Method of producing ventilator grills

A method of producing a ventilator grill of the type which comprises a grill frame and substantially parallel louver vanes pivotally mounted on said grill frame, said grill frame including a pair of opposite sides in which aligned pairs of axle holes are formed, said louver vanes having axles extending from the opposite ends of said vanes respectively and rotatably received in respective aligned pairs of axle holes, said grill frame being provided with at least two recesses formed in the outer surfaces of said pair of opposite sides of said frame and communicated with one of said aligned pairs of axle holes, the louver vane associated with said one aligend pair of axle holes having disc-like friction portions integrally connected to the outer ends of the axles of said one vane and received in said recesses rotatably but frictionally to provide a slight frictional resistance to angular movements of said louver vane relative to said grill frame, said method comprising the steps of:

• gathering together first and second mould halves and cores in a first predetermined position in which they cooperate to define a first mould cavity for moulding said grill frame, said cores defining surfaces for moulding said axle holes and said recesses;
• injecting a first plastics material into said first mould cavity;
• allowing said first plastics material to solidify in said first mould cavity to form said grill frame having axle holes and recesses;
• removing said grill frame from said first mould half and from said cores while said grill frame is retained on said second mould half;
• gathering together said second mould half with said grill frame thereon and a third mould half in a second predetermined position in which the part of said grill frame moulded by said first mould half is received in said third mould half and in which said second and third mould halves and said grill frame cooperate to define a second mould cavity for moulding said louver vanes, said second mould cavity including spaces for moulding said axles and friction portions, said spaces being defined by said axle holes and recesses formed in said grill frame;
• injecting into said second mould cavity a second plastics material which is not weldable to said first plastics material and has a melting point lower than that of said first plastics material;
• and
• allowing said second plastics material to solidify in said second mould cavity to form said vanes, said axles and disk-like friction portions of said vanes being shrunk when solidified in said axle holes and recesses to allow said vanes to be angularly movable relative to said grill frame.