Molding system and related methods

Abstract

The present disclosure provides a molding system and related methods. In one embodiment, a system (42) for conditioning a preform (34) for molding includes: a heating chamber (46) for receiving the preform (34); a heater (48) configured to heat gas; and a blower (58) configured to force the gas heated by the heater (48) into the heating chamber (46) and onto the outer surface of the preform (34). In another embodiment, a method for conditioning a preform (34) for molding includes: positioning the preform (34) in the heating chamber (46); and forcing the heated gas into the heating chamber (46) and onto the outer surface of the preform (34). In another embodiment, a system (70) for molding an object is provided. In yet another embodiment, an actuator system for a mold system (70) is provided.

Description

[0001] This application is a divisional application of the Chinese invention patent application with application number 201880006130.2, application date January 5, 2018, and invention name “Molding System and Related Methods”.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS

[0003] This application claims the benefit of U.S. Provisional Patent Application Serial No. 62 / 442,984, filed on January 6, 2017, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0004] The present invention relates to an apparatus, system and process for manufacturing articles such as plastic bottles or containers using molding techniques (e.g., blow molding). More specifically, the present invention relates to an apparatus, system and process for manufacturing containers that are expandable, modular, and can be locked laterally and vertically with other similar containers. Background Art

[0005] Blow molding is a well-known technique used to manufacture plastic articles such as bottles, containers, automotive parts or housings. In a one-stage or "single-stage" blow molding machine, the process begins with the production of a hot injection molded preform or "parison" of hollow plastic material at a first station, which is further conditioned at a second station and then moved and positioned at a third station having a mold cavity with inner walls in the shape of the final article to be molded. In a "two-stage" machine, the preform is manufactured externally but is conveyed to a conditioning station and reheated there before being moved to the blow molding cavity.

[0006] Injection stretch blow molding (ISBM) is a term of art and refers to biaxial PET blow molding from preforms in most cases (if not all cases). The history of ISBM technology can be traced back to about 35 years ago. Some blow-molded plastic bottles are blown out of an extruded tube, and the closed mold is pinched off at the bottom end. ISBM is used to provide the manufacture of plastic containers or other useful products formed on a machine by a preform, which is first stretched in the axial direction and then blown out in a circular direction in the mold by high-pressure air. The hot preform can be manufactured by the injection molding station on a "one-stage" or "single-stage" stretch blow molding machine, and then the preform is temperature regulated, then stretch blow molded into the final product, and finally cooled on the same machine before discharge.

[0007] Materials used for blow molding plastic products include polyethylene (PE) and polyethylene terephthalate (PET) because of their high levels of thermoplasticity.

[0008] The typical sequence of operations in a single-stage ISBM machine is as follows. PET is delivered to the machine site, usually in the form of small flakes contained in a fairly large box ("gaylord" box). Once the gaylord box is opened, the PET particles immediately begin to absorb a large amount of moisture from the ambient air. Therefore, almost all single-stage ISBM machines process PET materials through a dryer. The material then enters a "manifold" that is intended to keep the PET heat and dryness during delivery to the preform molding station, where a parison is formed by injecting the liquefied PET material into the mold cavity, and the parison thickness and its internal profile are functions of the shape of the preformed insert rod that meets the specifications. Once cooled enough to be delivered, the molded preform moves to an adjustment station, in which an optimal (e.g., product-specific) pre-blow temperature is achieved on the internal and external surfaces of the parison. The regulated parison then moves to the blow molding station, where compressed air works with a stretch rod to expand the PET resin until it contacts the mold cavity wall, at which point the PET resin cools and hardens rapidly, and then the mold is opened to allow the article to be discharged.

[0009] Manufacturers and other practitioners of molding techniques are continually striving to improve these techniques. Accordingly, it would be desirable to provide improved apparatus, systems and processes for making articles using molding techniques. Summary of the invention

[0010] In one embodiment, a system for conditioning a preform for molding includes: a heating chamber for receiving the preform; a heater configured to heat gas; and a blower configured to force the gas heated by the heater into the heating chamber and onto the outer surface of the preform. The system may also include a nozzle including at least one sidewall and positioned within the heating chamber for at least partially surrounding the preform. The at least one sidewall may include at least one hole for guiding gas therethrough (such as guiding gas to a predetermined portion of the outer surface of the preform). In one embodiment, the at least one hole includes at least one of a bore, a slot, a bend, or a funnel. Additionally or alternatively, the at least one hole may include an adjustable cross-sectional size. In one embodiment, the at least one sidewall includes at least one cylindrical sidewall, and the at least one hole includes a plurality of holes arranged in a uniform pattern on the at least one cylindrical sidewall.

[0011] In another embodiment, a method of conditioning a preform for molding includes: positioning the preform in a heating chamber; and forcing heated gas into the heating chamber and onto an outer surface of the preform. The method may also include positioning a nozzle having at least one sidewall within the heating chamber to at least partially surround the preform. The at least one sidewall may include at least one hole, and forcing the heated gas into the heating chamber may include directing the heated gas through the at least one hole, such as directing the heated gas to a predetermined portion of the outer surface of the preform. In one embodiment, forcing the heated gas into the heating chamber includes forcing heated air into the heating chamber.

[0012] In another embodiment, a system for molding an object includes a hinged mold having an axis and including a plurality of mold parts, the plurality of mold parts being configured to collectively define a molding cavity for forming the object when arranged in a corresponding molding position. The system also includes a plurality of actuators, wherein each of the plurality of actuators is operably coupled to a corresponding mold part of the plurality of mold parts and is configured to move the corresponding mold part along the axis from the corresponding molding position toward the corresponding ejection position to release the object. The system also includes a controller, the controller communicating with each of the plurality of actuators and configured to independently activate each of the plurality of actuators so that one of the plurality of mold parts moves along the axis from the corresponding molding position toward the corresponding ejection position, while at least another of the plurality of mold parts remains stationary relative to the object to at least partially support the object. The molding cavity may include at least one of a tongue or a groove extending in a direction parallel to the axis. Additionally or alternatively, the plurality of actuators may be configured to move the corresponding mold part along the axis from the corresponding molding position in the same direction toward the corresponding ejection position.

[0013] In one embodiment, the controller is configured to sequentially activate each of the plurality of actuators. For example, the plurality of mold portions may include a bottom portion and at least one side portion distributed along an axis, and the at least one side portion may be configured to move along the axis from the corresponding molding position toward the corresponding ejection position before the bottom portion moves along the axis from the corresponding molding position toward the corresponding ejection position, so that the bottom portion supports the object during the movement of the at least one side portion. In another embodiment, the plurality of mold portions may include an upper side portion and a lower side portion distributed along the axis, and the lower side portion may be configured to move along the axis from the corresponding molding position toward the corresponding ejection position before the upper side portion moves along the axis from the corresponding molding position toward the corresponding ejection position, so that the upper side portion supports the object during the movement of the lower side portion. In another embodiment, the multiple mold portions may include a first side-by-side portion and a second side-by-side portion distributed around an axis, and the first side-by-side portion may be configured to move along the axis from the corresponding molding position toward the corresponding ejection position before the second side-by-side portion moves along the axis from the corresponding molding position toward the corresponding ejection position, so that the second side-by-side portion supports the object during the movement of the first side-by-side portion.

[0014] In another embodiment, a method of releasing a molded object from a molding cavity defined by a plurality of mold sections of a hinged mold having an axis is provided. The method includes moving a first mold section of the plurality of mold sections along the axis from a corresponding molding position toward a corresponding ejection position, wherein during the movement of the first mold section, the object is supported by a second mold section of the plurality of mold sections. The method also includes subsequently moving the second mold section along the axis from the corresponding molding position toward the corresponding ejection position. In one embodiment, moving the first mold section includes activating a first actuator operably coupled to the first mold section. Moving the second mold section may include activating a second actuator operably coupled to the second mold section.

[0015] In one embodiment, the first mold portion is arranged below the second mold portion along the axis when the first mold portion and the second mold portion are in the respective molding positions. In another embodiment, the first mold portion is arranged above the second mold portion along the axis when the first mold portion and the second mold portion are in the respective molding positions. In yet another embodiment, the first mold portion and the second mold portion are arranged side by side about the axis when the first mold portion and the second mold portion are in the respective molding positions.

[0016] In another embodiment, an actuator system for a mold system includes a first actuator operably coupled to a first mold portion and configured to move the first mold portion in a first direction along an axis from a first molding position toward a first ejection position. The system also includes a second actuator operably coupled to a second mold portion and configured to move the second mold portion in a first direction along an axis from a second molding position toward a second ejection position. The system also includes a controller that communicates with the first actuator and the second actuator and is configured to independently activate the first actuator and the second actuator. In one embodiment, the controller is configured to sequentially activate the first actuator and the second actuator to move the corresponding mold portion in the first direction. For example, the controller may be configured to activate the first actuator before activating the second actuator. At least one of the first actuator or the second actuator may include a hydraulic actuator.

[0017] In one embodiment, the first actuator and the second actuator are configured to respectively move the first mold portion and the second mold portion in a second direction opposite to the first direction from the corresponding ejection position toward the corresponding molding position. For example, the controller can be configured to simultaneously activate the first actuator and the second actuator to move the corresponding mold portion in the second direction.

[0018] In another embodiment, a method for manufacturing an object in a hinged mold having an axis is provided. The method includes arranging a plurality of mold parts of the hinged mold in corresponding molding positions to define a molding cavity and molding the object in the molding cavity. The method also includes moving a first mold part of the plurality of mold parts along the axis from the corresponding molding position toward a corresponding ejection position, wherein during the movement of the first mold part, the object is supported by a second mold part of the plurality of mold parts. The method also includes subsequently moving the second mold part along the axis from the corresponding molding position toward the corresponding ejection position. In one embodiment, moving the first mold part includes activating a first actuator operably coupled to the first mold part. Moving the second mold part may include activating a second actuator operably coupled to the second mold part.

[0019] In one embodiment, the first mold portion is arranged below the second mold portion along the axis when the first mold portion and the second mold portion are in the respective molding positions. In another embodiment, the first mold portion is arranged above the second mold portion along the axis when the first mold portion and the second mold portion are in the respective molding positions. In another embodiment, the first mold portion and the second mold portion are arranged side by side about the axis when the first mold portion and the second mold portion are in the respective molding positions.

[0020] The step of molding the object may include blowing the object from the preform. For example, blowing the object may include stretching the blow molded object from the preform. The method may further include adjusting the preform before blow molding, wherein adjusting the preform includes positioning the preform in a heating chamber and forcing heated gas into the heating chamber and onto an outer surface of the preform. Adjusting the preform may also include positioning a nozzle having at least one side wall in the heating chamber to at least partially surround the preform. The at least one side wall may include at least one hole, and forcing the heated gas into the heating chamber may include directing the heated gas through the at least one hole. For example, directing the heated gas through the at least one hole may include directing the heated gas to a predetermined portion of the outer surface of the preform. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Various additional features and advantages of the present invention will become more apparent to those skilled in the art by reading the following detailed description of one or more illustrative embodiments in conjunction with the accompanying drawings. The accompanying drawings, which are included in and constitute a part of this specification, illustrate one or more embodiments of the present invention and, together with the general description given above and the detailed description given below, are used to explain one or more embodiments of the present invention.

[0022] Figure 1 is a perspective view of a modular interlocking container made according to an embodiment of the present invention.

[0023] Figure 2 is a cross-sectional view of a heating station according to an embodiment of the present invention showing heated air directed therein during a conditioning operation.

[0024] Figure 3 is a cross-sectional view of a molding station according to an embodiment of the present invention showing mold portions of a hinged mold in various molding positions.

[0025] Figure 4 yes Figure 3 A partial cross-sectional view of a molding station showing pressurized gas directed therein during a blow molding operation.

[0026] Figure 5 yes Figure 3 A partial cross-sectional view of a molding station showing the side mold portions being retracted during a demolding operation.

[0027] Figure 6 is similar to Figure 5 , showing the bottom mold section and the side mold sections being retracted during the demolding operation.

[0028] Figure 7 is similar to Figure 6, showing the bottom and side mold parts in respective ejection positions and the top mold part being retracted during the demoulding operation.

[0029] Figure 8 is similar to Figure 7 , showing the bottom, side and top mold parts in respective ejection positions during the demoulding operation, and a conveying device for releasing the blow molded containers.

[0030] Fig. 9 is similar to Figure 8 , which shows the containers falling onto the collection ramp during the demoulding operation.

[0031] Fig.10 is a partial cross-sectional view of an alternative molding station according to an embodiment of the present invention showing the lowermost horizontal section of the side mold portion being retracted during a demolding operation.

[0032] Fig.11 is similar to Fig.10 , showing the middle and uppermost horizontal sections of the side mould parts being retracted during the demoulding operation.

[0033] Fig.12 is similar to Fig.11 , showing the bottom mold part and the horizontal section being retracted during the demoulding operation.

[0034] Fig.13 is a partial cross-sectional view of an alternative molding station according to an embodiment of the present invention showing a first vertical section of a side mold portion being retracted during a demolding operation.

[0035] Fig.14 is similar to Fig.13 , showing the second and third vertical sections of the side mould part being retracted during the demoulding operation.

[0036] Fig.15 is similar to Fig.14 , showing the bottom mould part and the vertical section being retracted during the demoulding operation. DETAILED DESCRIPTION

[0037] Although the following describes an exemplary embodiment for a stretch blow molding process, those skilled in the art will appreciate that the embodiments described herein may be used in other molding or die casting applications including, but not limited to, extrusion blow molding, injection molding, or rotational molding.

[0038] As used herein, relational terms such as first and second, top and bottom, etc., may be used solely to distinguish one entity or action from another entity or action, without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms "include," "comprises," or any other variation thereof, are intended to encompass a non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements, but may also include elements not explicitly listed or inherent to the process, method, article, or apparatus. An element beginning with "includes..." does not, without more constraints, exclude the presence of additional identical elements in the process, method, article, or apparatus that includes the element.

[0039] Embodiments of the present invention include systems, apparatus, and processes for making expandable, modular, interconnected, and interlocking containers having multiple uses and applications, such as those described in U.S. patent application Ser. No. 14 / 777,210 filed Sep. 15, 2015 ("the '210 Application"), the disclosure of which is incorporated herein by reference in its entirety. A first exemplary use of such containers is for transporting and / or storing flowable materials (such as liquids or pourable solids). An exemplary second use of such containers is for creative modeling elements or for strong, low-cost, easily assembled building block materials of standardized nature. Embodiments may be used to construct housing, storage, or other practical structures, including applications for disaster relief, humanitarian development projects, for military or defense purposes, and for other practical and modeling purposes. Embodiments include systems, apparatus, and processes for making a single container that interlocks with other modular containers of the same or different sizes. Each modular container slides and locks with other containers to form a solid wall and building structure that can be filled with liquid (such as water, natural soil, sand or other natural or processed materials), thereby forming a strong structure without the need for mortar and can adapt to uneven base surfaces commonly found in natural terrain.

[0040] Reference now Figure 1 The exemplary expandable modular interconnected container 10 is a hollow or partially hollow element that can be made of plastic, metal, resin or composite material. For example, in some embodiments, the container is made of PE, PET and / or other thermoplastic materials. Alternatively, the container 10 can be made of any rigid material that has a suitable high strength and can provide sufficient rigidity for stacking and connecting. The container 10 includes a plurality of upright walls 12. Figure 1In the exemplary embodiment of the container 10, the container 10 is shown as having eight longitudinal walls 12 of equal or different heights, and the eight longitudinal walls 12 form a latitudinal cross-section that is generally octagonal. In other embodiments, the container 10 can be formed with a latitudinal cross-section of a different shape (e.g., circular, oval, polygonal, triangular, square, rectangular, or hexagonal). In any case, the container 10 can be configured to contain liquids, solids, and / or gases, and can also be configured to be used as a modeling or building element with or without any contents.

[0041] As shown, the container 10 includes a top section 14, which includes a neck 16 terminating in a hole 18 for filling the container 10 with any gas, fluid, granules, flakes or other materials. In one embodiment, the container 10 can be manufactured with an airtight or pressure-resistant seal or lid (not shown). The neck 16 is configured to be connected to the lid by threads 20 provided on the neck 16 to seal the contents within the container 10. Alternatively, the neck 16 can be configured to be connected to the lid by a snap-fit ​​mechanism or other suitable type of connection to form a suitable seal to prevent the contents of the container 10 from leaking out and / or to prevent foreign matter from entering the container 10. By forming a suitable seal between the neck 16 and the lid, the container 10 can be made liquid-tight to contain and transport liquids (e.g., water, juice, cooking oil), or can form a suitable seal for granular or powdered items (e.g., grains, seeds, flour, flakes), household materials (e.g., soap, detergents) or building materials (e.g., cement, grout, sand). As shown, the ring 22 is formed near the base of the neck 16 and may provide a seat for a tamper-indicating ring (not shown) which may be positioned between the base of the neck 16 and the threads 20 as desired.

[0042] The illustrated container 10 includes a bottom end section 24 including vertically interconnected receptacles 25 ( Figure 4 ), the receiver 25 has a cross-sectional dimension designed to receive the closure cap and ring 22 from a similar second container 10. The receiver 25 can have a limiting edge having a cross-sectional dimension designed to engage with the ring 22 during vertical interconnection with the similar second container 10 to provide a stop therewith.

[0043] In the illustrated embodiment, the container 10 provides a mechanism for lateral connection with other containers 10 in a slidable interlocking manner. For example, the lateral connection of multiple containers 10 can be achieved by tongues 26 and grooves 28 distributed laterally in multiple positions on or inside the wall 12 of the container 10. In this regard, each tongue 26 is configured as a convex, flat and / or slightly rounded protrusion formed on or inside the corresponding wall 12. Each groove 28 is recessed in the corresponding wall 12 and is configured to receive the corresponding tongue 26 from the second container 10 with similar connection features. In one embodiment, the tongue 26 and the groove 28 are formed along the wall 12 in an orientation substantially perpendicular to the top and bottom sections 14, 24. As shown, the tongue 26 and the groove 28 can be positioned at alternating positions around the container 10, wherein the tongue 26 is positioned on each alternating wall 12 and the groove 28 is positioned on each wall 12 therebetween. Alternatively, one or more tongues 26 can be formed on one or more of the walls 12, and one or more grooves 28 can be formed on the remaining walls 12. In other embodiments, the container 10 may have only grooves 28 on its respective sidewalls, while other containers 10 may have only tongues 26 formed in its respective sidewalls 12. Regardless of the dispensing mode, the separate containers 10 may interlock with each other via the tongues 26 and grooves 28.

[0044] To this end, an interlocking mechanism is provided using an undercut 30 of each tongue 26 that can be received into a corresponding extended cutout 32 of each groove of a similar second container 10. Together with their respective tongues 26 and / or grooves 28, the undercuts 30 and / or extended cutouts 32 can be referred to as "dovetails". The undercuts 30 are formed so that each tongue 26 abuts against a corresponding wall 12, the base of the tongue 26 being narrower than the width of the tongue 26 at its outermost portion. Similarly, the width of each groove 28 including a corresponding extended cutout 32 is greater than the width of each groove 28 not including a corresponding extended cutout 32, so that when two containers 10 are connected by sliding the tongue 26 longitudinally into the corresponding groove 28, the width of the outer edge of the tongue 26 is laterally locked behind each corresponding extended cutout 32. It should be understood that each container 10 may include any number of tongues 26 and / or grooves 28 to interconnect as desired. In one embodiment, the construction of the container, including any tongue 26, groove 28, undercut 30, and / or expanded cutout 32, may be similar to those described in the '210 application.

[0045] Reference now Figure 2, a preform 34 can be used to form the container 10. The preform 34 can be similar to the preform described in the '210 application. For example, the preform 34 can be formed into a closed-end cylindrical article by injection blow molding in a preforming mold cavity (not shown), and its shape is generally similar to a test tube. As shown, the preform 34 is initially formed with the neck 16, opening 18, threads 20 and ring 22 of the final container 10, and a generally cylindrical body 36. As described in more detail below, during the stretch blow molding process, the cylindrical body 36 can expand to conform to the inner wall of the mold, while the neck 16 can remain substantially the same in shape, size and configuration. In the illustrated embodiment, the cylindrical body 36 terminates in a closed end 38, and the closed end 38 includes a protruding tip 40, which is an artifact of the injection molding process. The thickness of the cylindrical body 36 and / or the closed end 38 can vary due to design or design factors. For example, closed end portion 38 may have a greater thickness than the thickness of cylindrical body 36 to facilitate flow of plastic into the lower portion of the mold, as described in more detail below.

[0046] In any case, ISBM techniques (e.g., hot parison techniques) may be employed with the preform 34, wherein the preform 34 is immediately transferred to a conditioning station after molding, where the latent heat within the preform 34 obtained during the injection molding process may be utilized and fine-tuned for use in the ISBM operation to produce the container 10. In this regard, the heat distribution in the hot closed-end preform 34 may significantly affect the wall thickness and plastic flow of the final blow molded container 10. Thus, non-uniform temperatures of the preform 34 may result in defects in the final blow molded container 10. For example, such irregularities may result in an undesirably thin wall of a portion of the container 10 and / or an inability of the material to properly flow into the mold due to cooling and hardening of the material. This may be particularly problematic for molds having complex geometries, such as deep and / or narrow cracks into which material needs to flow in order to form features such as the dovetail of the container 10.

[0047] Continue to refer Figure 2In one embodiment, an exemplary conditioning or heating station 42 for heating the exterior surface of a preform 34 is provided that overcomes certain problems or disadvantages of conventional preform heating stations, particularly when used to manufacture articles having complex geometries, such as the dovetails of an interlocking container 10. For example, it will be appreciated that conventional preform heating stations are generally unable to heat the exterior of a preform 34 to a sufficiently high temperature required to blow the preform 34 into a mold having complex geometry to form features such as the dovetails of a container 10. Conventional preform heating stations also are unable to accurately measure heat and are unable to accurately regulate the amount of heat transferred from the heating station to the exterior of the preform 34. Additionally, conventional preform heating stations are unable to uniformly heat the exterior of the preform 34 and are unable to direct heat to specific areas of the exterior of the preform 34 where more material flow is desired in the next stage of the blow molding process.

[0048] The exemplary heating station 42 is capable of addressing challenges that exist when making a container 10 with a dovetail and that are not typically present when making conventional articles, such as conventional containers. In this regard, the container 10 may be particularly sensitive to heating temperatures, and it may be desirable to provide very high heat to the exterior of the preform 34 during the preform heating phase in order to allow material to flow into the dovetail and / or vertical interconnect receiver 25. The difference in wall thickness from one side of the container 10 to the other may affect the strength of the dovetail connection and thus significantly affect the function. The difference in wall thickness from the top of the container 10 to the bottom of the container 10 may affect the strength of the container 10 and thus affect the stability of the container 10. For example, a weakness in wall thickness may result in blowout during blow molding. The features and characteristics of the container 10 vary significantly from top to bottom and from side to side, for example, due to the dovetail and vertical receiver.

[0049] The exemplary heating station 42 is configured to heat the exterior of the preform 34 in preparation for blow molding. More specifically, the heating station 42 includes a manifold 44 defining a heating chamber 46 for receiving the preform 34 and a heater 48 in thermal communication with the heating chamber 46 and configured to heat a suitable gas, such as air. In one embodiment, the heating station 42 may also include a transport device 49 configured to securely clamp the neck 16 of the preform 34 outside the heating chamber 46 while the cylindrical body 36 of the preform 34 is positioned within the heating chamber 46. In this regard, the transport device 49 includes first and second arms 50, 52, each arm having a groove or thread 53 for mating with the thread 20 of the neck 16 when the neck 16 is clamped between the first and second arms 50, 52. As shown, the first and second arms 50, 52 are carried by first and second supports 54, 56, respectively. As discussed in more detail below, the arms 50, 52 and / or the supports 54, 56 may be movable to grip, release, and / or transport the preform 34 between the heating station 42 and other stations to perform the blow molding process. A core rod 57 may extend downward from the transport device 49 into the interior of the preform 34 to support the preform 34. In one embodiment, the core rod 57 may help heat the preform 34 and / or maintain the temperature of the preform 34. For example, the core rod 57 may be heated to approximately 60° C. In one embodiment, the core rod 57 may be inserted into the preform 34 only during a portion of the time period during which the preform 34 is conditioned at the preform heating station 42. For example, the core rod 57 may be inserted into the preform 34 for approximately 3 seconds, while the cylindrical body 36 of the preform 34 may be positioned within the heating chamber 46 for approximately 10 seconds.

[0050] The heating station 42 also includes a blower 58, which is configured to force the gas heated by the heater 48 into the heating chamber 46 as shown by the arrow A1, and to the outside of the preform 34. Therefore, unlike conventional heating or conditioning stations that generally utilize radiant heat, the heating station 42 uses forced hot air to heat the outside of the preform 34 in the heating chamber 46. By forcing the hot air to reach the outside of the preform 34, the exemplary heating station 42 allows the outside of the preform 34 to be heated faster and more thoroughly than conventional radiant heating methods. The heating station 42 can also provide the ability to heat the outside of the preform 34 to a higher temperature in a shorter time than conventional radiant heating methods. In one embodiment, the temperature of the hot air in the heating chamber 46 and at or near the outside of the preform 34 can be between about 200°C and about 600°C. For example, the temperature of the hot air can be between about 285°C and about 315°C. In one embodiment, the temperature of the hot air can be about 300°C. Additionally or alternatively, the heating station 42 can be configured to expose the preform 34 to hot forced air for approximately 10 seconds. The 10 second period can be substantially the entire period that the cylindrical body 36 of the preform 34 is within the heating chamber 46. In one embodiment, the pressure of the hot air blown to the exterior of the preform 34 can be approximately 20 PSI. A portion of the hot air may escape between the neck 16 of the preform 34 and the arms 50, 52.

[0051] In one embodiment, the exemplary heating station 42 can be configured to direct forced hot air to specific points on the exterior of the preform 34, which is different from conventional heating stations in which radiant heat cannot be directed to specific areas where increased heating may be required to allow effective blowing. In this regard, temperature differences in the mold wall may undesirably cause certain parts of the blown preform to cool before other parts unless offset by increasing the heating of the preform 34 at the corresponding position. Similarly, the dovetail formed when blowing the preform 34 cools faster due to the fact that it may protrude beyond the inner wall of the mold and engage with the relatively thin outer wall of the mold. In some embodiments, the closed end 38 of the preform 34 may need to flow farther than the cylindrical body 36 of the preform 34 in order to flow into the dovetail at the bottom of the mold, but may cool before filling the dovetail due to contact with the bottom wall of the mold. Therefore, it may be desirable to direct heat to specific areas on the exterior of the preform 34 to prevent these areas in the mold from cooling prematurely and to maintain the preform 34 in a properly temperature-regulated plasticized state before stretch blow molding.

[0052] To this end, the illustrated heating station 42 includes a nozzle 60 that includes a cylindrical sidewall or housing 62 and is positioned within the heating chamber 46 to at least partially surround the preform 34. The nozzle 60 provides targeted heating of a specific area on the exterior of the preform 34. In this regard, the sidewall 62 of the nozzle 60 includes a plurality of holes (such as boreholes 64) for guiding gas therethrough. For example, hot forced air can be directed through the boreholes 64 in the sidewall 62 by the blower 58 to a predetermined area or portion of the exterior of the preform 34 where increased heating is desired. In one embodiment, the borehole 64 has a cross-sectional dimension (such as a diameter) between about 0.200 inches and about 0.205 inches. Although a generally circular hole 64 is shown, the holes of other embodiments may include slots, bends, funnels, or any suitable type and / or hole shape that can direct forced hot air to a specific or target area of ​​the exterior of the preform 34 located within the heating chamber 46. The nozzle 60 may partially or completely surround the preform 34 in the heating chamber 46 and may direct the hot air to a portion of the preform 34 located at any desired location on the exterior of the preform 34. Additionally or alternatively, the bore 64 may be adjustable, for example, in position, cross-sectional size, and / or shape. For example, the bore 64 may be opened and closed, moved, or redirected to direct the hot air to an area on the exterior of the preform 34 that requires more heat and / or to direct the hot air away from an area on the exterior of the preform 34 that requires less heat to achieve the desired flow results in the next blow molding stage.

[0053] In one embodiment, the bores 64 are arranged in a uniform pattern on the sidewall 62 of the nozzle 60 to provide uniform heat distribution around the nozzle 60. The bores 64 can be arranged in a pattern that minimizes the total temperature difference and maximizes uniformity. In this regard, the pattern of the bores 64 can be different from the pattern shown in order to cause the forced air flow to move in a manner that eliminates any temperature gradients. In another embodiment, the bores 64 can be arranged to provide different heat applications around the circumference of the nozzle. The specific locations of the bores 64 can correspond to the locations of various geometric features (such as dovetails) on the blown container 10.

[0054] The nozzle 60 can be configured to provide a gap between the preform 34 and the sidewall 62 of the nozzle 60 when the preform 34 is inserted into the heating chamber 46 and at least partially surrounded by the nozzle 60. For example, the outer diameter of the cylindrical body 36 of the preform 34 can be approximately 24 mm, and the inner diameter of the cylindrical sidewall 62 of the nozzle 60 can be approximately 34.5 mm, thereby providing a gap of approximately 5.25 mm between the preform 34 and the sidewall 62.

[0055] Thus, the heating station 42 can precisely direct more heat to areas on the outside of the preform 34 that require additional flow during the next blowing stage of the blow molding process, and precisely avoid heating those areas on the outside of the preform 34 that do not require additional flow during the next blowing stage of the blow molding process.

[0056] It should be understood that the container 10 and / or the preform 34 may need to be heated to a significantly higher temperature than a conventional container. In some embodiments, the temperature required for the blow molding process may reach the temperature limit to which the preform 34 can be heated without beginning to melt or otherwise deform. For example, the temperature of the hot air forced to the outside of the preform 34 may approach the melting temperature of the material of the preform 34. Such deformation may prevent the container 10 from being properly blown. Therefore, it may be desirable to be able to accurately raise the temperature of the air blown on the outside of the preform 34 in very small increments to a degree that achieves the desired material flow during the blow molding process without the preform 34 deforming.

[0057] To this end, the heating station 42 can be configured to accurately regulate and measure the temperature of the hot air forced onto the exterior of the preform 34. In this regard, the heating station 42 includes a temperature controller 66 in communication with the heater 48 and a thermometer 68 in communication with the temperature controller 66. The temperature controller 66 is configured to regulate the output of the heater 48, thereby regulating the temperature of the air forced onto the exterior of the preform 34, and the thermometer 68 is configured to measure the temperature of the hot air blown onto the exterior of the preform 34. For example, the thermometer 68 can be positioned in the heating chamber 46 near the exterior of the preform 34 to accurately measure the temperature of the air blown thereon. In one embodiment, the thermometer 68 can be positioned within the nozzle 60. In any case, the thermometer 68 can be configured to send a signal indicating the temperature measurement to the temperature controller 66, which can use the signal to determine the appropriate output of the heater 48 and adjust the output of the heater 48 accordingly. In this manner, the temperature controller 66 and the thermometer 68 may provide accurate measurement of the temperature of the air blown onto the exterior of the preform 34 , as well as accurate regulation of the temperature of the air blown onto targeted or specific areas of the exterior of the preform 34 .

[0058] Now turn to Figure 3-9In one embodiment, an exemplary blow molding station 70 for molding an article (e.g., container 10) from a preform 34 is provided, the blow molding station 70 overcoming various problems and / or disadvantages of conventional blow molding stations. As discussed in more detail below, the blow molding station 70 is configured to mold the preform 34 into the final shape of the container 10 including the dovetail. The blow molding station 70 is capable of addressing various challenges that exist in the manufacture of the container 10, but are not typically present in the manufacture of conventional articles (e.g., conventional containers). In this regard, conventional articles such as conventional containers are typically removed from a mold in an injection stretch blow molding machine by a clamshell opening process. The container 10 may not be suitable for removal from a mold by a clamshell opening process, for example, due to the undercut 30 and extended cut 32 of the dovetail. In one embodiment, the exemplary blow molding station 70 is capable of removing various interlocking articles including undercuts 30 and extended cuts 32 on the tongue 26 and groove 28 that are deeper than those described in the '210 application.

[0059] In one embodiment, the exemplary blow molding station 70 can be used in conjunction with the exemplary heating station 42 so that during the blow molding process, the material flows better into the deeper cracks of the dovetail. For example, the heating station 42 can be configured as a separate device that can be adjusted to be attached to the blow molding station 70 and operably integrated with the blow molding station 70. In other words, the heating station 42 can be operationally synchronized with the process of the blow molding station 70 so as to heat the preform 34 before the preform 34 is automatically moved to the blow molding station 70 for blow molding. For example, this modularity can enable an existing blow molding station 70 to be upgraded.

[0060] It should be understood that various challenges and difficulties may exist during the demolding process, such as when manufacturing the container 10 after subjecting the associated preform 34 to the exemplary preform heating station 42. For example, because the heating process at the preform heating station 42 successfully helps the material flow into and / or around the dovetail portion during the blowing step, when the mold is lowered to remove the container 10 after the blowing stage, the container may be more firmly "grabbed" by at least a portion of the mold due to the static friction between the container 10 and the mold. As a result, the container 10 may be undesirably deformed or damaged when it is removed from the mold. Such deformation may include an area on or around the neck 16 of the container 10 that is stretched because the neck 16 is firmly held in place when the wall 12 of the container 10 is pulled downward by the exiting mold or mold portion (due to the static friction between them). The resulting tension may stretch the neck 16, making the container 10 unusable and / or tearing the container 10 into separate pieces. As described below, the exemplary blow molding station 70 can be configured to address one or more of these issues.

[0061] In the illustrated embodiment, the blow molding station 70 includes a hinged mold 72 having a plurality of mold sections that are configured to move when arranged in respective molding positions ( Figure 3 ) together define a mold cavity 74 for molding the preform 34 into a finished product (such as a container 10). More specifically, the illustrated hinge mold 72 includes a bottom mold portion 76, a generally cup-shaped side mold portion 78, and first and second top mold portions 80, 82. The hinge mold 72 has a longitudinal axis L, and the bottom mold portion 76, the side mold portion 78, and the top mold portions 80, 82 are distributed along the longitudinal axis L. In the illustrated embodiment, the side mold portion 78 includes at least one dovetail 84, which includes a tongue or groove extending in a direction parallel to the axis L for forming a corresponding dovetail on the container 10.

[0062] As shown, the bottom mold portion 76 is mounted at its bottom end to a bottom mold platform 86 having a pair of holes 88 extending therethrough, the purpose of which is discussed below. The side mold portion 78 is mounted at its bottom end to a side mold platform 90 having a generally centrally located hole 92 through which the bottom mold portion 76 extends. In the illustrated embodiment, the side mold platform 90 itself may provide a molding surface for the container 10. The first and second top mold portions 80, 82 are mounted at their outer sides to first and second top mold platforms 94, 96, respectively. In some embodiments, any of the mold portions 76, 78, 80, 82 may be integrally formed as a unitary piece with their respective platforms 86, 90, 94, 96.

[0063] In the blow molding station 70 shown, the conveyor 49 previously described with respect to the heating station 42 is configured to firmly clamp the neck 16 of the preform 34 outside the molding cavity 74 while the cylindrical body 36 of the preform 34 is positioned within the molding cavity 74. In this regard, the conveyor 49 can be configured to move (e.g., rotate and / or translate) from the heating station 42 to the blow molding station 70 so as to automatically transport the preform 34 from the heating cavity 46 to the molding cavity 74. In this way, the heating station 42 can be integrated with the blow molding station 70. In another embodiment, the blow molding station 70 can include a dedicated conveyor (not shown).

[0064] In any case, the blow molding station 70 also includes a compressed gas conduit 98 and a nozzle 100, which is configured to extend at least partially into the neck 16 of the preform 34 for blowing a compressed gas (such as air) as shown by arrow A2 ( Figure 4) is guided into the preform 34 to blow mold the preform 34 into the final shape of the container 10. A stretch rod 102 terminating in a stretch rod tip 104 extends through the conduit 98 and the nozzle 100 and is configured to lower the stretch rod tip 104 into the preform 34 so as to stretch the preform 34 into the molding cavity 74. In one embodiment. The preform 34 can be stretched into the molding cavity 74 by the stretch rod 102 and / or the stretch rod tip 104 until the bottom mold portion 76 (wherein the protruding tip 40 can interact with the bottom mold portion 76 to help center the preform 34 in the molding cavity 74), and can be subjected to compressed gas guided to the interior of the preform 34 through the compressed gas conduit 98 and the nozzle 100. For example, the pressure of the gas introduced into the interior of the preform 34 can be about 585PSI. In one embodiment, stretching the preform 34 by the stretch rod 102 and / or the stretch rod tip 104 and blowing the preform 34 by the compressed gas may occur substantially simultaneously.

[0065] After blow molding the container 10, the exemplary blow molding station 70 is configured to provide effective and efficient demolding of the finished container 10 with minimal risk of damaging the container 10 including the neck 16 and the dovetail (which includes the tongue 26 and the groove 28). In the illustrated embodiment, each of the mold portions 76, 78, 80, 82 and the arms 50, 52 is independently movable. More specifically, the bottom and side mold portions 76, 78 are independently movable along the axis L, and the top mold portions 80, 82 and the arms 50, 52 are independently movable radially relative to the axis L. In this regard, the blow molding station 70 includes a plurality of actuators (e.g., hydraulic actuators 110), each of which is operably coupled to a corresponding mold portion 76, 78, 80, 82 or arm 50, 52. Each illustrated actuator 110 includes a cylinder 112 and a piston 114 that can be extended from and / or retracted into the respective cylinder 112 and is coupled at its distal end to one of the platforms 86, 90, 94, 96 or arms 50, 52. In the illustrated embodiment, the piston 114 coupled to the side mold platform 90 extends through the hole 88 of the bottom mold platform 86 to reach the side mold platform 90. Although a hydraulic actuator 110 is illustrated, it should be understood that any suitable actuator (e.g., a pneumatic actuator or a translating screw actuator) may be used.

[0066] The blow molding station 70 includes a controller 120 that is in communication with each of the actuators 110 and is configured to independently activate each of the actuators to retract the corresponding mold portion 76, 78, 80, 82 and arms 50, 52 during the demolding process, and more specifically, to independently "pull down" the bottom and side portions 76, 78 during the demolding process. In this regard, the controller 120 can be configured to sequentially activate the actuators 110 of each of the platforms 86, 90, 94, 96 and / or supports 54, 56. For example, the controller 120 can initially activate the actuator 110 of the side mold portion 78 to retract the corresponding piston 114 to move the side mold portion 78 downwardly from the corresponding molding position toward the corresponding ejection position along the axis L, as shown by arrow A3 ( Figure 5 ). As the side mold portion 78 moves toward the corresponding ejection position, the inner surface of the hole 92 of the side mold platform 90 can traverse along the outer surface of the bottom mold portion 76. The controller 120 can then activate the actuator 110 of the bottom mold portion 76 to retract the corresponding piston 114 to move the bottom mold portion 76 downward from the corresponding molding position toward the corresponding ejection position along the axis L ( Figure 6 ). In the illustrated embodiment, the controller 120 is configured to activate the actuator 110 of the bottom mold portion 76 when the side mold platform 90 contacts or is about to contact the bottom mold platform 86. In this manner, when the side mold platform 90 reaches the bottom mold platform 86, the bottom and side mold portions 76, 78 can move together toward the corresponding ejection position, as shown by arrow A4. Alternatively, the bottom mold portion 76 can begin to move toward the corresponding ejection position substantially immediately after the side mold portion 78 begins to move and overcome the static friction with the container 10.

[0067] Thus, the bottom mold portion 76 can provide support for the blow molded container 10 for at least a predetermined amount of time until the static friction between the container 10 and the side mold portions 78 is overcome. Once the static friction is overcome and the side mold portions 78 move downward, any friction between the container 10 and the side mold portions 78 is dynamic. This dynamic friction can be lower than the static friction previously present between the container 10 and the side mold portions 78. More specifically, the dynamic friction can be low enough that the bottom mold portion 76 can move downward without stretching the container 10 beyond normal limits associated with damage or rupture.

[0068] In other words, after the static friction between the container 10 and the side mold portions 78 is overcome, the dynamic friction between the container 10 and the moving side mold portions 78 may not be sufficient to deform or break the container 10. The support from the bottom mold portion 76 can help prevent the container 10 from stretching beyond its limit and / or being split during the demolding process. In this way, the side mold portions 78 can begin the demolding process before the lower mold portion 76 is pulled downward.

[0069] With the bottom and side mold sections 76, 78 moving toward or in their respective ejection positions, the top mold sections 80, 82 may be moved laterally away from the axis L in opposite directions via the controller 120 and respective actuators 110, as indicated by arrows A5 ( Figure 7 Similarly, the first arm 50 and the second arm 52 can be moved laterally away from the axis L in opposite directions via the controller 120 and the corresponding actuator 110, as shown by arrow A6, to release the container 10 and allow the container 10 to fall, as shown by arrow A7 ( Figure 8 In the illustrated embodiment, the container 10 falls onto the collection ramp 122, as indicated by arrow A8 ( Fig. 9 ), the collection ramp 122 can guide the container 10 to a collection box (not shown). When the container 10 has left the blow molding station 70, the controller 120 can be configured to activate the actuator 110 to extend the corresponding piston 114 to move the corresponding mold part 76, 78, 80, 82 in the direction opposite to the above direction, so that each of the mold parts 76, 78, 80, 82 returns to their respective molding positions. For example, the controller 120 can simultaneously activate the actuators 110 of the mold parts 76, 78, 80, 82 to return each of the mold parts 76, 78, 80, 82 to their respective molding positions to perform subsequent molding operations.

[0070] In one embodiment, the actuator 110 and / or controller 120 allow for multiple, sequential, coordinated, and / or timed movements of the bottom and side mold portions 76, 78 along the axis L to enable the bottom and side mold portions 76, 78 to be pulled downward sequentially, in tandem, and / or carefully. Such coordination may allow the container 10 to be removed without deforming or breaking the container 10 due to excessive friction or other strong lateral connections caused by such deep blown undercuts 30 and / or expanded cuts 32, even when configured.

[0071] The controller 120 may be configured with timing software and / or hardware for coordinating the activation of the various actuators 110. For example, the controller 120 may include software instructions and a microprocessor (not shown) for executing the instructions to operate and / or synchronize the actuators 110. In one embodiment, the controller 120 may be configured to synchronize the actuators 110 with other components and / or processes of the blow molding station 70 or the blow molding process to achieve fast and efficient production.

[0072] For example, there is a limited amount of time between different blow molding process stages. Therefore, the sequential "pulling" of the various mold sections 76, 78, 80, 82 must be completed within the time window allocated for the pull phase of the blow molding machine process. Coordinating and timing the activation of the actuators 110 to effectively move the corresponding mold sections 76, 78, 80, 82 toward the discharge position within this window can allow the use of the minimum amount of time required to sequentially overcome static friction forces, which then minimizes the overall cycle time, thereby reducing the manufacturing cost of each container 10 and increasing productivity.

[0073] In one embodiment, where the preform heating station 42 and the blow molding station 70 are integrated with a preform forming (e.g., injection molding) station (not shown) for initially forming the preform 34, the conveyor 49 can convey the formed preform 42 from the preform forming station to the preform heating station 42 and position the cylindrical body 36 of the preform 34 in the heating cavity 46. The core rod 57 can be lowered into the preform 34 substantially simultaneously. The cylindrical body 36 of the preform 34 can remain in the heating cavity 46 for about 10 seconds. Hot air can be directed to the exterior of the preform 34 for substantially the entire 10 seconds, wherein the temperature of the hot air is between about 285° C. and about 310° C., and the pressurization of the hot air is about 20 PSI. The conveyor 49 can then convey the conditioned preform 34 to the blow molding station 70 and position the cylindrical body 36 of the preform 34 in the molding cavity 74. The stretch rod 102 may be lowered to stretch the preform 34 to the bottom mold portion 76, and pressurized air at approximately 585 PSI may be introduced into the interior of the preform 34 through the compressed gas nozzle 100 to blow mold the preform 34 into a final container 10. The container 10 may then be demolded and deposited on a collection ramp 122.

[0074] In one embodiment, the preform forming station, the preform heating station 42, and the blow molding station 70 can be angularly displaced from each other by about 120 degrees (angularly separated by 120 degrees). Therefore, the conveyor 49 can be configured to rotate between the stations at intervals of 120 degrees. In one embodiment, the preform 34 and / or container 10 can be present at each station for about 16.8 seconds. Therefore, the total cycle time for forming, conditioning, blowing into the final container 10, and depositing the preform 34 can be about 50.4 seconds.

[0075] Reference now Figure 10-12 , an alternative exemplary blow molding station 70' is provided. The blow molding station 70' of this embodiment is substantially similar to the blow molding station of the previous embodiment, with the primary difference being that the side mold portion is divided into three horizontal segments 78a, 78b, 78c, which are independently movable along the axis L by actuators and controllers (not shown) similar to those previously described. In this regard, the lowermost horizontal segment 78a can be mounted to the side mold platform 90, while the remaining horizontal segments 78b, 78c can be mounted to separate platforms (not shown) or directly coupled to their respective actuators. In any case, the horizontal segments 78a, 78b, 78c can collectively define at least one dovetail, which includes a tongue or groove (not shown) extending in a direction parallel to the axis L and is used to form a corresponding dovetail on the container 10.

[0076] Thus, in the illustrated embodiment, the side mold portion is divided into horizontal segments 78a, 78b, 78c arranged in a stacked arrangement along axis L. In one embodiment, the segments 78a, 78b, 78c may be connected together, such as using a connecting mechanism or mechanical fasteners (not shown) when in respective molding positions. Although three such segments 78a, 78b, 78c are shown, any suitable number may be used. For example, the number of individual horizontal segments 78a, 78b, 78c may be selected based on the amount of static friction that must be overcome during demolding and the number of segments required to overcome the static friction in a manner sufficient to avoid deformation or damage to the container 10.

[0077] In one embodiment, the controller may be configured with a timed stroke sequence during the demolding process in which the horizontal segments 78a, 78b, 78c of the side mold portion are pulled downward in sequence (starting from the lowest horizontal segment 78a to the highest horizontal segment 78c). For example, each horizontal segment 78a, 78b, 78c may remain stationary until the next lowest horizontal segment is pulled downward. In this manner, the static upper horizontal segments 78b, 78c may provide short-term support for the container 10 at least until the static friction between the lower horizontal segment 78a and the container 10 is overcome. Once the static friction between the container 10 and the lower horizontal segment 78a is overcome, the lower horizontal segment 78a is caused to move downward (as indicated by arrow A9 ( Fig.10), the reduced dynamic friction between the moving horizontal segment 78a and the container 10 is low enough to allow the next highest horizontal segment 78b to move downward without stretching the container 10. As the lower horizontal segments 78a, 78b move downward, the upper horizontal segment 78c can help support the container 10, thereby allowing the overall friction on the container 10 to be reduced by a factor corresponding to the number of horizontal segments 78a, 78b, 78c. In the illustrated embodiment with three horizontal segments 78a, 78b, 78c, the initial friction that exists between the first moving (e.g., lowest) horizontal segment 78a and the container 10 can be only about one-third of the friction that exists between the container 10 and the entire side mold portion 78.

[0078] Once the static friction on the lower horizontal sections 78a, 78b is overcome, the remaining dynamic friction caused by the lower moving horizontal sections 78a, 78b is reduced so that the container 10 will not be deformed or damaged by the demolding process. After the static friction on each horizontal section is overcome, the horizontal sections 78a, 78b, 78c can be moved downward one by one (as shown by arrow A10 ( Fig.11 ), the remaining dynamic friction on the horizontal sections 78a, 78b, 78c that move downward to release the container 10 may not be sufficient to deform or break the container 10. Therefore, the exemplary blow molding station 70' can prevent the container 10 from being stretched and / or torn into separate pieces during the demolding process.

[0079] In the illustrated embodiment, the bottom mold portion 76 can be independently moved in a manner similar to the previous embodiment. Thus, the controller can be configured to pull the bottom mold portion 76 downward (as indicated by arrow A11 ( )) after the side mold portions (e.g., each of the horizontal sections 78a, 78b, 78c) have been at least partially pulled downward in a manner similar to the previous embodiment. Fig.12 ) to support the container 10 during demolding. In another embodiment, the controller can be configured to pull the bottom mold portion 76 downward simultaneously with one or more of the horizontal sections 78a, 78b, 78c of the side mold portions. For example, the controller can be configured to pull the bottom mold portion 76 simultaneously with the lowermost horizontal section 78a of the side mold portions. In one embodiment, the bottom mold portion 76 can be integrally formed as a unitary piece with the lowermost horizontal section 78a of the side mold portions.

[0080] The remaining features and benefits of the blow molding station 70 ′ are substantially similar to those of the blow molding station 70 and will be readily understood, and therefore will not be repeated for the sake of brevity.

[0081] Reference now Figure 13-15, an alternative exemplary blow molding station 70" is provided. The blow molding station 70" of this embodiment is substantially similar to the blow molding station of the aforementioned embodiment, with the primary difference being that the side mold portion is divided into four vertical segments 78e, 78f, 78g (three shown), which can be independently moved in a direction parallel to the axis L by actuators and controllers (not shown) similar to those previously described. In this regard, each of the vertical segments 78e, 78f, 78g can be mounted on a corresponding dedicated platform 90a, 90b, 90c. At least one of the vertical segments 78e, 78f, 78g can define at least one dovetail, which includes a tongue or groove (not shown) extending in a direction parallel to the axis L and is used to form a corresponding dovetail on the container 10.

[0082] Thus, in the illustrated embodiment, the side mold portions are divided into vertical segments 78e, 78f, 78g arranged side by side about the axis L. In one embodiment, the segments 78e, 78f, 78g may be connected together, for example, using a connection mechanism or mechanical fasteners (not shown) when in respective molding positions. Although there are four such segments 78e, 78f, 78g in the illustrated embodiment, any suitable number may be used. For example, the number of individual vertical segments 78e, 78f, 78g may be selected based on the amount of static friction that must be overcome during demolding and the number of segments required to overcome the static friction in a manner sufficient to avoid deformation or damage to the container 10.

[0083] In one embodiment, the controller can be configured with a timed stroke sequence during the demolding process in which the vertical segments 78e, 78f, 78g of the side mold portion are pulled downward in sequence, starting with one or more vertical segments 78e, 78f, 78g and continuing with the remaining vertical segments 78e, 78f, 78g in sequence. In this way, the static vertical segments 78e, 78f, 78g can provide short-term support for the container 10 at least until the static friction force is overcome by the moving vertical segments 78e, 78f, 78g. Once the static friction force on at least one vertical segment 78e is overcome, the at least one vertical segment 78e, 78f, 78g is moved downward (as shown by arrow A12 ( Fig.13), the reduced dynamic friction between the moving vertical section 78e and the container 10 is low enough that one or more of the other vertical sections 78f, 78g can move downward without stretching the container 10. The static vertical sections 78e, 78f, 78g can help support the container as the other vertical sections 78e, 78f, 78g move downward, thereby allowing the overall friction on the container 10 to be reduced to a factor corresponding to the number of vertical sections 78e, 78f, 78g. In the illustrated embodiment having four vertical sections 78e, 78f, 78g, the initial friction existing between the first moving vertical section 78e and the container 10 can be about one-fourth of the friction existing between the container 10 and the entire side mold portion 78.

[0084] Once the static friction on the first vertical segment 78e is overcome, the remaining dynamic friction caused by moving the vertical segment 78e is reduced so that the container 10 will not be deformed or damaged by the demolding process. After the static friction on each vertical segment is overcome, the vertical segments 78e, 78f, 78g can be moved downward one by one (as shown by arrow A13 ( Fig.14 ), the residual dynamic friction on the vertical sections 78e, 78f, 78g that move downward to release the container may not be sufficient to deform or break the container 10. Therefore, the exemplary blow molding station 70" can prevent the container 10 from being stretched and / or torn into separate pieces during the demolding process.

[0085] In the illustrated embodiment, the bottom mold portion 76 can be independently moved in a manner similar to the previous embodiment. Thus, the controller can be configured to pull the bottom mold portion 76 downward (as indicated by arrow A14 ( )) after the side mold portions (e.g., each of the vertical sections 78e, 78f, 78g) have been at least partially pulled downward in a manner similar to the previous embodiment. Fig.15 ) to support the container 10 during demolding. In another embodiment, the controller can be configured to pull the bottom mold portion 76 downward simultaneously with one or more of the vertical sections 78e, 78f, 78g of the side mold portions. In one embodiment, the bottom mold portion 76 can be integrally formed as a unitary piece with the vertical sections 78e, 78f, 78g of the side mold portions.

[0086] The remaining features and benefits of the blow molding station 70 ″ are substantially similar to those of the blow molding station 70 and will be readily understood, and therefore will not be repeated for the sake of brevity.

[0087] Although the present invention has been illustrated by the description of various embodiments of the present invention, and although the embodiments have been described in considerable detail, it is not intended that the scope of the appended claims be limited or in any way restricted to these details. Therefore, the various features discussed herein may be used alone or in any combination. Other advantages and modifications will be apparent to those skilled in the art. Therefore, the present invention in its broader aspects is not limited to the specific details and illustrative examples shown and described. Therefore, these details may be deviated from without departing from the scope of the general concept of the present invention.

[0088] To further illustrate the molding systems and related methods disclosed herein, the following non-limiting examples are provided:

[0089] Example 1 is a system for conditioning a preform for molding, comprising:

[0090] a heating chamber for receiving the preform;

[0091] a heater configured to heat the gas; and

[0092] A blower is configured to force the gas heated by the heater into the heating chamber and onto the outer surface of the preform.

[0093] In Example 2, the system of Example 1 further includes a nozzle including at least one sidewall and positioned within the heating chamber for at least partially surrounding the preform.

[0094] In Example 3, according to the system of Example 2, the at least one side wall includes at least one hole for directing gas therethrough.

[0095] In Example 4, according to the system of Example 3, the at least one hole is configured to direct the gas to a predetermined portion of the outer surface of the preform.

[0096] In Example 5, according to the system of Example 3, the at least one hole includes at least one of a bore, a slot, a bend, or a funnel.

[0097] In Example 6, according to the system of Example 3, the at least one hole includes an adjustable cross-sectional dimension.

[0098] In Example 7, according to the system of Example 3, the at least one sidewall includes at least one cylindrical sidewall, and wherein the at least one hole includes a plurality of holes arranged in a uniform pattern on the at least one cylindrical sidewall.

[0099] In Example 8, the system of Example 1 further includes a thermometer for measuring the temperature of the gas.

[0100] In Example 9, the system of Example 1 further includes a temperature controller for adjusting an output temperature of the heater.

[0101] In Example 10, according to the system of Example 1, the heater is in communication with the heating chamber.

[0102] Example 11 is a method of conditioning a preform for molding, comprising:

[0103] positioning the preform in a heating chamber; and

[0104] Heated gas is forced into the heating chamber and onto the outer surface of the preform.

[0105] In Example 12, the method of Example 11 further includes positioning a nozzle having at least one sidewall within the heating chamber to at least partially surround the preform.

[0106] In Example 13, according to the method of Example 12, the at least one side wall includes at least one hole, and wherein forcing the heated gas into the heating chamber includes directing the heated gas through the at least one hole.

[0107] In Example 14, according to the method of Example 13, directing the heated gas through the at least one hole includes directing the heated gas to a predetermined portion of the outer surface of the preform.

[0108] Example 15 is an actuator system for a mold system, comprising:

[0109] a first actuator operably coupled to the first mold portion and configured to move the first mold portion in a first direction along an axis from a first molding position toward a first ejection position;

[0110] a second actuator operably coupled to the second mold portion and configured to move the second mold portion along the axis in the first direction from a second molding position toward a second ejection position; and

[0111] A controller is in communication with the first and second actuators and is configured to independently activate the first and second actuators.

[0112] In Example 16, according to the system of Example 15, the controller is configured to sequentially activate the first actuator and the second actuator to move the corresponding mold parts in the first direction.

[0113] In Example 17, according to the system of Example 16, the controller is configured to activate the first actuator before activating the second actuator.

[0114] In Example 18, according to the system of Example 15, at least one of the first actuator or the second actuator includes a hydraulic actuator.

[0115] In Example 19, according to the system of Example 15, the first actuator and the second actuator are configured to respectively move the first mold part and the second mold part from the corresponding ejection position toward the corresponding molding position in a second direction opposite to the first direction.

[0116] In Example 20, according to the system of Example 19, the controller is configured to activate the first actuator and the second actuator simultaneously to move the corresponding mold part in the second direction.

[0117] Example 21 is a system for molding an object, comprising:

[0118] a hinged mold having an axis and comprising a plurality of mold portions configured to collectively define a molding cavity for forming the object when arranged in respective molding positions;

[0119] a plurality of actuators, wherein each of the plurality of actuators is operably coupled to a corresponding mold portion of the plurality of mold portions and is configured to move the corresponding mold portion along the axis from a corresponding molding position toward a corresponding ejection position to release the object; and

[0120] a controller in communication with each of the plurality of actuators and configured to independently activate each of the plurality of actuators so that one of the plurality of mold sections moves along the axis from a corresponding molding position toward a corresponding ejection position while at least another of the plurality of mold sections remains stationary relative to the object so as to at least partially support the object.

[0121] In Example 22, according to the system of Example 21, the molding cavity includes at least one of a tongue or a groove extending in a direction parallel to the axis.

[0122] In Example 23, according to the system of Example 21, the plurality of actuators are configured to move the corresponding mold parts in the same direction along the axis from the corresponding molding position toward the corresponding ejection position.

[0123] In Example 24, according to the system of Example 21, the controller is configured to activate each of the plurality of actuators sequentially.

[0124] In Example 25, according to the system of Example 24, the plurality of mold portions includes a bottom portion and at least one side portion distributed along the axis.

[0125] In Example 26, according to the system of Example 25, the at least one side portion is configured to move along the axis from the corresponding molding position toward the corresponding ejection position before the bottom portion moves along the axis from the corresponding molding position toward the corresponding ejection position, so that the bottom portion supports the object during the movement of the at least one side portion.

[0126] In Example 27, according to the system of Example 24, the plurality of mold portions includes upper side portions and lower side portions distributed along the axis.

[0127] In Example 28, according to the system of Example 27, the lower side portion is configured to move along the axis from the corresponding molding position toward the corresponding ejection position before the upper side portion moves along the axis from the corresponding molding position toward the corresponding ejection position, so that the upper side portion supports the object during movement of the lower side portion.

[0128] In Example 29, according to the system of Example 24, the plurality of mold sections includes first and second side-by-side sections distributed about the axis.

[0129] In Example 30, according to the system of Example 29, the first side-by-side portion is configured to move along the axis from the corresponding molding position toward the corresponding ejection position before the second side-by-side portion moves along the axis from the corresponding molding position toward the corresponding ejection position, so that the second side-by-side portion supports the object during movement of the first side-by-side portion.

[0130] Example 31 is a method of releasing a molded object from a molding cavity defined by a plurality of mold portions of a hinged mold having an axis, the method comprising:

[0131] moving a first mold portion of the plurality of mold portions along the axis from a respective molding position toward a respective ejection position, wherein during the movement of the first mold portion, the object is supported by a second mold portion of the plurality of mold portions; and

[0132] The second mold part is then moved along the axis from a respective molding position toward a respective ejection position.

[0133] In Example 32, the method of Example 31 is described, wherein moving the first mold portion includes activating a first actuator operably coupled to the first mold portion.

[0134] In Example 33, the method of Example 32 is described, wherein moving the second mold portion includes activating a second actuator operably coupled to the second mold portion.

[0135] In Example 34, according to the method of Example 31, when the first mold portion and the second mold portion are in respective molding positions, the first mold portion is arranged below the second mold portion along the axis.

[0136] In Example 35, according to the method of Example 31, when the first mold portion and the second mold portion are in respective molding positions, the first mold portion is arranged above the second mold portion along the axis.

[0137] In Example 36, according to the method of Example 31, the first mold portion and the second mold portion are arranged side by side about the axis when the first mold portion and the second mold portion are in respective molding positions.

[0138] Example 37 is a method of manufacturing an object in a hinged mold having an axis, comprising:

[0139] arranging a plurality of mold sections of the hinged mold in respective molding positions to define a molding cavity;

[0140] molding the object in the molding cavity;

[0141] moving a first mold section of the plurality of mold sections along the axis from a respective molding position toward a respective ejection position, wherein during the movement of the first mold section, the object is supported by a second mold section of the plurality of mold sections; and

[0142] The second mold part is then moved along the axis from a respective molding position toward a respective ejection position.

[0143] In Example 38, according to the method of Example 37, moving the first mold portion includes activating a first actuator operably coupled to the first mold portion.

[0144] In Example 39, the method of Example 38 is described, wherein moving the second mold portion includes activating a second actuator operably coupled to the second mold portion.

[0145] In Example 40, according to the method of Example 37, when the first mold portion and the second mold portion are in respective molding positions, the first mold portion is disposed below the second mold portion along the axis.

[0146] In Example 41, according to the method of Example 37, when the first mold portion and the second mold portion are in respective molding positions, the first mold portion is arranged above the second mold portion along the axis.

[0147] In Example 42, according to the method of Example 37, the first mold portion and the second mold portion are arranged side by side about the axis when the first mold portion and the second mold portion are in respective molding positions.

[0148] In Example 43, according to the method of Example 37, molding the object includes blow molding the object from a preform.

[0149] In Example 44, the method of Example 43 wherein blow molding the object comprises stretch blow molding the object from the preform.

[0150] In Example 45, the method of Example 43 further includes conditioning the preform prior to blow molding, wherein conditioning the preform includes:

[0151] positioning the preform in a heating chamber; and

[0152] Heated gas is forced into the heating chamber and onto the outer surface of the preform.

[0153] In Example 46, according to the method of Example 45, conditioning the preform further comprises positioning a nozzle having at least one sidewall within the heating chamber to at least partially surround the preform.

[0154] In Example 47, according to the method of Example 46, the at least one side wall includes at least one hole, and wherein forcing the heated gas into the heating chamber includes directing the heated gas through the at least one hole.

[0155] In Example 48, according to the method of Example 47, directing the heated gas through the at least one hole includes directing the heated gas to a predetermined portion of the outer surface of the preform.

Claims

1. A method of releasing a molded container including a dovetail from a mold cavity defined by a plurality of mold portions of a hinged mold having an axis, the method comprising: moving side mold portions of the plurality of mold portions along the axis from respective molding positions toward respective ejection positions, wherein during movement of the side mold portions, the container is supported by a bottom mold portion of the plurality of mold portions at least until static friction between the container and the side mold portions is overcome; as well as Once the static friction force is overcome, the bottom mold part is subsequently moved along the axis from a respective molding position toward a respective ejection position, wherein the bottom mold part comprises at least one dovetail for forming a corresponding dovetail on the container. 2 . The method of claim 1 , wherein moving the side mold portion comprises activating a first actuator operably coupled to the side mold portion. 3 . The method of claim 2 , wherein moving the bottom mold portion comprises activating a second actuator operably coupled to the bottom mold portion.

4. The method of claim 1, wherein the side mold portion is disposed below the bottom mold portion along the axis when the side mold portion and the bottom mold portion are in respective molding positions.

5. The method of claim 1, wherein the side mold portion is arranged above the bottom mold portion along the axis when the side mold portion and the bottom mold portion are in respective molding positions.

6. The method of claim 1, wherein the side mold portion and the bottom mold portion are arranged side by side about the axis when the side mold portion and the bottom mold portion are in respective molding positions.

7. A method of manufacturing a container including a dovetail joint in a hinged mold having an axis, comprising: arranging a plurality of mold sections of the hinged mold in respective molding positions to define a molding cavity; molding the container in the molding cavity; moving a side mold section of the plurality of mold sections along the axis from a corresponding molding position toward a corresponding ejection position, wherein during the movement of the side mold section, the container is supported by a bottom mold section of the plurality of mold sections at least until static friction between the container and the side mold section is overcome; as well as Once the static friction force is overcome, the bottom mold part is subsequently moved along the axis from a respective molding position toward a respective ejection position, wherein the bottom mold part comprises at least one dovetail for forming a corresponding dovetail on the container.

8. The method of claim 7, wherein moving the side mold portion comprises activating a first actuator operably coupled to the side mold portion.

9. The method of claim 8, wherein moving the bottom mold portion comprises activating a second actuator operably coupled to the bottom mold portion.

10. The method of claim 7, wherein the side mold portion is disposed below the bottom mold portion along the axis when the side mold portion and the bottom mold portion are in respective molding positions.

11. The method of claim 7, wherein the side mold portion is arranged above the bottom mold portion along the axis when the side mold portion and the bottom mold portion are in respective molding positions.

12. The method of claim 7, wherein the side mold portion and the bottom mold portion are arranged side by side about the axis when the side mold portion and the bottom mold portion are in respective molding positions.

13. The method of claim 7, wherein molding the container comprises blow molding the container from a preform.

14. The method of claim 13, wherein blow molding the container comprises stretch blow molding the container from the preform.

15. The method of claim 13, further comprising conditioning the preform prior to blow molding, wherein conditioning the preform comprises: positioning the preform in a heating chamber; as well as Heated gas is forced into the heating chamber and onto the outer surface of the preform.

16. The method of claim 15, wherein conditioning the preform further comprises positioning a nozzle having at least one sidewall within the heating chamber to at least partially surround the preform.

17. The method of claim 16, wherein the at least one sidewall comprises at least one hole, and wherein forcing heated gas into the heating chamber comprises directing the heated gas through the at least one hole.

18. The method of claim 17, wherein directing the heated gas through the at least one hole comprises directing the heated gas to a predetermined portion of an outer surface of the preform.

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