Multiaxis rotational molding method, apparatus and structure

A method of continuously forming integrally molded structures in a multiaxis rotational molding operation including the steps of forming a plurality of preselected polymerizable mixtures including mixing liquid reactive resin forming material and particulate solid additive material substantially continuously while tumbling said materials along a generally cylindrical path in a preselected orientation and reversing the direction of said tumbling as said materials advance along said cylindrical path;

• rotating a plurality of multisection mold assemblies about a plurality of axes, indexing a freshly formed supply of a first polymerizable mixture into alignment with a first mold assembly, flowing said first polymerizable mixture over surfaces of a first enclosed mold cavity within said first mold assembly, monitoring said flowing of said first mixture over said first mold cavity surfaces and formation of a first resin therefrom, indexing said supply of said first polymerizable mixture into alignment with an adjacent second mold assembly, flowing said first polymerizable mixture over surfaces of a second enclosed mold cavity within said second mold assembly, simultaneously therewith indexing a freshly formed supply of a second polymerizable mixture into alignment with said first mold assembly, flowing said second polymerizable mixture over said first resin within said first mold cavity, monitoring said flowing of said first and second mixtures within said first and second mold cavities and formation of a first and second resin therefrom, indexing said supply of said first polymerizable mixture into alignment with an adjacent third mold assembly, flowing said first polymerizable mixture over surfaces of a third enclosed mold cavity within said third mold assembly, simultaneously therewith indexing said supply of said second polymerizable mixture into alignment with said second mold assembly, flowing said second polymerizable mixture over said first resin within said second mold cavity, monitoring said flowing of said first and second polymerizable mixtures within said second and third mold cavities and formation of first and second resins therefrom, continuing said indexing of said supplies of other of said polymerizable mixtures into alignment with said mold assemblies and the flowing of said mixtures into the respective mold cavities until all of the mold assemblies have received all of said mixtures, monitoring said flowing of said mixtures and formation of resins therefrom, continuing said rotation of said mold assemblies throughout said steps of said continuous molding operation while monitoring individually each axis rotation of said mold assemblies, and coordinating said monitored flowing of each mixture and said monitored formation of each resin with each monitored axis rotation in a preselected profile to form said integrally molded structures of said resins, separating said mold sections of each mold assembly after each integrally molded structure therein has achieved structural integrity within said mold cavity, removing said integrally molded structure from said separated mold sections and repeating said steps to form a multiplicity of said integrally molded structures on a continuing basis.