WO2010096892A1 - Mold insert stack - Google Patents

Mold insert stack Download PDF

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Publication number
WO2010096892A1
WO2010096892A1 PCT/CA2009/001740 CA2009001740W WO2010096892A1 WO 2010096892 A1 WO2010096892 A1 WO 2010096892A1 CA 2009001740 W CA2009001740 W CA 2009001740W WO 2010096892 A1 WO2010096892 A1 WO 2010096892A1
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WO
WIPO (PCT)
Prior art keywords
core
coupler
interface
structured
molding
Prior art date
Application number
PCT/CA2009/001740
Other languages
French (fr)
Inventor
Arnold Mai
Rainer Kintzinger
Original Assignee
Husky Injection Molding Systems Ltd.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Husky Injection Molding Systems Ltd. filed Critical Husky Injection Molding Systems Ltd.
Publication of WO2010096892A1 publication Critical patent/WO2010096892A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/2673—Moulds with exchangeable mould parts, e.g. cassette moulds
    • B29C45/2675—Mounting of exchangeable mould inserts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/25—Solid
    • B29K2105/253—Preform

Definitions

  • the present invention generally relates to, but is not limited to, injection molding, and more specifically the present invention relates to, but is not limited to, a mold insert stack.
  • Molding is a process by virtue of which a molded article can be formed from molding material by using a molding system.
  • Various molded articles can be formed by using the molding process, such as an injection molding process.
  • a molded article that can be formed, for example, from polyethylene terephthalate (PET) material is a preform that is capable of being subsequently blown into a beverage container, such as, a bottle and the like.
  • a typical molding system includes an injection unit, a clamp assembly and an injection mold.
  • the injection unit can be, for example, of a reciprocating screw type or of a two-stage type.
  • the clamp assembly includes, inter alia, a frame, a movable platen, a fixed platen and an actuator for moving the movable platen and to apply tonnage to the injection mold arranged between the platens.
  • the injection mold includes, inter alia, a cold half and a hot half with one or more mold insert stacks disposed therein. Each mold insert stack typically includes a core insert and a cavity insert that cooperate, in use, to define a molding cavity.
  • each mold insert stack can be associated with a number of additional components such as, for example, a split insert (sometimes referred to as neck rings), a gate insert, a retainer, or a core support.
  • the hot half is usually associated with one or more cavities (and, hence, also sometimes referred to by those of skill in the art as a "cavity half"), while the cold half is usually associated with one or more cores (and, hence, also sometimes referred to by those of skill in the art as a "core half).
  • the hot half can also be associated with a melt distribution system (also referred to sometimes by those of skill in the art as a "hot runner") for melt distribution.
  • the injection mold can be associated with a number of additional components, such as slides for positioning of the split insert, ejector structures, wear pads, etc.
  • injection molding of PET material involves heating the PET material (ex.
  • PET pellets, PEN powder, PLA, etc. to a homogeneous molten state and injecting, under pressure, the so-melted PET material into the one or more molding cavities to form preforms.
  • the cavity plate and the core plate are urged together and are held together by clamp force, the clamp force being sufficient enough to keep the cavity and the core pieces together against the pressure of the injected PET material.
  • the molding cavity has a shape that substantially corresponds to a final cold-state shape of the molded article to be molded.
  • the so-injected PET material is then cooled to a temperature sufficient to enable ejection of the so-formed molded article from the mold.
  • the molded article When cooled, the molded article shrinks inside of the molding cavity and, as such, when the cavity and core plates are urged apart, the molded article tends to remain associated with the core. Accordingly, by urging the core plate away from the cavity plate, the molded article can be demolded, i.e. ejected from the core piece.
  • Ejection structures are known to assist in removing the molded articles from the core halves. Examples of the ejection structures include stripper plates, ejector pins, etc.
  • a molded article that can be formed is a preform of the type that is capable of being subsequently blown into a beverage container, such as, a bottle and the like.
  • the following references disclose one or more means for providing a quick-coupling between a member of a mold insert stack and a mold base of an injection mold.
  • the sectional die includes a reciprocal ejector plate, there being at least one reciprocal knock-out bar on the molding machine.
  • a reciprocal lifter plate within the bottom anchor plate is connected to the ejector plate and removably interlocked with the knock-out bar.
  • United States patent 4,684, 101 to Wagner et al. published on August 4, 1987, teaches an injection molding mold including an insert in-part defining the mold cavity and readily accessible for replacement from the side of the mold.
  • the insert has a molding head at the mold cavity, a shank extending into a socket in the mold, a mortice in the shank for receiving a retainer to hold the insert in place and, preferably, a camming surface on the end of the shank for dislodging the insert from the mold.
  • the retainer will preferably be a sliding pin having a bifurcated keeper portion providing two tapered prongs engaging opposed slots on the insert's shank for holding the insert in place during molding and subsequently for camming the insert loose from the socket at replacement time.
  • United States patent 4,91 1 ,632 to Mansfield, published on March 27, 1990, teaches a structure for releasably securing a plurality of mold inserts to a mold plate attached to a power press machine is disclosed.
  • the mold plate has a plurality of apertures formed therethrough. Within each aperture, a plurality of inwardly extending spaced apart protrusions are formed.
  • the mold inserts include end portions having a plurality of tabs formed thereon.
  • a mold insert is inserted within an aperture by aligning the tabs with the spaces between the protrusions and moving the mold insert axially therein. Then, by rotating the mold insert relative to the mold plate, the tabs are moved over the protrusions. As a result, the mold insert is retained within the aperture.
  • Locking bars prevent rotation of the mold inserts at undesired times to prevent them from being removed from the mold plate.
  • a locking mechanism may be used to secure the locking bars, and therefore the mold inserts, in their locked positions during use
  • United States patent 5,750, 161 to Schock et al., published on May 12, 1998, teaches a mold core assembly for removable installation in a molding machine includes a first lock element attached to a core and a second lock element movably attached to a core retainer.
  • the second lock element is movable between a locked position fitted in locking connection with the first lock element and an unlocked position separated from the first lock element.
  • a slip ring surrounds the first lock element of the core, engaging and holding the second lock element in its locked position.
  • a spring is connected between the core retainer and the slip ring, with the spring biased to oppose movement of the slip ring away from its locked position so that the core is normally held in its locked position in the core retainer.
  • a molding apparatus that includes a member of a mold insert stack.
  • the member defines a molding surface that provides a portion of a molding cavity.
  • the member also defines a first bayonet having a camming surface at a free end thereof for sake of cooperating, in use, with a socket and a spring-arm to provide a quick-coupling therebetween.
  • a technical effect of the quick-coupling is that it provides for quick and easy exchange of the member of the mold insert stack particularly with respect to the mold insert stack having been arranged in an injection mold.
  • Figure 1 depicts a side view of a mold insert stack for use in an injection mold, the mold insert stack being structured according to a non-limiting embodiment of the present invention
  • Figure 2 depicts a section view through the mold insert stack of Figure 1 ;
  • Figure 3 depicts another section view through the mold insert stack of Figure 1 ;
  • Figure 4 depicts an exploded perspective view of a core member and a coupler member belonging to a core assembly of the mold insert stack of Figure 1 ;
  • Figure 5 depicts a perspective view of a support member belonging to the core assembly of the mold insert stack of Figure 1 ;
  • Figure 6 depicts a perspective view of the core assembly and the support member of the molding stack of Figure 1 , wherein the core member is arranged in, but uncoupled from, the support member;
  • Figure 7 depicts a perspective view of the core assembly and the support member of the molding stack of Figure 1 , wherein the core member is in the midst of being coupled with the support member;
  • Figure 8 depicts a perspective view of the core assembly of the molding stack of Figure 1 , wherein the core member is coupled with the support member;
  • Figure 9 depicts a perspective view of the core assembly of the molding stack of Figure 1 , wherein the core member is in the midst of being uncoupled from the support member.
  • a mold insert stack 100 is shown that has been configured in accordance with a non-limiting embodiment of the present invention. Consistent with common practice in the art of injection molding, the mold insert stack 100 is structured for installation, in use, in a mold base (not shown) of an injection mold (not shown).
  • the mold insert stack 100 includes members that are structured to cooperate, in use, when arranged in a mold closed configuration, to define a molding cavity 101 , reference Figures 2 or 3, within which a molded article (not shown), such as a preform of the type for blow molding into a bottle (not shown), may be formed upon injection of molding material therein.
  • the members (including a member, another member, and other members) of the mold insert stack 100 include a cavity insert 1 10, a gate insert 120, a split insert 140, and a core assembly 130 each of which define a portion of the molding cavity 101.
  • a cavity insert 1 10 a cavity insert 1 10
  • a gate insert 120 a gate insert 120
  • a split insert 140 a core assembly 130
  • the non-limiting embodiment of the cavity insert 1 10 is shown to have a generally tubular shape with a cavity plate connecting flange 1 1 1 outwardly depending from a bottom end thereof through which fasteners (not shown) may be arranged for connecting the cavity insert 1 10 to a cavity plate (not shown) of the mold base (not shown).
  • the cavity insert 1 10 defines, amongst other things, a cavity molding surface 1 15, a cavity- split interface 1 13, a cavity-gate interface 1 16, a cavity-plate interface 1 17, and a cavity coolant groove 1 19.
  • the cavity molding surface 1 15 defines an outer portion of the molding cavity 101.
  • the cavity-split interface 1 13 can have a structure, as shown, that is a conical recess formed through a bottom end of the cavity insert 1 10.
  • the cavity-split interface 1 13 cooperates, in use, with a split-cavity interface 143 that is defined on the split insert 140 to align the cavity insert 1 10 with the split insert 140 with an arranging of the injection mold into the mold closed configuration.
  • the cavity-gate interface 1 16 can have a structure, as shown, that is a face on an upper end of the cavity insert 1 10.
  • the cavity-gate interface 1 16 mates, in use, with a gate- cavity interface 126 that is defined on the gate insert 120, as shown, when the cavity insert 1 10 and the gate insert 120 are installed in the cavity plate (not shown).
  • the cavity-plate interface 1 17 can have a structure, as shown, that is an outer cylindrical surface of the cavity insert 1 10.
  • the cavity-plate interface 1 17 mates, in use, with a plate-cavity interface (not shown) that is defined within the cavity plate (not shown).
  • the cavity coolant groove 1 19 can have a helical profile that is formed through the outer cylindrical surface of the cavity insert 1 10, shown with reference to Figure 1 , that cooperates, in use, with the cavity plate (not shown) to define a coolant channel for sake of circulating a coolant, in use, to cool the cavity insert 1 10.
  • the non-limiting embodiment of the gate insert 120 is shown to have a generally annular shape.
  • the gate insert 120 defines, amongst other things, a gate molding surface 125, the gate-cavity interface 126, a gate-plate interface 124, a nozzle interface 122, and a set of gate coolant passageways 129.
  • the gate molding surface 125 defines a domed-end portion of the molding cavity 101.
  • the gate-cavity interface 126 can have a structure, as shown, that is a face on a lower end of the gate insert 120.
  • the gate-plate interface 124 can have a structure, as shown, that is an outer cylindrical surface of the gate insert 120.
  • the gate-plate interface 124 mates, in use, with a plate-gate interface (not shown) that is defined within the cavity plate (not shown).
  • the nozzle interface 122 can have a structure, as shown, that is a contoured pocket through an upper portion of the gate insert 120.
  • the nozzle 122 mates, in use, with a nozzle (not shown) of a melt distribution apparatus for channeling molding material into the molding cavity 101.
  • the set of gate coolant passageways 129 may be formed, as shown, as a network of interconnected passageways within the gate insert 120 that form a coolant channel in cooperation with the cavity plate (not shown) for sake of circulating a coolant, in use, to cool the gate insert 120.
  • the non-limiting embodiment of the split insert 140 is shown to include of a first split insert member 140A and a second split insert member 140B each of which may have a complementary semi-annular shape with a slide connecting flange 141 and 142 depending from a middle thereof, respectively, through which fasteners (not shown) may be arranged for connecting the first split insert member 140A and the second split insert member 140B to respective slide members (not shown) of the mold base.
  • the construction and operation of the slide members is well known to those of ordinary skill in art and hence will not be reviewed herein. A description of several non-limiting embodiments thereof may also be referenced in USP 7,381 ,049.
  • the first split insert member 140A and the second split insert member 140B together define, amongst other things, a split molding surface 145, the split-cavity interface 143, a split-coupler interface 147, and a set of split insert coolant passageways 149.
  • the split molding surface 145 defines an encapsulated portion of the molding cavity 101.
  • the split-cavity interface 143 can have a structure, as shown, that is a conical protuberance formed around a top end of the split insert 140.
  • the split-coupler interface 147 can have a structure, as shown, that is a conical protuberance formed around a bottom end of the split insert 140.
  • the split-coupler interface 147 cooperates, in use, with a coupler-split interface 167 that is defined on a coupler member 160 of the core assembly 130 to align the split insert 140 with a core member 150 of the core assembly 130 with an arranging of the injection mold into the mold closed configuration.
  • the set of split insert coolant passageways 149 may be formed, as shown, as a network of interconnected passageways within each of the first split insert member 140A and the second split insert member 140B that form a coolant channel in cooperation with the respective slide member (not shown) of the injection mold (not shown) for sake of circulating a coolant, in use, to cool the split insert 140.
  • the non-limiting embodiment of the core assembly 130 is shown to include the core member 150 and the coupler member 160, as previously mentioned, as well as a support member 170.
  • the non-limiting embodiment of the core member 150 may have, as shown, a generally tubular shape with a closed upper end and a coupling flange 151 outwardly depending in a mid-region thereof.
  • the core member 150 defines, amongst other things, a core molding surface 155, a core-support interface 152, a core-coupler interface 153, and a core coolant chamber 159.
  • the core molding surface 155 may be provided, as shown, on the top end of the core member 150, the core molding surface 155 defines an inner portion of the molding cavity 101.
  • the core- coupler interface 153 may be structured, as shown, to include a conical outer surface and an upper surface of the coupling flange 151.
  • the core-coupler interface 153 mates, in use, with a coupler-core interface 161 that is defined on the coupler member 160, as shown, when the coupler member 160 is coupled to the core member 150, whereby the coupler member 160 and the core member 150 are aligned together.
  • a retainer 191 may be provided, such as a snap-ring, as shown with reference to Figures 2 and 3.
  • the retainer 191 is first arranged with an inner periphery thereof seated in a first groove 104 that is provided through the core-coupler interface 153 of the core member 150.
  • the coupler member 160 is slid over the core member 150 and in so doing the retainer 191 is compressed into the first groove 104 as a result of an interaction of an outer surface of the retainer 191 with the tapered surface of the coupler-core interface 161.
  • the retainer 191 is positioned adjacent to a second groove 105 that is provided through the coupler-core interface 161 on the coupler member 160, whereupon the retainer 191 is able to expand such that the inner periphery thereof is seated in the first groove 104 and wherein an outer periphery thereof is seated in the second groove 105, whereby the core member 150 and the coupler member 160 are fully coupled.
  • the retainer 191 may be compressed into the first groove 104 in the core member 150 by inserting a tool (not shown) through an access channel 164, as shown with reference to Figure 4, one or more of which may be formed through a side wall of the coupler member 160 to intersect with the second groove 105, after which the coupling member 160 may then be slid off of the core member 150.
  • a tool not shown
  • the core-support interface 152 can have a structure that is a bottom surface of the coupling flange 151.
  • the core-support interface 152 mates, in use, with a support-core interface 163 that may be defined on an upper surface of the support member 170 and in this way support the core member by channeling an axially applied force, such as a mold clamping force, therethrough and on into the mold base.
  • the core member 150 may also include a pair of smaller flanges on the outer surface thereof, including a first flange 154 that may be provided just beneath the coupling flange 151 , and a second flange 156 that may be provided, as shown, near the bottom end of the core member 150.
  • a gap 'G' may be provided, as shown, between an outer cylindrical surface of the first and second flanges 154, 156 and an adjacent inner surface of the support member 170, whereby the core member 150 may some freedom to move relative to the support member 170, as required, with an opening and/or closing of the injection mold.
  • the core member 150 is free to be aligned with the split insert 140 by cooperation of the coupler member 160 with both the core member 150 and the split insert 140. With any such movement there will be a sliding relative movement between the core-support interface 152 and the support-core interface 163.
  • the spigot interface 157 may be structured, as shown, to include the outer cylindrical surface of the core member 150 at the end thereof.
  • a spigot interface 157 that may be provided at the bottom end of the core member 150 may be structured, as shown, to mate, in use, with a plate-core interface (not shown) that is defined within the core plate (not shown) when the core member 150 is installed therein.
  • the core member 150 may also include a first bayonet 182A and a second bayonet 182B that project outwardly from the outer cylindrical surface of the core member 150, in an opposite direction from each other, adjacent to the spigot interface 157.
  • the first bayonet 182A and the second bayonet 182B each define a camming surface 183 at a free end thereof that is curved.
  • the first bayonet 182A and the second bayonet 182B cooperate, in use, with a socket 184 that may be defined, as shown, in the support member 170 to provide a quick-coupling between the core member 150 and the mold base of the injection mold.
  • the core coolant chamber 159 provides a space for defining a coolant channel in cooperation with a cooling tube 194 for sake of circulating a coolant, in use, to cool the core member 150.
  • the non-limiting embodiment of the coupler member 160 is shown to have an annular shape.
  • the coupler member 160 defines, amongst other things, a coupling molding surface 165, the coupler-split interface 167, and the coupler-core interface 161.
  • the coupling molding surface 165 defines a top corner portion of the molding cavity 101.
  • the coupler-split interface 167 can have a structure, as shown, that is an upper conical recess formed through a top end of the coupler member 160.
  • the coupler-core interface 161 can have a structure, as shown, that is a lower conical recess formed through a bottom end of the coupler member 160.
  • Arranged between the upper and the lower conical recesses is an inner flange 168, and wherein a vent 'V (i.e.
  • a small gap may be provided, as shown, between an inner cylindrical surface of the inner flange 168 and an adjacent outer cylindrical surface of the core member 150.
  • a vent passage 169 is also provided through a sidewall of the coupler member 160, including passing through the inner flange 168, that connects with the vent 'V, whereby air that is displaced from the molding cavity 101 during an injection of molding material therein may pass through the vent 'V and then through the vent passage 169 and into the environment.
  • an alignment groove 166 may be formed through a bottom surface of the coupler member 160.
  • the alignment groove 166 cooperates, in use, with a shank of an alignment member 192 that extends from a side of the coupling flange 151 of the core member 150, as shown in Figure 2, for retaining the coupler member 160 in a desired angular orientation with respect to the core member 150.
  • an air nozzle 162 that may be formed, as shown with reference to Figure 3, between an upper surface and a lower surface of the inner flange 168 is aligned with an outlet of a first branch channel 158 of an air passageway in the core member 150.
  • an air blow structure that is to assist with a transferring of the molded article (not shown) from the core member 150 is shown to include the air nozzle 162, the first branch channel 158, of the coupler member 160 and the core member 150, respectively, as well as a second branch channel 177, a third branch channel 178, and a fourth branch channel 179 of the air passageway, all of which may be formed, as shown, in the support member 170.
  • the first branch channel 158 of the core member 150 is shown as extending between the upper surface and the bottom surface of the coupling flange 151.
  • An inlet to the first branch channel 158 that is on the bottom surface of the coupling flange 151 is in turn connected to the second branch channel 177 that is formed between an upper surface and a lower surface of the upper flange 171 of the support member 170, as shown with reference to Figure 3.
  • the second branch channel 177 is in turn connected to the third branch channel 178 that may be provided, as shown, by an annular space that is between an inner surface of the support member 170 and an outer surface of the core member 150 and between the first and second flanges 154, 156 of the core member 150.
  • the third branch channel is in turn connected to the fourth branch channel 179 that is formed through a base connecting flange 172 of the support member 170, as shown with reference to
  • the non-limiting embodiment of the support member 170 is shown to have a generally tubular shape with the previously mentioned base connecting flange 172 outwardly depending from a bottom end thereof.
  • the support member 170 may also include an hour-glass shaped variation in its contour in the vicinity of a middle thereof that provides an upper portion of the support member 170 with a degree of flexibility, and as such is configured as a so-called 'compensating component' that is consistent with the teachings of commonly assigned United States Patent Application No. 1 1/780814, to Mai et al. and published as US 2009/0022844 on January 22, 2009.
  • Other non-limiting embodiments of the mold insert stack may not necessarily be structured as a compensating component.
  • the base connecting flange 172 of the support member 170 defines, amongst other things, the socket 184, a spring groove 186, a release bore 199, a set of four fastener bores 180, the fourth branch channels 179 (as described previously), and pair of dowel bores 103.
  • the socket 184 includes a pocket 185 that may be defined, as shown, through a bottom face of the base connecting flange 172.
  • the pocket 185 can have a generally square-shape however with a first inset corner 174A and a second inset corner 174B in opposed corners thereof.
  • the socket 184 may also include a first locking- web 189 and a second locking- web 187 that are defined in the base connecting flange 172 between the pocket 185 and a cylindrical space 173 that may be defined, as shown, by an inner surface of a tubular portion of the support member 170.
  • the socket 184 further includes an opening 188 that may be defined, as shown, in the base connecting flange 172, and wherein the first locking- web 189 and the second locking-web 187 are arranged on opposite sides thereof.
  • the opening 188 may be structured, as shown, to connect the pocket 185 with the cylindrical space 173 in the tubular portion.
  • the opening 188 includes a cylindrical portion 188A that is outlined by a first curved inner surface 189A and a second curved inner surface 187A of the first locking- web 189 and the second locking-web 187, respectively.
  • the opening 188 may also include a first wing portion 188B and a second wing portion 188C that are arranged between the first locking- web 189 and the second locking- web 187 and on opposite sides of a perimeter outlined by the cylindrical portion 188A.
  • the spring groove 186 is formed through the bottom face of the base connecting flange 172 along a generally L-shaped profile to a depth of the pocket 185, and wherein a spring-arm 193 may have, as shown, a similar shape is arranged therein.
  • the spring groove 186 includes a first portion 186A and a second portion 186B.
  • a first segment 193A of the spring-arm 193 is bent, as shown, such as to grip the sidewall of the first portion 186A of the spring groove 186, whereby the spring-arm 193 is held therein.
  • a second segment 193B of the spring-arm 193 is arranged within the second portion 186B of the spring groove 186, and wherein the second segment 193B is configured to allow the second segment 193B to flex between a neutral configuration, as shown in Figures 5, 6, and 8, and a deflected configuration, as shown in Figures 7 and 9.
  • the second segment 193B of the spring-arm 193 is furthermore structured to extend across a side of the first wing portion 188B for sake of cooperating, in use, with the first bayonet 182A of the core member 150, in a manner that is to be described later.
  • the spring-arm 193 may be formed from a resilient material, such as, for example, sheet metal of stainless spring steel (DIN 1.4310). In the present non-limiting example, the sheet metal thickness may be between 0.8 mm - 2.5 mm.
  • the release bore 199 may be structured, as shown, to pass through the base connecting flange 172, from a top face (not shown) and through the bottom face thereof, on a shallow angle, whereby a tool 195, as shown with reference to Figure 9, such as an end of an Allen key or a screwdriver, may be passed through the release bore 199, from the top face of the base connecting flange 172, for sake of flexing the second segment 193B of the spring-arm 193 into the deflected configuration.
  • the fastener bores 180 are structured to cooperate, in use, with fasteners (not shown) for connecting the support member 170 to the core plate (not shown) of the mold base (not shown).
  • the pair of dowel bores 103 are structured to cooperate with dowels (not shown) for aligning the support member 170 to a prescribed location on the core plate (not shown).
  • the structure involved in the quick-coupling between the core member 150 and the support member 170 may be provided between other members of the mold insert stack and between any member of the mold insert stack and the mold base of the injection mold.
  • the support member 270 is structured for use in place of the support member 170 (as shown in Figure 5) within the non-limiting embodiment of the mold insert stack 100.
  • the support member 270 as shown, is structured identically to the support member 170, as described previously, with the exception of having a spring groove 286 that has a somewhat different configuration to that of the spring groove 186 as described previously.
  • the support member 270 includes a socket 284 that is structured to be the same as the socket 184 as described previously.
  • the spring groove 286 is structured to cooperate, in use, with an alternative embodiment of a spring-arm 293, as shown.
  • a basic structure of the spring groove 286 and the spring-arm 293 are much the same as the spring groove 186 and the spring-arm 193, respectively, as described previously.
  • the spring groove 286 includes a first portion 286A and a second portion 286B, and likewise the spring-arm 293 includes a first segment 293 A and a second segment 293B.
  • the first portion 286A of the spring groove 286 and the corresponding first segment 293A of the spring-arm 293 are unique in that they further define a curved seat 286C and a corresponding looped portion 293C, respectively.
  • the curved seat 286C and the looped portion 293C are structured to cooperate in a close-fitting relation, as shown, whereby the spring-arm 293 is retained in the spring groove 286.
  • the support member 370 is structured for use in place of the support member 170 (as shown in Figure 5) within the non-limiting embodiment of the mold insert stack 100.
  • the support member 370 as shown, is structured identically to the support member 170, as described previously, with the exception of having a spring groove 386 that has a somewhat different configuration to that of the spring groove 186 as described previously.
  • the support member 370 includes a socket 384 that is structured to be the same as the socket 184 as described previously.
  • the spring groove 386 is structured to cooperate, in use, with an alternative embodiment of a spring-arm 393, as shown.
  • a basic structure of the spring groove 386 and the spring-arm 393 are much the same as the spring groove 186 and the spring-arm 193, respectively, as described previously.
  • the spring groove 386 includes a first portion 386A and a second portion 386B, and likewise the spring- arm 393 includes a first segment 393A and a second segment 393B. That being said, the first portion 386A of the spring groove 386 and the corresponding first segment 393A of the spring- arm 393 are unique in that they further define a tab seat 386C and a corresponding tab portion 393C, respectively.
  • the tab seat 386C and the tab portion 393C are structured to cooperate in a close-fitting relation, as shown, whereby an orientation of the first segment 393A of the spring- arm 393 is generally fixed within the first segment 386A of the spring groove 386. Furthermore, the tab portion 393C may be structured, as shown, to cooperate with a fastener 309 to fasten the spring-arm 393 to the support member 370.
  • the first step that can be followed in coupling the core member 150 to the support member 170 involves passing the bottom end of the core member 150 through the support member 170 with the first bayonet 182A and the second bayonet 182B of the core member 150 being oriented to pass through the first wing portion 188B and the second wing portion 188C of the support member 170.
  • the core-support interface 152 on the core member 150 meets the support-core interface 163 of the support member 170 the core member 150 will be arranged within the support member 170 as shown with reference to Figure 6.
  • a top surface (not shown) of each of the first bayonet 182A and the second bayonet 182B are positioned just below a bottom face of each of the first locking- web 189 and the second locking- web 187.
  • the second step that can be followed in coupling the core member 150 to the support member 170 involves rotating the core member 150 in the direction 'CR', as shown in Figure 7, for sake of positioning the top face of each of the first bayonet 182A and the second bayonet 182B over the bottom face of each of the first locking- web 189 and a second locking-web 187.
  • the camming surface 183 on the first bayonet 182A engages a free-end of the second segment 193B of the spring-arm 193 causing the second segment 193B to deflect into the deflected configuration as shown.
  • the second segment 193B of the spring-arm 193 returns to the neutral configuration, as shown with reference to Figure 8, and wherein a first side 196 and a second side 197 of the first bayonet 182A are positioned between an end of the second segment 193B and a sidewall of the first inset corner 174 A, respectively, at which point the core member 150 can be considered to be coupled to the support member 170.
  • To decouple the core member 150 from the support member 170 involves inserting the tool 195 through the release bore 199 for sake of deflecting the second segment 193B of the spring- arm 193 into the deflected configuration, as shown with reference to Figure 9, whereafter the core can be rotated in the direction 'CCR' until the first bayonet 182A and the second bayonet 182B of the core member 150 are once again in registration with the first wing portion 188B and the second wing portion 188C of the support member 170 after which the core member 150 may be withdrawn from the support member 170.

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Abstract

According to embodiments of the present invention, there is provided a molding apparatus that includes a member of a mold insert stack (100). The member defines a molding surface that provides a portion of a molding cavity (101). The member also defines a first bayonet (182A) having a camming surface (183) at a free end thereof for sake of cooperating, in use, with a socket (184, 284, 384) and a spring-arm (193, 293, 393) to provide a quick-coupling therebetween.

Description

MOLD INSERT STACK
FIELD OF THE INVENTION
The present invention generally relates to, but is not limited to, injection molding, and more specifically the present invention relates to, but is not limited to, a mold insert stack.
BACKGROUND OF THE INVENTION
Molding is a process by virtue of which a molded article can be formed from molding material by using a molding system. Various molded articles can be formed by using the molding process, such as an injection molding process. One example of a molded article that can be formed, for example, from polyethylene terephthalate (PET) material is a preform that is capable of being subsequently blown into a beverage container, such as, a bottle and the like.
A typical molding system includes an injection unit, a clamp assembly and an injection mold. The injection unit can be, for example, of a reciprocating screw type or of a two-stage type. The clamp assembly includes, inter alia, a frame, a movable platen, a fixed platen and an actuator for moving the movable platen and to apply tonnage to the injection mold arranged between the platens. The injection mold includes, inter alia, a cold half and a hot half with one or more mold insert stacks disposed therein. Each mold insert stack typically includes a core insert and a cavity insert that cooperate, in use, to define a molding cavity. However, each mold insert stack can be associated with a number of additional components such as, for example, a split insert (sometimes referred to as neck rings), a gate insert, a retainer, or a core support. The hot half is usually associated with one or more cavities (and, hence, also sometimes referred to by those of skill in the art as a "cavity half"), while the cold half is usually associated with one or more cores (and, hence, also sometimes referred to by those of skill in the art as a "core half). The hot half can also be associated with a melt distribution system (also referred to sometimes by those of skill in the art as a "hot runner") for melt distribution. The injection mold can be associated with a number of additional components, such as slides for positioning of the split insert, ejector structures, wear pads, etc.
As an illustration, injection molding of PET material involves heating the PET material (ex.
PET pellets, PEN powder, PLA, etc.) to a homogeneous molten state and injecting, under pressure, the so-melted PET material into the one or more molding cavities to form preforms. The cavity plate and the core plate are urged together and are held together by clamp force, the clamp force being sufficient enough to keep the cavity and the core pieces together against the pressure of the injected PET material. The molding cavity has a shape that substantially corresponds to a final cold-state shape of the molded article to be molded. The so-injected PET material is then cooled to a temperature sufficient to enable ejection of the so-formed molded article from the mold. When cooled, the molded article shrinks inside of the molding cavity and, as such, when the cavity and core plates are urged apart, the molded article tends to remain associated with the core. Accordingly, by urging the core plate away from the cavity plate, the molded article can be demolded, i.e. ejected from the core piece. Ejection structures are known to assist in removing the molded articles from the core halves. Examples of the ejection structures include stripper plates, ejector pins, etc.
One common example of a molded article that can be formed is a preform of the type that is capable of being subsequently blown into a beverage container, such as, a bottle and the like.
The following references disclose one or more means for providing a quick-coupling between a member of a mold insert stack and a mold base of an injection mold.
United States patent 3,871 ,61 1 to Taketa, published on March 18, 1975, teaches an improved mold having removable and replaceable cores and cavities, so that the need of providing a new mold base for every new part or product is eliminated. By doing so, the mold cost is substantially reduced, since only the cores and cavities need be replaced. The arrangement of the mold is such that the cores and cavities can be easily and quickly removed and replaced, with minimum down time of the molding apparatus. Furthermore, the replacement can be accomplished without having to remove the mold base from the molding apparatus. Not only does the arrangement provide for reduced mold costs, but it has the further attendant advantage that only the removable cores and cavities need be stored, thus eliminating the need and cost of arranging for the storage of the weighty and bulky mold bases.
United States patent 4,472, 128 to Ruhl et al., published on September 18th, 1984, teaches a quick change locator clamp assembly for a plastic molding machine having opposed top and bottom platens adapted to receive, mount and support a sectional die having top and bottom clamp plates which comprises laterally spaced pairs of opposed locator clamp assemblies mounted upon and projecting from the platens. Formed within the clamp plates on one side of the molding die are similarly spaced opposed pairs of locator slots. Each clamp assembly includes a locator key mounted upon a platen of a shape to snugly receive the corresponding clamp plate slot for locating the molding die in a predetermined position relative to the platens. A rotatable clamp is mounted upon the key and adapted for operative retaining engagement with an adjacent clamp plate. The sectional die includes a reciprocal ejector plate, there being at least one reciprocal knock-out bar on the molding machine. A reciprocal lifter plate within the bottom anchor plate is connected to the ejector plate and removably interlocked with the knock-out bar.
United States patent 4,684, 101 to Wagner et al., published on August 4, 1987, teaches an injection molding mold including an insert in-part defining the mold cavity and readily accessible for replacement from the side of the mold. The insert has a molding head at the mold cavity, a shank extending into a socket in the mold, a mortice in the shank for receiving a retainer to hold the insert in place and, preferably, a camming surface on the end of the shank for dislodging the insert from the mold. The retainer will preferably be a sliding pin having a bifurcated keeper portion providing two tapered prongs engaging opposed slots on the insert's shank for holding the insert in place during molding and subsequently for camming the insert loose from the socket at replacement time.
United States patent 4,91 1 ,632 to Mansfield, published on March 27, 1990, teaches a structure for releasably securing a plurality of mold inserts to a mold plate attached to a power press machine is disclosed. The mold plate has a plurality of apertures formed therethrough. Within each aperture, a plurality of inwardly extending spaced apart protrusions are formed. The mold inserts include end portions having a plurality of tabs formed thereon. A mold insert is inserted within an aperture by aligning the tabs with the spaces between the protrusions and moving the mold insert axially therein. Then, by rotating the mold insert relative to the mold plate, the tabs are moved over the protrusions. As a result, the mold insert is retained within the aperture. Locking bars prevent rotation of the mold inserts at undesired times to prevent them from being removed from the mold plate. A locking mechanism may be used to secure the locking bars, and therefore the mold inserts, in their locked positions during use.
United States patent 5,750, 161 to Schock et al., published on May 12, 1998, teaches a mold core assembly for removable installation in a molding machine includes a first lock element attached to a core and a second lock element movably attached to a core retainer. The second lock element is movable between a locked position fitted in locking connection with the first lock element and an unlocked position separated from the first lock element. A slip ring surrounds the first lock element of the core, engaging and holding the second lock element in its locked position. A spring is connected between the core retainer and the slip ring, with the spring biased to oppose movement of the slip ring away from its locked position so that the core is normally held in its locked position in the core retainer.
SUMMARY OF THE INVENTION
In accordance with a first aspect of the present invention, there is provided a molding apparatus that includes a member of a mold insert stack. The member defines a molding surface that provides a portion of a molding cavity. The member also defines a first bayonet having a camming surface at a free end thereof for sake of cooperating, in use, with a socket and a spring-arm to provide a quick-coupling therebetween.
A technical effect of the quick-coupling is that it provides for quick and easy exchange of the member of the mold insert stack particularly with respect to the mold insert stack having been arranged in an injection mold.
These and other aspects and features of non-limiting embodiments of the present invention will now become apparent to those skilled in the art upon review of the following description of specific non-limiting embodiments of the invention in conjunction with the accompanying drawings.
DETAILED DESCRIPTION OF THE DRAWINGS
A better understanding of the non-limiting embodiments of the present invention (including alternatives and/or variations thereof) may be obtained with reference to the detailed description of the non-limiting embodiments along with the following drawings, in which:
Figure 1 depicts a side view of a mold insert stack for use in an injection mold, the mold insert stack being structured according to a non-limiting embodiment of the present invention;
Figure 2 depicts a section view through the mold insert stack of Figure 1 ;
Figure 3 depicts another section view through the mold insert stack of Figure 1 ; Figure 4 depicts an exploded perspective view of a core member and a coupler member belonging to a core assembly of the mold insert stack of Figure 1 ;
Figure 5 depicts a perspective view of a support member belonging to the core assembly of the mold insert stack of Figure 1 ;
Figure 6 depicts a perspective view of the core assembly and the support member of the molding stack of Figure 1 , wherein the core member is arranged in, but uncoupled from, the support member;
Figure 7 depicts a perspective view of the core assembly and the support member of the molding stack of Figure 1 , wherein the core member is in the midst of being coupled with the support member;
Figure 8 depicts a perspective view of the core assembly of the molding stack of Figure 1 , wherein the core member is coupled with the support member;
Figure 9 depicts a perspective view of the core assembly of the molding stack of Figure 1 , wherein the core member is in the midst of being uncoupled from the support member.
The drawings are not necessarily to scale and may be illustrated by phantom lines, diagrammatic representations and fragmentary views. In certain instances, details that are not necessary for an understanding of the embodiments or that render other details difficult to perceive may have been omitted.
DETAILED DESCRIPTION OF EMBODIMENTS
With reference to Figure 1 , a mold insert stack 100 is shown that has been configured in accordance with a non-limiting embodiment of the present invention. Consistent with common practice in the art of injection molding, the mold insert stack 100 is structured for installation, in use, in a mold base (not shown) of an injection mold (not shown). The mold insert stack 100 includes members that are structured to cooperate, in use, when arranged in a mold closed configuration, to define a molding cavity 101 , reference Figures 2 or 3, within which a molded article (not shown), such as a preform of the type for blow molding into a bottle (not shown), may be formed upon injection of molding material therein. The members (including a member, another member, and other members) of the mold insert stack 100 include a cavity insert 1 10, a gate insert 120, a split insert 140, and a core assembly 130 each of which define a portion of the molding cavity 101. However, those skilled in the art will appreciate that the teachings that follow may be readily applied to alternative forms of the mold insert stack (not shown) including those having variations in the structure of the foregoing members, as well as those having some other combination and permutation of the foregoing members, and/or other members, present therein.
A description of several non-limiting embodiments of an injection mold that include a mold base that is suitable to receive the mold insert stack 100 may be referenced in commonly assigned United States Patent 7,381 ,049 (USP 7,381 ,049), granted June 3, 2008.
With reference to Figures 1 , 2, and 3, the non-limiting embodiment of the cavity insert 1 10 is shown to have a generally tubular shape with a cavity plate connecting flange 1 1 1 outwardly depending from a bottom end thereof through which fasteners (not shown) may be arranged for connecting the cavity insert 1 10 to a cavity plate (not shown) of the mold base (not shown). The cavity insert 1 10 defines, amongst other things, a cavity molding surface 1 15, a cavity- split interface 1 13, a cavity-gate interface 1 16, a cavity-plate interface 1 17, and a cavity coolant groove 1 19. The cavity molding surface 1 15 defines an outer portion of the molding cavity 101. The cavity-split interface 1 13 can have a structure, as shown, that is a conical recess formed through a bottom end of the cavity insert 1 10. The cavity-split interface 1 13 cooperates, in use, with a split-cavity interface 143 that is defined on the split insert 140 to align the cavity insert 1 10 with the split insert 140 with an arranging of the injection mold into the mold closed configuration. The cavity-gate interface 1 16 can have a structure, as shown, that is a face on an upper end of the cavity insert 1 10. The cavity-gate interface 1 16 mates, in use, with a gate- cavity interface 126 that is defined on the gate insert 120, as shown, when the cavity insert 1 10 and the gate insert 120 are installed in the cavity plate (not shown). The cavity-plate interface 1 17 can have a structure, as shown, that is an outer cylindrical surface of the cavity insert 1 10. The cavity-plate interface 1 17 mates, in use, with a plate-cavity interface (not shown) that is defined within the cavity plate (not shown). Lastly, the cavity coolant groove 1 19 can have a helical profile that is formed through the outer cylindrical surface of the cavity insert 1 10, shown with reference to Figure 1 , that cooperates, in use, with the cavity plate (not shown) to define a coolant channel for sake of circulating a coolant, in use, to cool the cavity insert 1 10.
With further reference to Figures 1 , 2, and 3, the non-limiting embodiment of the gate insert 120 is shown to have a generally annular shape. The gate insert 120 defines, amongst other things, a gate molding surface 125, the gate-cavity interface 126, a gate-plate interface 124, a nozzle interface 122, and a set of gate coolant passageways 129. The gate molding surface 125 defines a domed-end portion of the molding cavity 101. The gate-cavity interface 126 can have a structure, as shown, that is a face on a lower end of the gate insert 120. The gate-plate interface 124 can have a structure, as shown, that is an outer cylindrical surface of the gate insert 120. The gate-plate interface 124 mates, in use, with a plate-gate interface (not shown) that is defined within the cavity plate (not shown). The nozzle interface 122 can have a structure, as shown, that is a contoured pocket through an upper portion of the gate insert 120. The nozzle 122 mates, in use, with a nozzle (not shown) of a melt distribution apparatus for channeling molding material into the molding cavity 101. Lastly, the set of gate coolant passageways 129 may be formed, as shown, as a network of interconnected passageways within the gate insert 120 that form a coolant channel in cooperation with the cavity plate (not shown) for sake of circulating a coolant, in use, to cool the gate insert 120.
With further reference to Figures 1 , 2, and 3, the non-limiting embodiment of the split insert 140 is shown to include of a first split insert member 140A and a second split insert member 140B each of which may have a complementary semi-annular shape with a slide connecting flange 141 and 142 depending from a middle thereof, respectively, through which fasteners (not shown) may be arranged for connecting the first split insert member 140A and the second split insert member 140B to respective slide members (not shown) of the mold base. The construction and operation of the slide members is well known to those of ordinary skill in art and hence will not be reviewed herein. A description of several non-limiting embodiments thereof may also be referenced in USP 7,381 ,049. The first split insert member 140A and the second split insert member 140B together define, amongst other things, a split molding surface 145, the split-cavity interface 143, a split-coupler interface 147, and a set of split insert coolant passageways 149. The split molding surface 145 defines an encapsulated portion of the molding cavity 101. The split-cavity interface 143 can have a structure, as shown, that is a conical protuberance formed around a top end of the split insert 140. The split-coupler interface 147 can have a structure, as shown, that is a conical protuberance formed around a bottom end of the split insert 140. The split-coupler interface 147 cooperates, in use, with a coupler-split interface 167 that is defined on a coupler member 160 of the core assembly 130 to align the split insert 140 with a core member 150 of the core assembly 130 with an arranging of the injection mold into the mold closed configuration. Lastly, the set of split insert coolant passageways 149 (Figure 1) may be formed, as shown, as a network of interconnected passageways within each of the first split insert member 140A and the second split insert member 140B that form a coolant channel in cooperation with the respective slide member (not shown) of the injection mold (not shown) for sake of circulating a coolant, in use, to cool the split insert 140.
With further reference to Figures 1 , 2, and 3, the non-limiting embodiment of the core assembly 130 is shown to include the core member 150 and the coupler member 160, as previously mentioned, as well as a support member 170.
The non-limiting embodiment of the core member 150 may have, as shown, a generally tubular shape with a closed upper end and a coupling flange 151 outwardly depending in a mid-region thereof. The core member 150 defines, amongst other things, a core molding surface 155, a core-support interface 152, a core-coupler interface 153, and a core coolant chamber 159. The core molding surface 155 may be provided, as shown, on the top end of the core member 150, the core molding surface 155 defines an inner portion of the molding cavity 101. The core- coupler interface 153 may be structured, as shown, to include a conical outer surface and an upper surface of the coupling flange 151. The core-coupler interface 153 mates, in use, with a coupler-core interface 161 that is defined on the coupler member 160, as shown, when the coupler member 160 is coupled to the core member 150, whereby the coupler member 160 and the core member 150 are aligned together. For sake of coupling the coupler member 160 to the core member 150, a retainer 191 may be provided, such as a snap-ring, as shown with reference to Figures 2 and 3. To make the coupling between the coupler member 160 and the core member 150, the retainer 191 is first arranged with an inner periphery thereof seated in a first groove 104 that is provided through the core-coupler interface 153 of the core member 150. Next, the coupler member 160 is slid over the core member 150 and in so doing the retainer 191 is compressed into the first groove 104 as a result of an interaction of an outer surface of the retainer 191 with the tapered surface of the coupler-core interface 161. With the coupler member 160 reaching a seated position on the core member 150, wherein the core-coupler interface 153 mates with the coupler-core interface 161 , the retainer 191 is positioned adjacent to a second groove 105 that is provided through the coupler-core interface 161 on the coupler member 160, whereupon the retainer 191 is able to expand such that the inner periphery thereof is seated in the first groove 104 and wherein an outer periphery thereof is seated in the second groove 105, whereby the core member 150 and the coupler member 160 are fully coupled. To decouple the coupler member 160 from the core member 150 the retainer 191 may be compressed into the first groove 104 in the core member 150 by inserting a tool (not shown) through an access channel 164, as shown with reference to Figure 4, one or more of which may be formed through a side wall of the coupler member 160 to intersect with the second groove 105, after which the coupling member 160 may then be slid off of the core member 150. Returning to the description of the core member 150, it can be seen, with reference to Figure 2, that the core-support interface 152 can have a structure that is a bottom surface of the coupling flange 151. The core-support interface 152 mates, in use, with a support-core interface 163 that may be defined on an upper surface of the support member 170 and in this way support the core member by channeling an axially applied force, such as a mold clamping force, therethrough and on into the mold base. The core member 150 may also include a pair of smaller flanges on the outer surface thereof, including a first flange 154 that may be provided just beneath the coupling flange 151 , and a second flange 156 that may be provided, as shown, near the bottom end of the core member 150. A gap 'G' may be provided, as shown, between an outer cylindrical surface of the first and second flanges 154, 156 and an adjacent inner surface of the support member 170, whereby the core member 150 may some freedom to move relative to the support member 170, as required, with an opening and/or closing of the injection mold. In this way the core member 150 is free to be aligned with the split insert 140 by cooperation of the coupler member 160 with both the core member 150 and the split insert 140. With any such movement there will be a sliding relative movement between the core-support interface 152 and the support-core interface 163. The spigot interface 157 may be structured, as shown, to include the outer cylindrical surface of the core member 150 at the end thereof. A spigot interface 157 that may be provided at the bottom end of the core member 150 may be structured, as shown, to mate, in use, with a plate-core interface (not shown) that is defined within the core plate (not shown) when the core member 150 is installed therein. The core member 150 may also include a first bayonet 182A and a second bayonet 182B that project outwardly from the outer cylindrical surface of the core member 150, in an opposite direction from each other, adjacent to the spigot interface 157. The first bayonet 182A and the second bayonet 182B each define a camming surface 183 at a free end thereof that is curved. The first bayonet 182A and the second bayonet 182B cooperate, in use, with a socket 184 that may be defined, as shown, in the support member 170 to provide a quick-coupling between the core member 150 and the mold base of the injection mold. Lastly, the core coolant chamber 159 provides a space for defining a coolant channel in cooperation with a cooling tube 194 for sake of circulating a coolant, in use, to cool the core member 150.
The non-limiting embodiment of the coupler member 160 is shown to have an annular shape.
The coupler member 160 defines, amongst other things, a coupling molding surface 165, the coupler-split interface 167, and the coupler-core interface 161. The coupling molding surface 165 defines a top corner portion of the molding cavity 101. The coupler-split interface 167 can have a structure, as shown, that is an upper conical recess formed through a top end of the coupler member 160. Likewise, the coupler-core interface 161 can have a structure, as shown, that is a lower conical recess formed through a bottom end of the coupler member 160. Arranged between the upper and the lower conical recesses is an inner flange 168, and wherein a vent 'V (i.e. small gap) may be provided, as shown, between an inner cylindrical surface of the inner flange 168 and an adjacent outer cylindrical surface of the core member 150. Also provided through a sidewall of the coupler member 160, including passing through the inner flange 168, is a vent passage 169 that connects with the vent 'V, whereby air that is displaced from the molding cavity 101 during an injection of molding material therein may pass through the vent 'V and then through the vent passage 169 and into the environment. Lastly, an alignment groove 166 may be formed through a bottom surface of the coupler member 160. The alignment groove 166 cooperates, in use, with a shank of an alignment member 192 that extends from a side of the coupling flange 151 of the core member 150, as shown in Figure 2, for retaining the coupler member 160 in a desired angular orientation with respect to the core member 150. In so doing, an air nozzle 162 that may be formed, as shown with reference to Figure 3, between an upper surface and a lower surface of the inner flange 168 is aligned with an outlet of a first branch channel 158 of an air passageway in the core member 150.
With reference to Figures 2 and 3, an air blow structure that is to assist with a transferring of the molded article (not shown) from the core member 150 is shown to include the air nozzle 162, the first branch channel 158, of the coupler member 160 and the core member 150, respectively, as well as a second branch channel 177, a third branch channel 178, and a fourth branch channel 179 of the air passageway, all of which may be formed, as shown, in the support member 170. With reference to Figure 2, the first branch channel 158 of the core member 150 is shown as extending between the upper surface and the bottom surface of the coupling flange 151. An inlet to the first branch channel 158 that is on the bottom surface of the coupling flange 151 is in turn connected to the second branch channel 177 that is formed between an upper surface and a lower surface of the upper flange 171 of the support member 170, as shown with reference to Figure 3. The second branch channel 177 is in turn connected to the third branch channel 178 that may be provided, as shown, by an annular space that is between an inner surface of the support member 170 and an outer surface of the core member 150 and between the first and second flanges 154, 156 of the core member 150. Lastly, the third branch channel is in turn connected to the fourth branch channel 179 that is formed through a base connecting flange 172 of the support member 170, as shown with reference to
K) Figure 2. In operation, air is channeled from an air source and through the first, second, third, and fourth branch channels 158, 177, 178, and 179 to the air nozzle 162 for sake of blowing against the molded article during a step of ejection thereof from the core member 150.
With reference to Figures 1 , 2, and 3, the non-limiting embodiment of the support member 170 is shown to have a generally tubular shape with the previously mentioned base connecting flange 172 outwardly depending from a bottom end thereof. The support member 170 may also include an hour-glass shaped variation in its contour in the vicinity of a middle thereof that provides an upper portion of the support member 170 with a degree of flexibility, and as such is configured as a so-called 'compensating component' that is consistent with the teachings of commonly assigned United States Patent Application No. 1 1/780814, to Mai et al. and published as US 2009/0022844 on January 22, 2009. Other non-limiting embodiments of the mold insert stack (not shown) may not necessarily be structured as a compensating component. With reference to Figure 5, it can be seen that the base connecting flange 172 of the support member 170 defines, amongst other things, the socket 184, a spring groove 186, a release bore 199, a set of four fastener bores 180, the fourth branch channels 179 (as described previously), and pair of dowel bores 103. The socket 184 includes a pocket 185 that may be defined, as shown, through a bottom face of the base connecting flange 172. The pocket 185 can have a generally square-shape however with a first inset corner 174A and a second inset corner 174B in opposed corners thereof. The socket 184 may also include a first locking- web 189 and a second locking- web 187 that are defined in the base connecting flange 172 between the pocket 185 and a cylindrical space 173 that may be defined, as shown, by an inner surface of a tubular portion of the support member 170. The socket 184 further includes an opening 188 that may be defined, as shown, in the base connecting flange 172, and wherein the first locking- web 189 and the second locking-web 187 are arranged on opposite sides thereof. The opening 188 may be structured, as shown, to connect the pocket 185 with the cylindrical space 173 in the tubular portion. The opening 188 includes a cylindrical portion 188A that is outlined by a first curved inner surface 189A and a second curved inner surface 187A of the first locking- web 189 and the second locking-web 187, respectively. The opening 188 may also include a first wing portion 188B and a second wing portion 188C that are arranged between the first locking- web 189 and the second locking- web 187 and on opposite sides of a perimeter outlined by the cylindrical portion 188A. The spring groove 186 is formed through the bottom face of the base connecting flange 172 along a generally L-shaped profile to a depth of the pocket 185, and wherein a spring-arm 193 may have, as shown, a similar shape is arranged therein. The spring groove 186 includes a first portion 186A and a second portion 186B. A first segment 193A of the spring-arm 193 is bent, as shown, such as to grip the sidewall of the first portion 186A of the spring groove 186, whereby the spring-arm 193 is held therein. A second segment 193B of the spring-arm 193 is arranged within the second portion 186B of the spring groove 186, and wherein the second segment 193B is configured to allow the second segment 193B to flex between a neutral configuration, as shown in Figures 5, 6, and 8, and a deflected configuration, as shown in Figures 7 and 9. The second segment 193B of the spring-arm 193 is furthermore structured to extend across a side of the first wing portion 188B for sake of cooperating, in use, with the first bayonet 182A of the core member 150, in a manner that is to be described later. The spring-arm 193 may be formed from a resilient material, such as, for example, sheet metal of stainless spring steel (DIN 1.4310). In the present non-limiting example, the sheet metal thickness may be between 0.8 mm - 2.5 mm. The release bore 199 may be structured, as shown, to pass through the base connecting flange 172, from a top face (not shown) and through the bottom face thereof, on a shallow angle, whereby a tool 195, as shown with reference to Figure 9, such as an end of an Allen key or a screwdriver, may be passed through the release bore 199, from the top face of the base connecting flange 172, for sake of flexing the second segment 193B of the spring-arm 193 into the deflected configuration. The fastener bores 180 are structured to cooperate, in use, with fasteners (not shown) for connecting the support member 170 to the core plate (not shown) of the mold base (not shown). Likewise, the pair of dowel bores 103 are structured to cooperate with dowels (not shown) for aligning the support member 170 to a prescribed location on the core plate (not shown).
In another alternative embodiment (not shown), the structure involved in the quick-coupling between the core member 150 and the support member 170 (i.e. the first bayonet 182A, the second bayonet 182B, the socket 184, and the spring-arm 193), including variations thereof, may be provided between other members of the mold insert stack and between any member of the mold insert stack and the mold base of the injection mold.
With reference to Figure 10, an alternative non-limiting embodiment of the support member 270 is shown. The support member 270 is structured for use in place of the support member 170 (as shown in Figure 5) within the non-limiting embodiment of the mold insert stack 100. As such, the support member 270, as shown, is structured identically to the support member 170, as described previously, with the exception of having a spring groove 286 that has a somewhat different configuration to that of the spring groove 186 as described previously. Accordingly, the support member 270 includes a socket 284 that is structured to be the same as the socket 184 as described previously. The spring groove 286 is structured to cooperate, in use, with an alternative embodiment of a spring-arm 293, as shown. A basic structure of the spring groove 286 and the spring-arm 293 are much the same as the spring groove 186 and the spring-arm 193, respectively, as described previously. As such, the spring groove 286 includes a first portion 286A and a second portion 286B, and likewise the spring-arm 293 includes a first segment 293 A and a second segment 293B. That being said, the first portion 286A of the spring groove 286 and the corresponding first segment 293A of the spring-arm 293 are unique in that they further define a curved seat 286C and a corresponding looped portion 293C, respectively. The curved seat 286C and the looped portion 293C are structured to cooperate in a close-fitting relation, as shown, whereby the spring-arm 293 is retained in the spring groove 286.
With reference to Figure 1 1 , yet another alternative non-limiting embodiment of the support member 370 is shown. The support member 370 is structured for use in place of the support member 170 (as shown in Figure 5) within the non-limiting embodiment of the mold insert stack 100. As such, the support member 370, as shown, is structured identically to the support member 170, as described previously, with the exception of having a spring groove 386 that has a somewhat different configuration to that of the spring groove 186 as described previously. Accordingly, the support member 370 includes a socket 384 that is structured to be the same as the socket 184 as described previously. The spring groove 386 is structured to cooperate, in use, with an alternative embodiment of a spring-arm 393, as shown. A basic structure of the spring groove 386 and the spring-arm 393 are much the same as the spring groove 186 and the spring-arm 193, respectively, as described previously. As such, the spring groove 386 includes a first portion 386A and a second portion 386B, and likewise the spring- arm 393 includes a first segment 393A and a second segment 393B. That being said, the first portion 386A of the spring groove 386 and the corresponding first segment 393A of the spring- arm 393 are unique in that they further define a tab seat 386C and a corresponding tab portion 393C, respectively. The tab seat 386C and the tab portion 393C are structured to cooperate in a close-fitting relation, as shown, whereby an orientation of the first segment 393A of the spring- arm 393 is generally fixed within the first segment 386A of the spring groove 386. Furthermore, the tab portion 393C may be structured, as shown, to cooperate with a fastener 309 to fasten the spring-arm 393 to the support member 370.
An example of the operation of the quick-coupling will now be discussed with reference to the sequence of views in Figures 6, 7, 8, and 9. The first step that can be followed in coupling the core member 150 to the support member 170 involves passing the bottom end of the core member 150 through the support member 170 with the first bayonet 182A and the second bayonet 182B of the core member 150 being oriented to pass through the first wing portion 188B and the second wing portion 188C of the support member 170. Once the core-support interface 152 on the core member 150 meets the support-core interface 163 of the support member 170 the core member 150 will be arranged within the support member 170 as shown with reference to Figure 6. In this configuration a top surface (not shown) of each of the first bayonet 182A and the second bayonet 182B are positioned just below a bottom face of each of the first locking- web 189 and the second locking- web 187. The second step that can be followed in coupling the core member 150 to the support member 170 involves rotating the core member 150 in the direction 'CR', as shown in Figure 7, for sake of positioning the top face of each of the first bayonet 182A and the second bayonet 182B over the bottom face of each of the first locking- web 189 and a second locking-web 187. As the core member 150 is rotated the camming surface 183 on the first bayonet 182A engages a free-end of the second segment 193B of the spring-arm 193 causing the second segment 193B to deflect into the deflected configuration as shown. Upon completion of the rotation of the core member 150 the second segment 193B of the spring-arm 193 returns to the neutral configuration, as shown with reference to Figure 8, and wherein a first side 196 and a second side 197 of the first bayonet 182A are positioned between an end of the second segment 193B and a sidewall of the first inset corner 174 A, respectively, at which point the core member 150 can be considered to be coupled to the support member 170.
To decouple the core member 150 from the support member 170 involves inserting the tool 195 through the release bore 199 for sake of deflecting the second segment 193B of the spring- arm 193 into the deflected configuration, as shown with reference to Figure 9, whereafter the core can be rotated in the direction 'CCR' until the first bayonet 182A and the second bayonet 182B of the core member 150 are once again in registration with the first wing portion 188B and the second wing portion 188C of the support member 170 after which the core member 150 may be withdrawn from the support member 170.
Description of the non-limiting embodiments of the present inventions provides examples of the present invention, and these examples do not limit the scope of the present invention. It is to be expressly 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 non-limiting embodiments of the present invention, 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. A molding apparatus, comprising: a member of a mold insert stack ( 100) for use in an injection mold, wherein the member defines: a molding surface that provides a portion of a molding cavity ( 101); a first bayonet (182A) having a camming surface ( 183) at a free end thereof for sake of cooperating, in use, with a socket ( 184, 284, 384) and a spring-arm (193, 293, 393) to provide a quick-coupling therebetween.
2. The molding apparatus of claim 1 , wherein: the camming surface (183) is curved.
3. The molding apparatus of claim 1 , further comprising: a mold base and wherein the socket (184, 284, 384) is defined therein; and receive the spring-arm ( 193, 293, 393) therein.
4. The molding apparatus of claim 1 , further comprising: another member of the mold insert stack (100) and wherein the socket (184, 284, 384) is defined therein; and receive the spring-arm ( 193, 293, 393) therein.
5. The molding apparatus of claim 1 , wherein: the member of the mold insert stack (100) is a core member (150), wherein the core member ( 150) defines: a core molding surface ( 155) that provides an inner portion of the molding cavity (K)I ); the first bayonet ( 182A) that project outwardly from an outer cylindrical surface of the core member (150).
6. The molding apparatus of claim 5, further comprising: other members of the mold insert stack ( 100) including one or more of a cavity insert (1 10), a gate insert (120), and a split insert (140), that are configured to cooperate with the core member ( 150) to define the molding cavity (101 ).
7. The molding apparatus of claim 5, wherein: the core member ( 150) includes a second bayonet ( 182B) that project outwardly from the outer cylindrical surface of the core member ( 150) in an opposite direction from the first bayonet ( 182A).
8. The molding apparatus of claim 5, further comprising: a support member (170, 270, 370) of the mold insert stack (100), the support member ( 170, 270, 370) and the core member ( 150) being structured to be coupled together as a core assembly (130); the support member ( 170, 270, 370) being structured to: support the core member ( 150); define the socket (184, 284, 384); and receive the spring-arm (193, 293, 393) therein.
9. The molding apparatus of claim 8, wherein: the support member (170, 270, 370) includes a base connecting flange ( 172) outwardly depending from a bottom end thereof that is structured to connect, in use, the support member ( 170, 270, 370) to a core plate of a mold base; the base connecting flange ( 172) of the support member (170, 270, 370) defines the socket ( 184, 284, 384), and a spring groove ( 186, 286, 386) for receiving the spring-arm (193, 293, 393).
10. The molding apparatus of claim 9, wherein: the base connecting flange (172) further defines a release bore (199) for receiving, in use, a tool ( 195) for deflecting the spring-arm (193, 293, 393) from a neutral configuration and into a deflected configuration to decouple the core member (150) from the support member (170, 270, 370).
1 1. The molding apparatus of claim 9, wherein: the socket (184, 284, 384) includes: a pocket (185) that is defined through a bottom face of the base connecting flange (172), the pocket ( 185) having a generally square-shape with a first inset corner (174A) and a second inset corner ( 174B) in opposed corners thereof; an opening ( 188) that is defined in the base connecting flange ( 172), the opening (188) being structured to connect the pocket ( 185) with a cylindrical space ( 173) that is defined by an inner surface of a tubular portion of the support member (170, 270, 370); a first locking- web ( 189) and a second locking- web (187) that are defined in the base connecting flange (172) between the pocket ( 185) and the cylindrical space (173); and wherein the first locking- web ( 189) and the second locking- web ( 187) are arranged on opposite sides of the opening (188), the opening (188) includes a cylindrical portion ( 188A) that is outlined by a first curved inner surface (189A) and a second curved inner surface ( 187A) of the first locking- web (189) and the second locking- web
(187), respectively, the opening (188) also includes a first wing portion (188B) and a second wing portion (188C) that are arranged between the first locking- web ( 189) and the second locking- web ( 187) and on opposite sides of a perimeter outlined by the cylindrical portion (188A).
12. The molding apparatus of claim 1 1 , wherein: the spring groove ( 186, 286, 386) is formed through the bottom face of the base connecting flange ( 172) along a generally L-shaped profile to a depth of the pocket ( 185), and wherein the spring-arm (193, 293, 393) having a similar shape is arranged therein; the spring groove ( 186, 286, 386) includes a first portion (186A, 286A, 386A) and a second portion ( 186B, 286B, 386B); a first segment (193 A, 293 A, 393A) of the spring-arm ( 193, 293, 393) structured to grip a sidewall of the first portion ( 186A, 286A, 386A) of the spring groove (186, 286, 386), whereby the spring-arm (193, 293, 393) is held therein; a second segment (193B, 293B, 393B) of the spring-arm (193, 293, 393) is arranged within the second portion ( 186B, 286B, 386B) of the spring groove ( 186, 286, 386), and wherein the second segment (193B, 293B, 393B) is configured to allow the second segment (193B, 293B, 393B) to flex between a neutral configuration and a deflected configuration; the second segment ( 193B, 293B, 393B) of the spring-arm (193, 293, 393) is furthermore structured to extend across a side of the first wing portion (188B) for sake of cooperating, in use, with the first bayonet ( 182A) of the core member (150).
13. The molding apparatus of claim 8, wherein: the core member (150) has a generally tubular shape with an upper end that is closed and a coupling flange ( 151) outwardly depending in a mid-region thereof; the core molding surface (155) is provided on the upper end of the core member (150), the core molding surface (155) defines the inner portion of the molding cavity (101 ); the coupling flange (151 ) defines a core-coupler interface ( 153) that is structured to mate, in use, with a coupler-core interface (161 ) that is defined on a coupler member (160), wherein the core-coupler interface ( 153) and the coupler-core interface (161 ) cooperate to align the coupler member ( 160) with the core member ( 150); the coupling flange ( 151) also defines a core-support interface (152) that is structured to mate, in use, with a support-core interface (163) that is defined on an upper surface of the support member (170, 270, 370), and wherein the core-support interface ( 152) and the support- core interface ( 163) are structured to allow a sliding relative movement therebetween.
14. The molding apparatus of claim 13, wherein: a spigot interface ( 157) is provided at a bottom end of the core member ( 150), the spigot interface (157) being structured to mate, in use, with a plate-core interface that is defined within a core plate of a mold base, and wherein the first bayonet (182A) and a second bayonet (182B) are adjacent to the spigot interface ( 157).
15. The molding apparatus of claim 13, wherein: a first groove (104) is provided through the core-coupler interface (153) on the core member ( 150); a second groove ( 105) is provided through the coupler-core interface (161 ) of the coupler member ( 160); and the first groove ( 104) and the second groove (105) are structured to cooperate with an inner periphery and an outer periphery of a retainer ( 191), respectively, for coupling, in use, the core member ( 150) with the coupler member ( 160).
16. The molding apparatus of claim 15, wherein: an access channel ( 164) is provided through a side wall of the coupler member ( 160) to intersect with the second groove (105).
17. The molding apparatus of claim 8, further comprising: a coupler member (160) of the mold insert stack (100), the coupler member (160) being structured to cooperate with the core member (150) and the support member ( 170, 270, 370) in the core assembly (130); a split insert (140) of the mold insert stack ( 100), the split insert being configured to define an encapsulated portion of the molding cavity (101 ); the coupler member ( 160), the split insert (140), and the core member being structured to cooperate together to align the split insert ( 140) with the core member (150) with an arranging, in use, of the injection mold into a mold closed configuration.
18. The molding apparatus of claim 17, wherein: the coupler member (160) being structured to have an annular shape on which are defined: a coupling molding surface ( 165) that provides a top corner portion of the molding cavity
(101); a coupler-split interface ( 167) that is structured on a top end of the coupler member
(160), the coupler-split interface (167) being structure to cooperate, in use, with a split-coupler interface (147) on the split insert (140); a coupler-core interface ( 161 ) that is structured on a bottom end of the coupler member
(160), the coupler-core interface (161 ) being structured to mate with a core-coupler interface
(153) that is provided on the core member (150).
19. The molding apparatus of claim 17, wherein: the coupler member ( 160) and the core member ( 150) are structured to cooperate together wherein a vent 'V is provided therebetween; and a vent passage ( 169) is provided through a sidewall of the coupler member ( 160) to connect with the vent 'V, whereby air that is displaced from the molding cavity (101 ) during an injection of molding material therein may pass through the vent 'V and then through the vent passage ( 169).
20. The molding apparatus of claim 17, wherein: the coupler member ( 160) is structured to define an air nozzle (162); the core member (150) and the support member (170, 270, 370) are configured to define an air passageway to channel air, in use, to the air nozzle ( 162).
PCT/CA2009/001740 2009-02-27 2009-12-04 Mold insert stack WO2010096892A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US15594709P 2009-02-27 2009-02-27
US61/155,947 2009-02-27

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012171118A1 (en) * 2011-06-14 2012-12-20 Husky Injection Molding Systems Ltd. Split insert half

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US7381049B2 (en) * 2006-03-08 2008-06-03 Husky Injection Molding Systems Ltd. Injection mold
US7575429B2 (en) * 2007-07-20 2009-08-18 Husky Injection Molding Systems Ltd. Compensating mold stack for use in a molding system

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7381049B2 (en) * 2006-03-08 2008-06-03 Husky Injection Molding Systems Ltd. Injection mold
US7575429B2 (en) * 2007-07-20 2009-08-18 Husky Injection Molding Systems Ltd. Compensating mold stack for use in a molding system

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012171118A1 (en) * 2011-06-14 2012-12-20 Husky Injection Molding Systems Ltd. Split insert half

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