WO2009143600A1

WO2009143600A1 - Injection molding system and an injection molding process

Info

Publication number: WO2009143600A1
Application number: PCT/CA2009/000326
Authority: WO
Inventors: Tiemo Dietmar Brand; Denise Davina Craig
Original assignee: Husky Injection Molding Systems Ltd.
Priority date: 2008-05-29
Filing date: 2009-03-20
Publication date: 2009-12-03

Abstract

Disclosed, amongst other things, is an injection molding process that is executable in an injection molding system. The injection molding system includes a first interchangeable mold half and a second interchangeable mold half arranged on a turret. The turret is rotatable and translatable for interchanging the first interchangeable mold half and the second interchangeable mold half between a first stationary mold half, at a first molding station, and a second stationary mold half, at a second molding station. The first stationary mold half and the second stationary mold half are arranged on a first stationary platen and a second stationary platen, respectively.

Description

INJECTION MOLDING SYSTEM AND AN INJECTION MOLDING PROCESS

TECHNICAL FIELD

The present invention generally relates to, but is not limited to, molding systems, and more specifically the present invention relates to, but is not limited to, an injection molding system, and an injection molding process, amongst other things.

BACKGROUND OF THE INVENTION

United States Patent No. 3,224,043 to Lameris et al., published on December 21^st, 1965, describes an injection moulding machine comprising at least two composite moulds, each of which is composed of at least two mould parts, viz. a nozzle mould part and a counter mould part, said mould parts being mounted for relative movement and adapted to be pressed against each other during the moulding process.

United States Patent No. 4,330,257to Rees et al., published on June 18^th, 1982, describes a four- sided turret interposed between a fixed and a movable platen of an injection-molding machine, mounted on a carriage which is slidable in the direction of platen motion, is rotatable about an axis perpendicular to that direction into four operative positions spaced 90 degree apart.

United States Patent No. 4,726,558 to Ozone et al., published on February 23, 1988, describes a method including the steps of forming either the retaining member or the body member by injection molding a first synthetic resin; and forming the other member on the first molded member by injection molding a second synthetic resin which is different in kind from and nonconjunctive to the first synthetic resin so as to obtain an assembly of the retaining member and the body member.

United States Patent No. 5,817,345 to Koch et al., published on October 6, 1998, describes an injection molding machine of the present invention includes a first mold half having one of at least one mold cavity and at least one mold core and a rotatable turret block rotatable on an axis for rotating a plurality of movable mold halves thereof into alignment with the first mold half.

United States Patent No. 6,139,305 to Nesch, published on October 31, 2000, describes an injection molding apparatus capable of producing injection molded articles from at least two plastic melts, includes an additional mold mounting device between a fixed mold mounting plate and a movable mold mounting plate that is traversed along four essentially horizontal tie rods. The additional mold mounting device is also pivotable around a rotational axis aligned perpendicular to the longitudinal axis of the tie rods, and carries additional mold halves that cooperate with the mold halves mounted on the mold mounting plates on at least two side surfaces that are aligned with a spacing parallel to each other and relative to the rotational axis.

United States Patent No. 6,558,149 to Bodmer et al., published on May 6, 2003, describes a holding device for injection molding mold halves or their holders that contain two displacement units on each of which a rotation unit is attached.

United States Patent No. 6,709,251 to Payette et al., published on March 23, 2004, describes a support for rotating molds used in multi-shot injection molding provides for platen mounting of a support track that may extend beneath the molds to support the rotating mold portion. The extensible track provides a telescoping configuration that allows a long support span independent of the mold width improving mold stability and increasing potential mold separation for easy access to the mold portions.

United States Patent No. 7,018,189 to Wobbe et al., published on March 28, 2006, describes a mold closing device of an injection molding machine for producing plastic parts made of two or more plastic components includes a central mold carrier element which is arranged between two outer mold mounting plates and has two or four opposing mold mounting areas arranged in pairs for affixing two or four mold halves and which is fitted with a turning device supported in a supporting frame. Each of the mold halves of the mold carrier element can be closed against the mold halves of the outer mold mounting plates by a drive mechanism and a mold pressure unit.

United States Patent No. 7,314,362 to Lichtinger, published on January 1, 2008, describes a horizontal injection molding machine includes a machine bed defining a longitudinal axis and two mold platens supported on the machine bed for movement in a direction of the longitudinal axis, whereby each of the mold platens carries a half-mold. Further provided is a turning device which carries at least two half-molds for interaction with the half- molds on the mold platens, and includes a base plate, which is fixedly mounted to the machine bed between the mold platens, a turntable, and a bearing unit supporting the turntable on the base plate on one side for rotation about a vertical axis. The half-molds of the turning device are hereby attachable on a base-plate distal side of the turntable. The mold platens are moved by a drive mechanism in relation to the turning device, and tie bars extend between the mold platens and are constructed to resist a clamping force. PCT Patent Publication WO00/12284(Al) to De Nardi, published on March 9, 2000, describes an apparatus for the production of multi-layer plastic preforms, comprising a plurality of pairs of mutually coupling mould-halves forming a multiplicity of moulding cavities, a plurality of mutually associated extruders and/or injectors to the injection nozzle of which a respective mould- half is coupled permanently, wherein said extruders -injectors are adapted to inject different types of plastic resin into each multiplicity of cavities of each pair of mould-halves. There is also provided a support structure consisting of a table rotating with respect to an axis that is firmly associated with the assembly of said extruders-injectors, said rotary table being provided on its outer edges with a plurality of mould-halves adapted to successively couple with the mould-halves provided on said extruders -injectors, thereby forming temporarily associated pairs of mould-halves which are exclusively fed with resin and/or plastic substance processed in and flowing from the extrusion-injection means associated to the respective mould-half.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the present invention, an injection molding process is provided that is executable in an injection molding system. The injection molding system includes a first interchangeable mold half and a second interchangeable mold half arranged on a turret. The turret is rotatable and translatable for interchanging the first interchangeable mold half and the second interchangeable mold half between a first stationary mold half, at a first molding station, and a second stationary mold half, at a second molding station. The first stationary mold half and the second stationary mold half are arranged on a first stationary platen and a second stationary platen, respectively. The injection molding process including arranging the first interchangeable mold half in a mold closed relation with respect to the first stationary mold half, at the first molding station, to define a first molding cavity therebetween. Molding a primitive molded article in the first molding cavity from a first molding material. Interchanging the first interchangeable mold half with the second interchangeable mold half, the primitive molded article remaining with the first interchangeable mold half. Arranging the first interchangeable mold half in a mold closed relation with respect to the second stationary mold half, at the second molding station, to define a second molding cavity therebetween with the primitive molded article arranged therein. Molding a finished molded article in the second molding cavity from a second molding material and the primitive molded article.

In accordance with a second aspect of the present invention there is provided an injection molding system that includes an injection molding clamp. The injection molding clamp includes a machine base, a first stationary platen fixed to the machine base. The first stationary platen is configured to receive, in use, a first stationary mold half. The injection molding clamp further includes a second stationary platen fixed to the machine base. The second stationary platen is configured to receive, in use, a second stationary mold half. The injection molding clamp further includes a carrier translatably linked to the machine base. The injection molding clamp further includes a turret that is configured to receive, in use, a first interchangeable mold half on a first face thereof, and a second interchangeable mold half on a second face thereof. The turret is rotatably linked to the carrier to selectively interchange, in use, the first interchangeable mold half and the second interchangeable mold half between the first stationary mold half, at a first molding station, and the second stationary mold half, at a second molding station, respectively. The injection molding clamp also includes a first clamping structure that selectively links, in use, the carrier with the first stationary platen, and a second clamping structure that selectively links, in use, the carrier with the second stationary platen.

BRIEF DESCRIPTION OF THE DRAWINGS

A better understanding of the exemplary embodiments of the present invention (including alternatives and/or variations thereof) may be obtained with reference to the detailed description of the exemplary embodiments along with the following drawings, in which: FIG. 1 is a side view of a non-limiting embodiment of an injection molding clamp;

FIG. 2 is a top view of a non-limiting embodiment of an injection molding system that includes the non-limiting embodiment of the injection molding clamp of FIG. 1 ;

FIG. 3A is a schematic view of the non-limiting embodiment of the injection molding system of FIG. 2 in a first configuration; FIG. 3B is a schematic view of the non-limiting embodiment of the injection molding system of FIG. 2 in a second configuration;

FIG. 3C is a schematic view of the non-limiting embodiment of the injection molding system of FIG. 2 in a third configuration; and

FIG. 3D is a schematic view of the non-limiting embodiment of the injection molding system of FIG. 2 in a fourth configuration;

FIG. 3E is a schematic view of the non-limiting embodiment of the injection molding system of FIG. 2 in a fifth configuration;

FIG. 3F is a schematic view of the non-limiting embodiment of the injection molding system of FIG. 2 in a sixth configuration; FIG. 3G is a schematic view of the non-limiting embodiment of the injection molding system of FIG. 2 in a seventh configuration; FIG. 4 is a flow-chart depicting the steps of an injection molding process that is executable in the injection molding system of FIG. 2.

The drawings are not necessarily to scale and are may be illustrated by phantom lines, diagrammatic representations and fragmentary views. In certain instances, details that are not necessary for an understanding of the exemplary embodiments or that render other details difficult to perceive may have been omitted.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Non-Limiting Embodiments of an Injection Molding System

With reference to FIG. 1 a non-limiting embodiment of an injection molding clamp 10 is shown. The injection molding clamp 10 is for use within an injection molding system such as the non- limiting embodiment of an injection molding system 8 that is shown with reference to FIG. 2. Referring back to FIG. 1, the injection molding clamp 10 includes a pair of stationary platens and a rotatable translatable turret arranged therebetween.

More particularly, the non-limiting embodiment of the injection molding clamp 10 includes a machine base 60 upon which a first stationary platen 12 fixed. The first stationary platen 12 is configured to receive, in use, a first stationary mold half 52. The first stationary platen 12 is further configured to include a first passage 68 to accommodate, in use, a portion of a first injection unit 102 (schematically shown with reference to any one of FIGs. 3A, 3B, 3C, 3D, 3E, 3F, or 3G), wherein the first injection unit 102 is fluidly connectable, in use, with a melt distribution network that is associated with the first stationary mold half 52.

The non- limiting embodiment of the injection molding clamp 10 also includes a second stationary platen 14 fixed to the machine base 60. The second stationary platen 14 is configured to receive, in use, a second stationary mold half 56. The second stationary platen 14 is further configured to include a second passage 71 to accommodate, in use, a portion of a second injection unit 104 (schematically shown with reference to any one of FIGs. 3A, 3B, 3C, 3D, 3E, 3F, or 3G), wherein the second injection unit 104 is fluidly connectable, in use, with a melt distribution network that is associated with the second stationary mold half 56.

One or both of the injection units 102, 104 may include a melt filter 106 to strain out debris and the like. The foregoing is helpful when molding with post-consumer regrinded thermoplastics such as recycled polyethylene terephthalate (i.e. PET) resin. The non-limiting embodiment of the injection molding clamp 10 also includes a carrier 20 translatably linked to the machine base 60. The carrier 20 itself includes a pair of frame members 18 (both shown with reference to FIG. 2) between which a turret 16 is rotatably supported.

The turret 16 is configured to receive, in use, a first interchangeable mold half 50A on a first face thereof, and a second interchangeable mold half 50B on a second face thereof. The turret 16 is selectively rotatable by a drive 21 (for example, in the direction 'C around an axis of the turret 16 as shown in FIG. 2), in use, to selectively interchange the first interchangeable mold half 50A and the second interchangeable mold half 50B between the first stationary mold half 52, at a first molding station 'I', and the second stationary mold half 56, at a second molding station 'II', respectively. The rotation of the turret 16 is provided by a motor 24 (e.g. computer-controlled servo motor). A frame of the motor 24 is connected to an upper portion 26 of the frame member. A belt drum 22 is fixed to the turret 16, for rotation therewith, and disposed exterior to the carrier 20. A belt 28 links the motor with a belt drum 22. A pair of belt idlers 27 are also rotatably linked to the upper portion 26 of the frame member, the belt idlers 27 being configured to provide adjustable tensioning of the belt 28.

Each frame member includes a pair of rollers 64 disposed on a lower portion thereof. The rollers 64 of each frame member are configured to cooperate with a pair of ways 62, 62' (both shown with reference to FIG. 2), that are fixed to a top surface of the machine base 60, for supporting the carrier 20 as it translates therealong. An actuator 66 connects the carrier 20 to the first stationary platen 12 and to the second stationary platen for sequential movements of the carrier 20 therebetween (i.e. along a longitudinal axis 'x' as shown in FIG. 1).

The non-limiting embodiment of the injection molding clamp 10 also includes a first clamping structure 30 that selectively links, in use, the carrier 20 with the first stationary platen 12. The first clamping structure 30 includes a first set of tie bars 32 that are fixed to a first side of the carrier 20. Each first tie bar of the first set of tie bars 32 includes a connector 34 formed at a free end thereof. The first clamping structure 30 also includes a first set of shutters 36 and a first set of clamping actuators 38 that are connected to the first stationary platen 12. The connector 34 of each first tie bar 32 is selectively lockable to a respective clamping actuator of the first set of clamping actuators 38 by a respective shutter of the first set of shutters 36.

The non-limiting embodiment of the injection molding clamp 10 also includes a second clamping structure 40 that selectively links, in use, the carrier 20 with the second stationary platen 14. The second clamping structure 40 includes a second set of tie bars 42 that are fixed to a second side of the carrier 20. Each second tie bar of the second set of tie bars 42 includes a connector 44 formed at a free end thereof. The second clamping structure 40 also includes a second set of shutters 46 and a second set of clamping actuators 48 that are connected to the second stationary platen 14. The connector 44 of each second tie bar is selectively lockable to a respective clamping actuator of the second set of clamping actuators 48 by a respective shutter of the second set of shutters 46.

With reference to FIG. 1, and for sake of configuring the injection molding system 8 to perform a non-limiting embodiment of the injection molding process, a description of which follows, the first stationary mold half 52 has been configured to define a plurality of first mold cavities 54 of a first size and a first shape, the second stationary mold half 56 has been configured to define a plurality of second mold cavities 58 of a second size and second shape. In this non-limiting embodiment the first shape and the second shape are substantially the same but for the second size being larger than the first size. In addition, the first interchangeable mold half 50A and the second interchangeable mold half 50B have been configured to define a plurality of first mold cores 51 and a plurality of second mold cores 53, respectively, the first mold cores 51 and the second mold cores 53 having substantially the same size and shape. By so doing, in a first molding cycle, a first molding cavity may be defined between the first mold cores 51 and the first mold cavities 54 for forming a primitive molded article that is later over-molded to form a finished molded article 100 in a second molding cavity that is defined between the second mold cavities 58 and the primitive molded articles that are left arranged on the first mold cores 51 after the interchange of the first interchangeable mold half 50A with the second interchangeable mold half 50B. Likewise, in a second molding cycle, a third molding cavity may be defined between the second mold cores 53 and the first mold cavities 54 for forming another primitive molded article that is later over- molded to form a finished molded article in a fourth molding cavity that is defined between the second mold cavities 58 and the another primitive molded articles that are left arranged on the second mold cores 53 after the interchange of the second interchangeable mold half 50B with the first interchangeable mold half 50A.

Various non-limiting alternative embodiments of the injection molding clamp are possible including the following examples:

In an alternative non-limiting embodiment, not shown, there may be multiple injection units (not shown) that are associated with the first stationary mold half 52. The foregoing may be used, for example, for a sequential or a simultaneous molding of different varieties of primitive molded articles, or, for example, a single variety of a primitive molded article having a layered construction (i.e. layers of different molding materials).

Likewise, in another alternative non-limiting embodiment, not shown, there may be multiple injection units (not shown) that are associated with the second stationary mold half 56. The foregoing may be used, for example, for a sequential or a simultaneous molding of different varieties of finished molded articles, or, for example, a single variety of a finished molded article having a layered construction (i.e. layers of different molding materials).

In an alternative embodiment of the injection molding clamp, not shown, the machine base 60 may be provided by multiple structures (not shown). As an example, the first stationary platen 12 may be fixed to a first machine base (not shown), the second stationary platen 14 may be fixed to a second machine base (not shown), and the carrier 20 may be slidably mounted to yet a third machine base (not shown). In the foregoing non-limiting embodiment, the first, second, and third machine bases may be connected together (e.g. welded, fastened, etc.). Further, the first injection unit 102 may be slidably arranged, for example, on yet another machine base or slidably arranged on the first machine base. Likewise, the second injection unit 104 may be slidably arranged on yet a further machine base or be slidably arranged on the second machine base.

Whereas the first injection unit 102 and the second injection unit 104, shown in any of FIG(s). 3A- 3G, are arranged in line with the machine clamp 10, in an alternative non-limiting embodiment, not shown, they may be differently configured. For example, one or both of the first and/or second injection unit 102, 104 may be arranged in any orientation with respect to the machine clamp 10.

Alternative structures for rotation of the turret 16 are possible, including, for example, a motor (not shown) with its rotor (not shown) directly coupled to the turret 16.

In an alternative non-limiting embodiment of the molding clamp 10, not shown, the turret 16 may be configured to receive any practical number of interchangeable mold halves, including, for example, as few as one, or in another example, four.

In an alternative non-limiting embodiment of the injection molding system (not shown) the mold cores may be arranged on the stationary mold halves and the mold cavities may be arranged on the interchangeable mold halves. The foregoing alternative arrangement may also include a similar or reversed size and shape relationship between the mold cores and molding cavities of the respective mold halves, as described previously, or any alternative thereto. With reference to FIG. 2, the non-limiting embodiment of the injection molding system 8 also includes a non-limiting embodiment of a post-mold device 90. The non-limiting embodiment of the post-mold device 90 includes a molded article carrier 95 that is selectively arrangeable for retrieving a finished molded article 100 from the second molding station 'II' as will be described hereinafter. In the non-limiting embodiment, the finished molded article 100 is a preform of the type for blow molding into a bottle. That is, the molded article carrier 95 is arrangeable between a receiving position that is within the second molding station 'II' for receiving the finished molded article 100 and an auxiliary position that is substantially outside the second molding station 'II'.

More particularly, the post-mold device 90 includes a base 72 on which a linear guide 92 is connected. A tool mount 94 is slidably connected to the linear guide 92 for movement therealong (i.e. along a lateral axis 'z' as shown in FIG. 2) by a carrier actuator (not shown). The molded article carrier 95 is releaseably connectable to the tool mount 94. A control structure 70 is associated with the post-mold device 90 for controlling, amongst other things, the carrier actuator, and hence the position of the molded article carrier 95.

The molded article carrier 95 includes a base plate 96 on which are arranged multiple stages of molded article receptacles 98. Each molded article receptacle 98 of the multiple stages of molded article receptacles 98 is configured to receive an outer portion of the finished molded article 100. In the non-limiting embodiment, and without being so restricted, the molded article carrier 95 includes three stages of molded article receptacles arranged on the base plate 96. That is, the molded article carrier 95 has three times the storage capacity for finished molded articles 100 as are produced during each molding cycle. In further non-limiting embodiments (not shown) the molded article carrier 95 could have as few as a single stage or any number of stages of the molded article receptacles 98 that may be feasibly fit on the base plate 96.

The non-limiting embodiment of the post-mold device 90 further includes a first structure that is configured to perform a post-mold operation on the finished molded article 100. In the non- limiting embodiment the first structure is associated with each molded article receptacle 98 in the form of a coolant channel for a cooling of the molded article receptacle 98, and hence, a cooling of the outer portion of the finished molded article 100 that is received therein. In further non-limiting embodiments (not shown) other forms of the first structure may be configured to perform, for example, one of more of ejecting of the finished molded article 100 from the molded article carrier 95, thermal conditioning (i.e. controlled heating or cooling) of the finished molded article 100, or a primitive thereof (previously produced at the first molding station 'I'), and/or dimensionally adjusting one or both of a shape and size of the finished molded article 100. The dimensional adjustment of a molded article may be accomplished, for example, in accordance with the teachings of commonly assigned United States patent 6,737,007 to Neter et al., published on May 18^th, 2004, wherein a fluid flow structure is provided within the molded article receptacle for evacuating air between the molded article and an inner surface of a porous member of the molded article receptacle to cause a molded plastic part therein to expand into contact with at least a portion of the inner surface of the porous member.

In an alternative non-limiting embodiment of the injection molding system, not shown, the post- mold device 90 and/or an auxiliary device (not shown), may be configured for performing an operation on one or more of the first stationary mold half 52, the second stationary mold half 58, the first interchangeable mold half 50A and/or the second interchangeable mold half 50B. The operation may include, for example, associating an insert (e.g. label, metal insert, etc.) with one or more of the first stationary mold half 52, the second stationary mold half 58, the first interchangeable mold half 50A and/or the second interchangeable mold half 50B. The insert could also be, for example, a liner that is inserted into the molding cavity (defined, in part, by the first stationary mold half 52, the second stationary mold half 58, the first interchangeable mold half 50A and/or the second interchangeable mold half 50B), the liner then being over-molded at one or both of the first and second molding stations 'I', 'II'. The liner, for example, may be of the type for imparting an oxygen barrier to the finished molded article 100 (e.g. preform, multi-material closure, etc.).

As shown with reference to FIG. 2, the non-limiting embodiment of the injection molding system 8 also includes a non-limiting embodiment of an auxiliary post-mold device 76 that is configured to perform another post- mold operation on the finished molded article 100 that is received in the molded article carrier 95. The non-limiting embodiment of the auxiliary post-mold device 76 includes an auxiliary tool 81. The auxiliary post-mold device 76 is configured to selectively arrange, in use, the auxiliary tool 81 between a remote position and a process position for performing several post mold operations. In an alternative, there may be any number of process positions such as a first process position for performing a first one of the post-mold operation, and a second process position for performing a second one of the post-mold operation. Accordingly, the auxiliary post-mold device 76 includes a first process actuator 80 for extending and retracting the auxiliary tool 81 with respect to a frame 78 (i.e. along an auxiliary axis 'y' as shown in FIG. 1). The frame 78 is itself rotatably connected to the base 72 of the post-mold device 90 by a rotary drive 74 whereby the frame 78, and with it the auxiliary tool 81, may rotated for performing yet another post-mold operation (e.g. ejection of finished molded articles 100 previously extracted from the post- mold device 90 onto a conveyor or into another post-mold device).

In the non-limiting embodiment, the auxiliary tool 81 includes a base plate 82 on which there are arranged several interlaced stages of cooling structures and a stage of extracting structures. Each cooling structure 84 of the stages of cooling structures are configured to cool (i.e. first post-mold operation), in use, an inner portion of the finished molded article 100 when the auxiliary tool 81 is arranged in the first process position. Each extracting structure 86 of the stage of extracting structures are configured to extract (i.e. second post-mold operation), in use, finished molded articles from the molded article carrier 95 when the auxiliary tool 81 is arranged in the second process position. In the non-limiting embodiment there are two stages of cooling structures and a single stage of extracting structures. Accordingly, the finished molded articles lOOwithin two of the stages of molded article receptacles 98, on the molded article carrier 95, may be cooled by the two stages of cooling structures while the remaining stage of molded articles 100 in the remaining stage of molded article receptacles 98 are being extracted by the stage of extracting structures.

Alternative post-mold operations may be performed by the auxiliary post-mold device 76 including one or more of extracting of the finished molded article 100 from the molded article carrier 95, thermal conditioning (i.e. controlled heating or cooling) of the finished molded article 100, or the primitive thereof, and/or dimensionally adjusting one or both of a shape and size of the finished molded article 100, or a primitive thereof. The dimensional adjustment of the finished molded article may be accomplished, for example, in accordance with the teachings of commonly assigned United States patent 6,951,452 to Unterlander et al., published on October 4, 2005, wherein the auxiliary tool 81 may be provided with a pressurizing structure for dispensing a pressurized fluid to cause the partially cooled molded article to expand and touch the inner wall of the molded article receptacle thereby ensuring sustained contact with the wall to permit efficient thermal transfer of heat from the molded article to the cooled receptacle wall by conduction.

In yet a further non-limiting embodiment of the injection molding system, not shown, one or both of the post-mold device 90 and the auxiliary post-mold device 76 may be omitted or differently arranged. For example, in an alternative non-limiting embodiment, not shown, the post-mold device 90 may be configured for moving the molded article carrier along any spatial axis (e.g. vertical, horizontal, angular, etc.) for effecting a transfer of one or both of the primitive molded article and/or the finished molded article 100 from one or both of the first molding station 'I' and the second molding station 'II'. Non-Limiting Embodiments of an injection molding process

A non-limiting embodiment of an injection molding process executable with the foregoing non- limiting embodiment of the injection molding system 8 will now be described with reference to the various configurations of the schematically depicted injection molding system in FIG(s). 3A, 3B, 3C, 3D, 3E, 3F and 3G.

The injection molding process begins, as shown with reference to FIG. 3 A, with arranging 202 the first interchangeable mold half 50A in a mold closed relation with respect to the first stationary mold half 52, at the first molding station 'I', to define the first molding cavity therebetween and thereafter molding 204 a primitive molded article in the first molding cavity from a first molding material. Next, interchanging 206 the first interchangeable mold half 50A with the second interchangeable mold half 50B, with the rotation, in the indicated direction 'c', and movement, in the indicated direction of the longitudinal axis 'x', of the turret 16 as shown in FIG. 3B, with the primitive molded article remaining with the first interchangeable mold half 50A. Next, arranging 208 the first interchangeable mold half 50A in a mold closed relation with respect to the second stationary mold half 56, at the second molding station 'II', as shown with reference to FIG. 3C, to define the second molding cavity therebetween with the primitive molded article arranged therein. Next, molding 210 the finished molded article 100 in the second molding cavity from a second molding material and the primitive molded article.

The injection molding process may further include arranging the second interchangeable mold half 50B in a mold closed relation with respect to the first stationary mold half 52, at the first molding station 'I' as shown in FIG. 3E, with a movement of the turret 16 in the indicated direction of the longitudinal axis 'x' as shown in FIG 3D, to define the third molding cavity therebetween and thereafter molding another of the primitive molded article in the third molding cavity from the first molding material. Substantially contemporaneously to the molding of the another of the primitive molded article (although the injection molding process is not so limited) arranging the molded article carrier 95 from a position that is substantially outside the second molding station 'II' to a first receiving position within the second molding station 'II', with movement thereof along the lateral axis 'z' as shown with reference to FIG. 3E, and thereafter transferring the finished molded article 100 from the first interchangeable mold half 50A to the molded article carrier 95. Next, and also substantially contemporaneously to the molding of the another of the primitive molded article (although the injection molding process is not so limited), arranging the molded article carrier 95 in a first auxiliary position that is substantially outside the second molding station 'II', as shown in FIG. 3G, with a movement thereof along the lateral axis 'z' as shown with reference to FIG. 3E. The injection molding process may also include interchanging the second interchangeable mold half 5OB with the first interchangeable mold half 50A, with the rotation, in the indicated direction 'c', and movement, in the indicated direction of the longitudinal axis 'x', of the turret 16 as shown in FIG. 3F, the another of the primitive molded article remaining with the second interchangeable mold half 50B. Next, arranging the second interchangeable mold half 50B in a mold closed relation with respect to the second stationary mold half 56, at the second molding station 'II', to define a fourth molding cavity therebetween with the another of the primitive molded article arranged therein, as shown with reference to FIG. 3G, and thereafter molding another of the finished molded article 100 in the fourth molding cavity from the second molding material and the another of the primitive molded article. The overall molding cycle then essentially begins again with arranging the first interchangeable mold half 50A in the mold closed relation with respect to the first stationary mold half 52, at the first molding station 'I', as shown with reference to FIG. 3A, to define the first molding cavity therebetween and thereafter molding a further of the primitive molded article in the first molding cavity from a first molding material. In addition, and substantially contemporaneously to the molding of the further of the primitive molded article (although the injection molding process is not so limited), arranging the molded article carrier 95 from the position (in this example the auxiliary position) that is substantially outside the second molding station 'II' to a second receiving position within the second molding station 'II', with a movement thereof along the lateral axis 'z' as shown in FIG. 3A, and thereafter transferring the another of the another of the finished molded article 100 from the second interchangeable mold half 50B to the molded article carrier 95. Next, and also substantially contemporaneously to the molding of the further of the primitive molded article (although the injection molding process is not so limited), arranging the molded article carrier 95 in a second auxiliary position, as shown in FIG. 3B, that is outside the second molding station 'II', with a movement thereof in along the lateral axis 'z' as shown with reference to FIG. 3A. The second auxiliary position may be offset from the first auxiliary position by an amount required to align the extracting structure 86 of the auxiliary tool 81 (i.e. a post- mold operation), into the stage of finished molded articles 100 that are ready for extraction from the molded article carrier 95 while the other stages of finished molded articles are cooled by the cooling structures 84 of the auxiliary tool 81 (i.e. another post-mold operation).

As mentioned hereinbefore, the non-limiting embodiment of the injection molding process may also include performing a post-mold operation on the finished molded article 100 that is received in the molded article carrier 95. The performing the post- mold operation on the finished molded article 100 may include one or more of removing of the finished molded article 100 from the molded article carrier 95, thermal conditioning of the finished molded article 100, dimensionally adjusting one or both of a shape and size of the finished molded article 100 (as discussed previously). The performing the post-mold operation on the finished molded article 100 is provided by one or both of the first structure belonging to the molded article carrier 95, or the auxiliary post-mold device 76.

Accordingly, the non-limiting embodiment of the injection molding process may further include cooling the outer portion of the finished molded article 100 with the first structure that is associated with the molded article receptacles 98. In addition, and with the molded article carrier 95 being in the auxiliary position further arranging the auxiliary post-mold device 76 in a first process position, as shown in FIG. 3C, with a movement thereof along the auxiliary axis 'y' as shown in FIG. 3B, wherein a portion of the cooling structure 84 is disposed within the finished molded article 100 and thereafter cooling an inner portion of the finished molded article 100 with the cooling structure. Next, arranging the auxiliary post-mold device 76 in a remote position, as shown in FIG. 3E, with a movement of the auxiliary post-mold device 76 in the indicated direction of axis 'y' shown in FIG. 3D. Likewise, with the molded article carrier 95 being in any one of the auxiliary positions arranging the auxiliary post-mold device 76 in a second process position wherein the extracting structure 86 are disposed adjacent the finished molded article 100 received in the molded article carrier 95 and thereafter extracting (not shown) the finished molded article 100 from the molded article carrier 95 with the extraction structure 86 of the auxiliary post-mold device 76 with the arranging the auxiliary post-mold device 76 in the remote position. At this point the auxiliary tool 81 may be rotated (not shown) by the rotary drive 74 for a subsequent ejection of at least a subset of finished the molded articles onto a conveyor (not shown) or into some other post-mold device (not shown).

A technical effect of the non-limiting embodiments of the injection molding system and the injection molding process may include one or more of productivity benefits and capital impacts. Productivity benefits may include optimized non-process times (i.e. no need to interrupt molding for finished molded article removal as this is done contemporaneously to the molding of the primitive molded article), fast transition between the molding of the primitive molded article to the molding of the finished molded article (which may be helpful to promote interface adhesion at an interface between the molding materials), minimizes moving masses (i.e. no need to move the injection units). The capital impacts of such a system may also include a reduced hydraulic demand as the injection molding process is sequential and hence does not require both injection units inject simultaneously (although plasticization therein may overlap). The description of the exemplary embodiments provides examples of the present invention, and these examples do not limit the scope of the present invention. It is understood that the scope of the present invention is limited by the claims. The concepts described above may be adapted for specific conditions and/or functions, and may be further extended to a variety of other applications that are within the scope of the present invention. Having thus described the exemplary embodiments, it will be apparent that modifications and enhancements are possible without departing from the concepts as described. Therefore, what is to be protected by way of letters patent are limited only by the scope of the following claims:

Claims

WHAT IS CLAIMED IS:

1. An injection molding process (200) that is executable in an injection molding system (8) that includes a first interchangeable mold half (50A) and a second interchangeable mold half (50B) arranged on a turret (16), the turret (16) being rotatable and translatable for interchanging the first interchangeable mold half (50A) and the second interchangeable mold half (50B) between a first stationary mold half (52), at a first molding station ('V), and a second stationary mold half (56), at a second molding station ('II'), the first stationary mold half (52) and the second stationary mold half (56) being arranged on a first stationary platen (12) and a second stationary platen (14), respectively, the injection molding process comprising: arranging (202) the first interchangeable mold half (50A) in a mold closed relation with respect to the first stationary mold half (52), at the first molding station ('I'), to define a first molding cavity therebetween; molding (204) a primitive molded article in the first molding cavity from a first molding material; interchanging (206) the first interchangeable mold half (50A) with the second interchangeable mold half (50B), the primitive molded article remaining with the first interchangeable mold half (50A); arranging (208) the first interchangeable mold half (50A) in a mold closed relation with respect to the second stationary mold half (56), at the second molding station ('II'), to define a second molding cavity therebetween with the primitive molded article arranged therein; molding (210) a finished molded article (100) in the second molding cavity from a second molding material and the primitive molded article.

2. The injection molding process according to claim 1, further comprising: arranging the second interchangeable mold half (50B) in a mold closed relation with respect to the first stationary mold half (52), at the first molding station ('I'), to define a third molding cavity therebetween; molding another of the primitive molded article in the third molding cavity from the first molding material; arranging a molded article carrier (95) from a position that is substantially outside the second molding station ('II') to a first receiving position within the second molding station ('II'); transferring the finished molded article (100) from the first interchangeable mold half (50A) to the molded article carrier (95); arranging the molded article carrier (95) in a first auxiliary position that is substantially outside the second molding station ('II').

3. The injection molding process according to claim 2, further comprising: interchanging the second interchangeable mold half (50B) with the first interchangeable mold half (50A), the another of the primitive molded article remaining with the second interchangeable mold half (50B); arranging the second interchangeable mold half (50B) in a mold closed relation with respect to the second stationary mold half (56), at the second molding station ('II'), to define a fourth molding cavity therebetween with the another of the primitive molded article arranged therein; molding another of the finished molded article (100) in the fourth molding cavity from the second molding material and the another of the primitive molded article; arranging the first interchangeable mold half (50A) in the mold closed relation with respect to the first stationary mold half (52), at the first molding station ('I'), to define the first molding cavity therebetween; molding a further of the primitive molded article in the first molding cavity from the first molding material; arranging the molded article carrier (95) from the position that is substantially outside the second molding station ('II') to a second receiving position within the second molding station ('II'); transferring the another of the another of the finished molded article (100) from the second interchangeable mold half (50B) to the molded article carrier (95); arranging the molded article carrier (95) in a second auxiliary position that is outside the second molding station ('II');

4. The injection molding process according to claim 3, wherein: the arranging of the molded article carrier (95) in the first receiving position, the transferring of the finished molded article (100), and the arranging of the molded article carrier (95) in the first auxiliary position are performed substantially contemporaneously to the molding of the another of the primitive molded article; and the arranging of the molded article carrier (95) in the second receiving position, the transferring of the another of the finished molded article (100), and the arranging of the molded article carrier (95) in the second auxiliary position are performed substantially contemporaneously to the molding of the further of the primitive molded article.

5. The injection molding process according to claim 3, further comprising: performing a post-mold operation on the finished molded article (100) that is received in the molded article carrier (95), including one or more of: removing of the finished molded article (100) from the molded article carrier (95); thermal conditioning of the finished molded article (100); dimensionally adjusting one or both of a shape and size of one of the finished molded article (100) and the primitive molded article.

6. The injection molding process according to claim 5, wherein: the performing the post-mold operation on the finished molded article (100) is provided by one or both of: a first structure belonging to the molded article carrier (95); an auxiliary post-mold device (76).

7. The injection molding process according to claim 6, wherein: the molded article carrier (95) includes a molded article receptacle (98) that is configured for receiving an outer portion of the finished molded article (100), the first structure being associated with the molded article receptacle (98); the auxiliary post-mold device (76) includes a cooling structure (84); the performing the post-mold operation on the finished molded article (100) includes: cooling the outer portion of the finished molded article (100) with the first structure; with the molded article carrier (95) being in one of the first auxiliary position or the second auxiliary position further arranging the auxiliary post-mold device (76) in a first process position wherein a portion of the cooling structure (84) is disposed within the finished molded article (100); cooling an inner portion of the finished molded article (100) with the cooling structure arranging the auxiliary post-mold device (76) in a remote position.

8. The injection molding process according to claim 6, wherein: the auxiliary post-mold device (76) includes an extracting structure (86) that is configured to extract, in use, the finished molded article (100) from the molded article carrier (95); and with the molded article carrier (95) being in one of the first auxiliary position or the second auxiliary position arranging the auxiliary post-mold device (76) in a second process position wherein the extracting structure (86) is disposed adjacent the finished molded article (100) received in the molded article carrier (95); extracting the finished molded article (100) from the molded article carrier (95) with the extracting structure (86) of the auxiliary post-mold device (76); arranging the auxiliary post-mold device (76) in a remote position.

9. The injection molding process according to claim 1, wherein: the injection molding system (8) further includes an auxiliary device, the injection molding process further comprising performing an operation on one or more of the first stationary mold half 52, the second stationary mold half 58, the first interchangeable mold half 5OA and the second interchangeable mold half 50B.

10. An injection molding system (8), comprising: an injection molding clamp (10) that includes: a machine base (60); a first stationary platen (12) fixed to the machine base (60), the first stationary platen (12) being configured to receive, in use, a first stationary mold half (52); a second stationary platen (14) fixed to the machine base (60), the second stationary platen (14) being configured to receive, in use, a second stationary mold half (56); a carrier (20) translatably linked to the machine base (60); a turret (16) that is configured to receive, in use, a first interchangeable mold half (50A) on a first face thereof, and a second interchangeable mold half (50B) on a second face thereof; the turret (16) being rotatably linked to the carrier (20) to selectively interchange, in use, the first interchangeable mold half (50A) and the second interchangeable mold half (50B) between the first stationary mold half (52), at a first molding station ('I'), and the second stationary mold half (56), at a second molding station ('II'), respectively; a first clamping structure (30) that selectively links, in use, the carrier (20) with the first stationary platen (12); a second clamping structure (40) that selectively links, in use, the carrier (20) with the second stationary platen (14).

11. The injection molding system (8) according to claim 10, further comprising: a first injection unit (102) that is fluidly connectable, in use, with the first stationary mold half (52); a second injection unit (104) that is fluidly connectable, in use, with the second stationary mold half (56).

12. The injection molding system (8) according to claim 10, further comprising: a post-mold device (90) that includes a molded article carrier (95), the post-mold device (90) being configured to selectively arrange, in use, the molded article carrier (95) between a receiving position that is within the second molding station ('II') for receiving a finished molded article (100) and an auxiliary position that is substantially outside the second molding station

('II').

13. The injection molding system (8) according to claim 12, wherein: the molded article carrier (95) includes a first structure that is configured to perform a post- mold operation on the finished molded article (100), and wherein the post-mold operation includes one or more of: ejecting of the finished molded article (100) from the molded article carrier (95); thermal conditioning of the finished molded article (100); and dimensionally adjusting one or both of a shape and size of one of the finished molded article (100) or a primitive molded article.

14. The injection molding system (8) according to claim 12, further comprising: an auxiliary post-mold device (76) that is configured to perform a post-mold operation on the finished molded article (100) that is received in the molded article carrier (95), the post- mold operation includes one or more of: extracting of the finished molded article (100) from the molded article carrier (95); thermal conditioning of the finished molded article (100); dimensionally adjusting one or both of a shape and size of the finished molded article (100).

15. The injection molding system (8) according to claim 10, further comprising: an auxiliary device for performing an operation on one or more of the first stationary mold half (52), the second stationary mold half (58), the first interchangeable mold half (50A) and the second interchangeable mold half (50B).