronic control unit (EC1) and an electronic control unit (EC2) respectively. The electronic control unit (EC1) and the electronic control unit (EC2) help in controlling the speed, the pressure and the volume of injection of the molten raw material into the mould (33). The electronic control unit (EC1) and the electronic control unit (EC2) help in controlling the flow of raw material into the Hot Runner manifold (32) by temperature of the raw material. The controlled flow of the molten raw material of two different colours into the mould (33) enable in giving the moulded article a finish resembling natural materials like wood, marble, granite, stone and the like.
Figure 7 illustrates the flow of the molten raw material to the mould (33) through the screw and barrel (Bl) and the screw and barrel (B2). The molten raw material is fed into the screw and barrel (B1) and the screw and barrel (B2) through the first hopper (H1) and the second hopper (H2) respectively. The molten raw material in the screw and barrel (Bl) is added to master batch in the range of 1.8 % to 2.0 % or as desired and is blended with a first

colour. The molten raw material in the screw and barrel (B2) is added to 1.25 % or as desired of master batch and is blended with a second colour. The molten raw material flows from the screw and barrel (Bl) and the screw and barrel (B2) into the Hot Runner manifold (32) from where the molten raw material in injected into the mould (33) to form the article. Once the mould article solidifies and cools, it can be withdrawn by the operation of the ejector cylinder (30).
TECHNICAL ADVANTAGES
The product as described herein above offers several advancements over similar products disclosed in the prior art. The product and process as described herein above helps in manufacturing article/product having finishing resembling that of natural materials. Further, the present invention helps in manufacturing article/product having better aesthetic appearance.
Wherever a range of values is specified, a value up to 10% below and above the lowest and highest numerical value respectively, of the specified range, is included in the scope of the invention.
In view of the wide variety of embodiments to which the principles of the present invention can be applied, it should be understood that the illustrated embodiments are exemplary only. The numerical values given of various physical parameters and dimensions are only approximations and it is envisaged that the values higher or lower than the numerical values assigned to the parameters, dimensions and quantities fall within the scope of the invention.

While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the invention. These and other changes in the preferred embodiment as well as other embodiments of the invention will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.

We claim:
1. An injection moulding apparatus for moulding an article from a molten raw material, said apparatus comprising:
an injection unit having a first hopper and a second hopper;
a first screw and barrel assembly and a second screw and barrel
assembly cooperating with said first hopper and said second
hopper respectively, each of said screw and barrel assemblies
being provided with a nozzle; and
a clamping unit cooperating with said injection unit, said
clamping unit having a hot runner manifold adapted to receive
molten raw material from said nozzle and injecting the molten
raw material into a mould.
2. The injection moulding apparatus as claimed in claim 1, wherein each of said screw and barrel assemblies and said hoppers are controlled by means of at least one electronic controller.
3. The injection moulding apparatus as claimed in claim 1, wherein each of said screw and barrel assemblies and said hoppers are hydraulically operated.
4. The injection moulding apparatus as claimed in claim 1, wherein said clamping unit is hydraulically operated.
5. The injection moulding apparatus as claimed in claim 1, wherein said first screw and barrel assembly and said second screw and barrel assembly are adapted to mix the molten raw material with a first colour and a second colour respectively, said molten raw material being selected from the group comprising Filled Polpropylene (FPP),

Polpropylene Homo Polymer (PPHP), Polpropylene Co Polymer (PPCP) and a combination thereof.
6. The injection moulding apparatus as claimed in claim 1, wherein said first screw and barrel assembly and said second screw and barrel assembly cooperates with said nozzle via a die head.
7. The injection moulding apparatus as claimed in claim 1, wherein said clamping unit is provided with an ejector cylinder for removal of the article from said mould.
8. The injection moulding apparatus as claimed in claim 1, wherein said mould is attached to a fixed platen and is closed by means of a moving platen, said moving platen is adapted to be moved to a predetermined position by means of a plurality of tie bars and at least one toggle plate.
9. The injection moulding apparatus as claimed in claim 1, wherein said clamping unit is provided with at least one door for inspection.
10. The injection moulding apparatus as claimed in claim 1, wherein said hot runner manifold is provided with a plurality of tubes having a coil heater, said hot runner manifold further provided with a tubular heater.
11. The injection moulding apparatus as claimed in claim 1, wherein said hot runner manifold is adapted to receive molten raw material from said nozzle through a gate.
12. A method for moulding an article from a molten raw material, said method comprising the steps of:
blending a group of raw material to form a molten raw material;

pouring said molten raw material through a first hopper and a
second hopper and causing the molten raw material to pass
through a first screw and barrel assembly and a second screw
and barrel assembly respectively;
mixing the molten raw material with a first colour and a second
colour in said first screw and barrel assembly and said second
screw and barrel assembly respectively;
injecting the molten raw material to flow into a mould to form
the article; and
cooling the article in the mould and withdrawing the article
from said mould.
13. The method as claimed in claim 1, wherein said step of injecting the molten raw material is controlled by means of at least one electronic controller.