Modular blow mold system for blow molding containers

Abstract

Disclosed herein is a modular system for blow molding containers. The system can include a first portion, a second portion, and a third portion. The first and second portions can each include a housing, a mold removably coupled to the housing, and a top plate. The third portion can include a base and a base mold. The molds can be 3D printed. Together, the molds can define a blow molding cavity. The modular system can be used at a lab scale, a pilot scale, or a full production scale. The molds can be durable and smooth enough for use at a full production scale. Some embodiments relate to methods for manufacturing a modular system for blow molding containers.

Description

Background Technology

[0001] This disclosure relates to a blow molding system for blow-molded containers. More specifically, embodiments relate to a modular system for blow-molded containers and a method for manufacturing the same. Summary of the Invention

[0002] Some embodiments relate to a modular system for blow molding a container comprising a first part, a second part, and a third part. The first part may include a first housing, a first mold removably coupled to the first housing, a first top plate removably coupled to the first housing, and a first filler material disposed in a volume defined by the first housing, the first mold, and the first top plate. The second part may include a second housing, a second mold removably coupled to the second housing, a second top plate removably coupled to the second housing, and a second filler material disposed in a volume defined by the second housing, the second mold, and the second top plate. The first mold and the second mold may be 3D printed. The third part may include a base and a base mold. The base can be removably coupled to the first housing and the second housing. When the first part is coupled to the second part, the first mold, the second mold, and the base mold together define a blow molding cavity.

[0003] In any of the various embodiments disclosed herein, the system further includes a first cavity retainer removably coupled to a first housing and a second cavity retainer removably coupled to a second housing.

[0004] In any of the various embodiments disclosed herein, each of the first mold, the second mold, and the base mold is 3D printed.

[0005] In any of the various embodiments disclosed herein, the first housing, the first top plate, the second housing, and the second top plate are made of CNC machined metal.

[0006] In any of the various embodiments disclosed herein, each of the first mold, the second mold, and the base mold is isotropic.

[0007] In any of the various embodiments disclosed herein, the filler material has an elastic modulus of at least 6300 MPa.

[0008] In any of the various embodiments disclosed herein, the first mold, the second mold, and the base mold are made of a polymer containing cyanate esters.

[0009] In any of the various embodiments disclosed herein, the system further includes at least one cooling channel in each of the first mold and the second mold.

[0010] In any of the various embodiments disclosed herein, the system further includes a locking ring removably coupled to the first housing. In any of the various embodiments disclosed herein, the base is configured to releasably engage with the locking ring to secure the third portion.

[0011] In any of the various embodiments disclosed herein, the system further includes a plurality of vertically aligned recesses configured to receive a locking ring, such that the vertical position of the third portion can be adjusted.

[0012] In any of the various embodiments disclosed herein, the first housing, the first top plate, the second housing, and the second top plate are made of CNC machined metal.

[0013] Some embodiments relate to interchangeable molds for blow-molded containers. The mold may include a first 3D-printed mold portion, a second 3D-printed mold portion, and a 3D-printed base portion. Together, the first 3D-printed mold portion, the second 3D-printed mold portion, and the 3D-printed base portion define a blow molding cavity. The first 3D-printed mold portion, the second 3D-printed mold portion, and the 3D-printed base portion may be isotropic. The first 3D-printed mold portion, the second 3D-printed mold portion, and the 3D-printed base portion are configured to engage with a housing compatible with a blow molding system to form a blow-molded container within the blow molding cavity.

[0014] In any of the various embodiments disclosed herein, the first filling portion includes a first side configured to mate with the back of the first 3D printed mold portion and a second side configured to mate with the inside of the housing. In any of the various embodiments disclosed herein, the second filling portion includes a first side configured to mate with the back of the second 3D printed mold portion and a second side configured to mate with the inside of the housing.

[0015] In any of the various embodiments disclosed herein, the first 3D printed mold portion, the second 3D printed mold portion, and the 3D printed base mold portion are made of a polymer containing cyanate esters.

[0016] In any of the various embodiments disclosed herein, the mold further includes a first filling portion and a second filling portion. In any of the various embodiments disclosed herein, the first filling portion has a first side contacting the back surface of a first 3D printed mold portion and a second side configured to contact the inner side of a housing, and the second filling portion has a first side contacting the back surface of a second 3D printed mold portion and a second side configured to contact the inner side of a housing.

[0017] In any of the various embodiments disclosed herein, both the first filler material and the second filler material are gypsum.

[0018] In any of the various embodiments disclosed herein, the first mold portion and the second mold portion each include a cooling channel.

[0019] In any of the various embodiments disclosed herein, the mold further includes a first cavity retainer and a second cavity retainer for securing the first filling portion and the second filling portion, respectively.

[0020] In any of the various embodiments disclosed herein, the mold further includes a first cavity retainer and a second cavity retainer for securing the first filling portion and the second filling portion, respectively.

[0021] Some embodiments relate to a method of manufacturing a modular blow molding system, the method comprising: 3D printing a first mold portion, a second mold portion, and a base portion; attaching the first mold portion to a first housing to form a first half, the first half including a first volume defined by the first mold portion and the first housing; attaching the second mold portion to a second housing to form a second half, the second half including a second volume defined by the second mold portion and the second housing; pouring filler material into the first volume; pouring filler material into the second volume; and cooling the filler material to form a solid filler.

[0022] In any of the various embodiments disclosed herein, the first mold portion, the second mold portion, and the base portion are made of a polymer containing cyanate esters.

[0023] In any of the various embodiments disclosed herein, the filler material includes plaster.

[0024] In any of the various embodiments disclosed herein, the gypsum is liquid before cooling.

[0025] In any of the various embodiments disclosed herein, cooling includes cooling the filler material at room temperature.

[0026] In any of the various embodiments disclosed herein, the 3D printing step includes forming at least one channel in a first mold portion and a second mold portion.

[0027] In any of the various embodiments disclosed herein, the method further includes joining the first half and the second half to form a blow molding die, the blow molding die including a blow molding cavity defined by the first mold portion and the second mold portion. Attached Figure Description

[0028] Figure 1 A half of the modular blow molding die system connected to the base portion is shown.

[0029] Figure 2 It shows Figure 1 A modular blow molding mold system for assembly.

[0030] Figure 3 It shows Figure 1 An exploded view of the half and base sections of a modular system.

[0031] Figure 4 It shows along Figure 1 The line 4-4 cut with filling material Figure 1 A cross-sectional view of half of a modular system.

[0032] Figure 5 It shows along Figure 1 The line cut from 5-5 Figure 1 A cross-sectional view of half of a modular system.

[0033] Figure 6 The assembly instructions are shown. Figures 1 to 5 A flowchart of a method for a modular blow molding die system.

[0034] Figure 7 Instructions for manufacturing are shown. Figures 1 to 5 A flowchart of a method for a modular blow molding die system. Detailed Implementation

[0035] Some blow molding systems (e.g., shell molds, hot-fill molds, integral molds, and small-cavity molds) use parts generated using CAD (Computer-Aided Design) / CAM (Computer-Aided Manufacturing) systems. These systems can utilize laser engraving or etching for complex design features. These systems can be expensive and require significant time to manufacture after design. These systems can be used to manufacture beverage containers using a blow molding process, which involves placing a preform in a mold. The preform is heated, and then air is blown into the preform to blow the heated preform material, thereby forming a container that matches the shape of the mold.

[0036] However, developing new container designs can be an iterative process. This design process may involve creating multiple new molds as the design is conceived, developed, and improved. Adapting to this iterative process can be lengthy and costly for existing blow molding systems. Furthermore, the time required to generate the next iteration can delay production cycles, making multiple iterations potentially economically infeasible. Therefore, with existing blow molding systems, cost and time constraints may prevent the production of more than one or two molds before producing a full-size production model.

[0037] Although attempts have been made to use 3D printing in blow molding systems, these existing systems are only suitable for lab-scale processes, producing poor surface quality and low strength that leads to short lifecycles—typically producing only a few hundred bottles before failure. This low strength and poor surface quality limit these systems to small-scale production in the very early stages of consumer or machine testing. Furthermore, existing 3D printing for blow molding systems uses additive technologies and materials such as acrylonitrile butadiene styrene (“ABS”) to produce polymer-based parts. However, the additive technologies used result in molds that produce containers with poor surface quality. Due to these issues, these 3D printing molding systems are not suitable for scaling up processes beyond lab scale. Therefore, existing 3D printing molding systems are generally suitable for low-volume runs during early design testing.

[0038] Therefore, there is a need for a 3D printing blow molding system that is cost-effective, improves the surface quality of the resulting containers, can withstand high temperatures and pressures, and is durable enough to be reliably used in large-scale applications (e.g., pilot-scale or full-scale production). Furthermore, there is a need for a system that possesses these advantages, is also modular, interchangeable, and can be integrated into existing production lines.

[0039] Using the blow molding die system according to the embodiments disclosed herein, modular blow molding die systems can be produced, which reduce processing costs and minimize lead time for each iteration of the design process for each container. Furthermore, the blow molding die system disclosed herein can be used in pilot-scale and production-scale processes. Additionally, the embodiments disclosed herein include interchangeable dies, allowing portions of the blow molding die system to be reused whenever a new bottle design is used. These die systems offer improved strength, flexibility, and surface quality, while also enabling the replication of prototype designs for new bottle designs.

[0040] The modularity of the disclosed system also allows the system (e.g., modular blow molding system 100) to adapt to various bottle sizes and concepts, providing rapid design changeover before the final design is locked in. Furthermore, the molding system disclosed herein is capable of producing bottles with surface quality sufficient for pilot-scale or even full-production scale, with the capacity to produce millions of bottles. And the same system (e.g., modular blow molding system 100) can be used on different platforms, from laboratory scale all the way to full-production scale.

[0041] All these benefits result in faster production times and more flexible blow molding systems. For example, after designing a new container, the new mold can be ready for use in 1 to 2 weeks, compared to 4 to 5 weeks with the existing system. Furthermore, the cost of producing each mold can be reduced by up to 80% to 90%.

[0042] As shown in the figure, the modular blow molding mold system 100 may include a first part 105, a second part 110, and a base 115. In some embodiments, the first part 105 and the second part 110 are mirror images of each other (they may differ within the mold cavity depending on the bottle design). Some embodiments disclosed herein have been discussed with reference to the first part 105; however, it should be understood that all discussions relating to the first part 105 apply to the second part 110. For example, all components present in the first part 105 may have corresponding components in the second part 110, and the second part 110 may have the same function as the first part 105.

[0043] Figure 1 A first portion 105 of a modular blow molding die system 100, coupled to a base portion 900, is shown. The first portion 105 may include a housing 200, a die portion 300, a retainer plate 400, a top plate 500, a cavity retainer 700, and a locking ring 800 (see, for example, [reference needed]). Figure 3 Part 110 may include corresponding parts (e.g., Figure 2 The housing 210 and top plate 510 shown, as well as the mold portion, retainer plate, cavity retainer, and locking ring. The base 115 may include a base portion 900 and a base mold portion 310.

[0044] Figure 2 This illustrates a modular blow molding die system 100 when the first part 105, the second part 110, and the base 115 are assembled. During assembly, as... Figure 2 As shown, the mold portions (e.g., mold portion 300 and base mold portion 310) form the opening 1000 and the blow molding cavity inside the modular blow molding system 100. The opening 1000 can be sized to receive a preform (e.g., preform 1200, see...). Figure 4 The blow molding cavity can correspond to the shape of the container to be blow molded.

[0045] Figure 3 An exploded view of the first part 105 of the modular blow molding mold system 100 is shown. Each of these parts is discussed in detail below. Figure 4 It shows along Figure 1 The diagram shows a cross-sectional view of the first part 105, the base mold part 310, and the base part 900 of the modular blow molding die system 100, taken by line 4-4. Figure 5 A cross-sectional view of the first part 105, the base mold part 310, and the base part 900 of the modular blow molding die system 100, taken along line 5-5, is shown.

[0046] The advantage of the disclosed system is its versatility. The modular blow molding system disclosed herein (e.g., modular blow molding system 100) can be adapted to any kind of container shape or size, but is also compatible with existing blow molding systems. For example, when assembled, the modular blow molding system 100 can have the same dimensions as a conventional blow molding system. Furthermore, the modular blow molding system 100 can be used at laboratory, pilot, or full-production scales.

[0047] The modular systems disclosed herein (e.g., modular blow molding system 100) also enhance flexibility. For example, certain components can be reused regardless of the shape or size of the container mold. For instance, housings 200 and 210, retainer plates (e.g., retainer plate 400), top plates 500 and 510, locking rings (e.g., locking ring 800), and base portion 900 can be reusable components. These reusable components can be made of metal. In some embodiments, the reusable components are computer numerical control (“CNC”) machined metal.

[0048] Other components, such as mold portions (e.g., mold portion 300 and base mold portion 310) and cavity retainers (e.g., cavity retainer 700), can be interchangeable. Interchangeable components are compatible with reusable components. For example, mold portions (e.g., mold portion 300) and base mold portion 310 together can form a mold corresponding to a bottle shape. Any bottle shape can be manufactured by simply replacing the mold portions (e.g., mold portion 300 and base mold portion 310) with different molds compatible with reusable components. In some embodiments, the interchangeable components are 3D printed using polymers. For example, the interchangeable components can be 3D printed using cyanate esters. In some embodiments, the interchangeable components are 3D printed using metals. For example, the interchangeable components can be made from 3D-printed aluminum alloys, bronze alloys, or stainless steel. 3D-printed components can be fully isotropic. Unlike layered 3D printing methods (which can introduce failure points at each layer), fully isotropic components offer improved strength and surface quality. As used herein, "isotropic" refers to a material in which its mechanical and thermal properties are identical in all material directions (e.g., modulus of elasticity, compressive strength). After 3D printing, interchangeable parts can be further processed. In some embodiments, the interchangeable parts are washed and cured in a temperature-controlled chamber.

[0049] The housing 200 may have a mold contact surface 203, a top plate contact surface 204, an inner surface 205, and an outer surface 206. The housing 200 may also have recesses 201 and 202.

[0050] The mold portion 300 may include a container mold 302 and a flange 303. The flange 303 may contact a mold contact surface 203 on the housing 200. Screws may be used to secure the mold portion 300 to the housing 200 at the point where the flange 303 and the mold contact surface 203 meet. When the mold portion 300 is attached to the housing 200, a space is formed between the inner surface 205 and the container mold 302. The container mold 302 may be a container-specific shape and may be redesigned as needed to accommodate different container designs and sizes. Even when the size and shape of the container mold 302 are adjusted, the shape and size of the portion of the flange 303 that contacts the mold contact surface 203 may remain the same. This allows the molded portion 300 to easily engage with the housing 200. In some embodiments, a retainer plate 400 and a top plate 500 are used to secure the mold portion 300 to the housing 200. For example, the retainer plate 400 may be placed on the flange 303, and screws may be used to secure the housing 200, the mold portion 300, and the retainer plate 400 together. The top plate can then be secured using screws 501.

[0051] The top plate 500 can be formed to sit on the top plate contact surface 204 of the housing 200. The top plate 500 can be attached to the housing 200 using screws. The housing 200, the mold portion 300, and the top plate 500 together form volume 1100 (see, for example, see...). Figure 4 and Figure 5 In some embodiments, volume 1100 remains empty during use. In some embodiments, filler is used to fill volume 1100. For example, the filler may be filler material 600, which will be discussed in more detail below.

[0052] The cavity retainer 700 can be positioned to enclose the volume 1100 (and, in embodiments using filler material 600, to hold the filler material 600 within the volume 1100). For example, the cavity retainer 700 can be coupled to the housing 200. In some embodiments, the cavity retainer 700 includes a flange 701 that mates with a corresponding recess 201. A locking ring 800 can be coupled to the housing 200. When coupled, the locking ring 800 engages with one of the recesses 202 and provides a manner for coupling the base mold portion 310 and the base portion 900 to the first portion 105. The cavity retainer 700 and the locking ring 800 can be moved up or down to accommodate molds for containers with different heights. For example, for shorter containers, the cavity retainer 700 and the locking ring 800 can be coupled using the topmost recesses 201 and 202, respectively.

[0053] In some embodiments, the second part 110 has the same parts as the first part 105. In some embodiments, all components of the second part 110 are mirror images of corresponding parts of the first part 105. For example, the second part 110 may include a housing 210 and a top plate 510 that are mirror images of the housing 200, mold portion 300, retainer plate 400, top plate 500, filler material 600, cavity retainer 700, and locking ring 800, respectively. In some embodiments, the second part 110 is a mirror image of the first part 110, except for differences within the mold cavity depending on the bottle design. The second part 110 may be coupled to the first part 105 and the base 115.

[0054] The base 115 of the modular blow molding system 100 may include a base portion 900 and a base mold portion 310. The base mold portion 310 may be a mold corresponding to the base of a container. The base mold portion 310 may be interchangeable based on the desired container base shape. The base mold portion 310 may be coupled to the base portion 900 using a pin (e.g., pin 311) to form the base 115. The base 115 may be coupled to a first portion 105 and a second portion 110 to form the modular blow molding system 100. When the first portion 105, the second portion 110, and the base 115 are coupled, the mold portions (e.g., mold portion 300 and base mold portion 310) form a blow molding cavity corresponding to the shape of the container.

[0055] The blow molding system 100 may include an opening 1000. In some embodiments, the opening 1000 is configured to receive a preform of the container (e.g., preform 1200), such as Figure 4 As shown. The preform can be a standard preform used to manufacture blow-molded containers. The preform can be made of any kind of blow-moldable plastic (e.g., PET).

[0056] The mold portions (e.g., mold portion 300 and base mold portion 310) and cavity retainers (e.g., cavity retainer 700) can be made of any suitable 3D printing material. To improve mold stability and thermal properties, the 3D printing material can have a high modulus of elasticity and a high thermal flexural temperature, while also providing a sufficiently smooth and durable surface to deliver a consistently high-quality container surface. The mold portions (e.g., mold portion 300 and base mold portion 310) can be made of a material having a tensile strength of at least 50 MPa (e.g., at least 75 MPa or at least 90 MPa), an elastic modulus of at least 2500 MPa (e.g., at least 3000 MPa or at least 3500 MPa), and a thermal flexural temperature of at least 200°C (e.g., at least 225°C or at least 250°C). In some embodiments, the 3D printing material is a cyanate ester. In some embodiments, the 3D printing material is a metal. In some embodiments, the mold portions (e.g., mold portion 300 and base mold portion 310) and the cavity retainer (e.g., cavity retainer 700) are made of the same material. In some embodiments, the mold portion (e.g., mold portion 300) is made of a different material than the base mold portion 310. For example, the 3D printing material may be a polymer or a metal. In some embodiments, the 3D printing material is a cyanate ester.

[0057] The filler material 600 further enhances the strength of the modular blow molding system 100. During blow molding, the mold is subjected to pressure from within the blow molding cavity. Existing systems use molds made of metals that can withstand pressure variations (e.g., steel), or 3D-printed molds that are prone to flexing or compression during blow molding, which reduces the overall lifespan and quality of the mold. The embodiments disclosed herein use strong 3D-printed materials (e.g., isotropic materials discussed above) to withstand the pressure. The filler material (e.g., filler material 600) further improves the strength of the mold because it is relatively incompressible and helps the mold withstand internal pressure without flexing.

[0058] In some embodiments, the filler material 600 also improves the thermal properties of the modular blow molding system 100. The filler material 600 can be a pourable plaster poured into volume 1100. The filler material can have a high modulus of elasticity and high compressive strength. After pouring, the filler material 600 can cure. In some embodiments, the filler material 600 has a density of 900 kg / m³. 3 and 1500kg / m 3 The plaster is between. In some embodiments, the filler material 600 has a density of about 1200 kg / m³. 3The plaster is used. The filler material 600 may have an elastic modulus. In some embodiments, the filler material 600 may have an elastic modulus of at least 5600 MPa (e.g., at least 6300 MPa, at least 7000 MPa). In some embodiments, the filler material 600 has an elastic modulus between 5600 MPa and 8400 MPa (e.g., between 6300 MPa and 7700 MPa). In some embodiments, the filler material 600 has an elastic modulus of about 7000 MPa.

[0059] Temperature regulation is beneficial during blow molding because operating conditions may involve elevated temperatures. For example, in some embodiments, the temperature of a mold portion (e.g., mold portion 300 or base mold portion 310) can be regulated to improve cooling efficiency by including optional internal cooling channels. In some embodiments, each mold portion (e.g., mold portion 300) includes at least one cooling channel (e.g., channel 301). In some embodiments, the mold portion (e.g., mold portion 300) includes at least three cooling channels (e.g., cooling channel 301) configured to receive cooling fluid. In some embodiments, the cooling channel (e.g., channel 301) is a vertically oriented conformal cooling channel, such as... Figure 5 The cross-section shown is illustrated. In use, gas or liquid may flow through the cooling channels to improve cooling of the mold portion (e.g., mold portion 300). In some embodiments, coolant flows through the cooling channels. In some embodiments, allowing coolant to flow through the cooling channels increases the productivity of the blow molding mold system 100.

[0060] The modular blow molding system disclosed herein (e.g., modular blow molding system 100) is durable enough for use at a pilot scale and has a lifespan of at least 5,000 containers (e.g., at least 7,500 containers, at least 10,000 containers, or at least 15,000 containers). In some embodiments, the modular blow molding system 100 is durable enough for use at a production scale and has a lifespan of at least 100,000 containers (e.g., at least 250,000 containers, at least 500,000 containers, at least 1,000,000 containers, or at least 2,000,000 containers).

[0061] The modular blow molding mold system 100 can be easily assembled and disassembled. Figure 6The flowchart illustrates the steps of assembling the blow molding mold system 100. The first part 105 can be assembled at steps 3000 to 3400. At step 3000, the mold part 300 is positioned such that the flange 303 of the mold part 300 is aligned with the mold contact surface 203 of the housing 200. Then, at step 3100, the retainer plate 400 is positioned on the flange 303 of the mold part 300. Screws can be used to connect the housing 200, the mold part 300, and the retainer plate 400. At step 3200, the top plate 500 is then fastened to the housing 200 using screws at the top plate contact surface 204. A locking ring 800 is then attached to the housing 200 at a recess in the recess 202. The position of the locking ring 800 can be adjusted according to the height of the container to be blow-molded. If filler material is used, the filler can be prepared at optional step 3300. The method for manufacturing the filler material 600 is discussed in detail below at step 4200. In some embodiments, no filler material is used. At step 3400, the cavity retainer 700 is attached to the housing 200 at the recess 202. Steps 3000 to 3400 may be repeated to assemble the second part 110.

[0062] At step 3500, the base mold portion 310 may be coupled to the base portion 900 to form the base 115. Then, at step 3600, the base 115 is coupled to the first portion 105 via a locking ring 800. After the base portion 900 is coupled to the first portion 105, at step 3700, the second portion 110 may be coupled to the first portion 105 to form the assembled modular blow molding system 100. Once the first portion 105 and the second portion 110 are coupled, the modular blow molding system 100 forms a blow molding cavity defined by each of the mold portions (e.g., mold portion 300 and base mold portion 310).

[0063] Various methods can be used to manufacture components of a modular blow molding system. For example, at step 4000, reusable components made of metal can be machined using CNC machining. Reusable components may include housings 200 and 210, a pair of cavity retainer plates (e.g., retainer plate 400), top plates 500 and 510, locking rings (e.g., locking ring 800), and a base portion 900. At step 4100, interchangeable components (e.g., mold portion 300, base mold portion 310, and cavity retainer 700) can be manufactured using 3D printing methods. In some embodiments, interchangeable components are made of polymers (e.g., cyanate esters). In some embodiments, interchangeable components are made of metal. For example, interchangeable components may be made of 3D-printed aluminum alloy, bronze alloy, or stainless steel.

[0064] At step 4200, a filler material 600 may be formed. Forming the filler material 600 may include first joining the housing 200, mold portion 300, retainer plate 400, and top plate 500, as discussed above in steps 3000 through 3300. Once these components are assembled, the assembled components may be inverted such that the top plate 500 is oriented downwards. The liquid filler material 600 may then be poured into the volume 1100 defined by the housing 200, mold portion 300, and top plate 500. In some embodiments, the liquid filler material 600 is poured in until the volume 1100 is filled. After the volume 1100 is filled, the liquid filler material 600 may be allowed to solidify (e.g., to cure). For example, the filler material may be allowed to cool naturally (e.g., at room temperature), during which time it will naturally cure by transforming into a solid form. In some embodiments, curing may be carried out in a temperature-controlled chamber (e.g., an oven). In some embodiments, the filler material 600 is a liquid plaster that transforms into (e.g., cures to form) a solid (e.g., cured) plaster. In some embodiments, the filler material does not cure at elevated temperatures but is allowed to cool at room temperature.

[0065] As used herein, the terms “top,” “inner,” “outer,” etc., are intended to aid in understanding embodiments of this disclosure with reference to the accompanying drawings regarding the orientation of the illustrated beverage carton, and are not intended to limit the scope of this disclosure or restrict its scope to the embodiments depicted in the drawings. Orientational terms are used for ease of description, and it should be understood that the carton and container can be positioned in any of a variety of orientations.

[0066] As used in this article, the term "3D printing" refers to the method of creating physical objects by using digital models to join or solidify printing materials into the shape of a physical object.

[0067] As used herein, when the term "about" is used to describe an endpoint of a value or range, this disclosure should be understood to include the specific value or endpoint mentioned. Regardless of whether an endpoint of a value or range is stated as "about," the value or endpoint is intended to include two embodiments: one modified by "about" and one not modified by "about." As used herein, the term "about" may include ±10%.

[0068] It should be understood that the Detailed Description section, and not the Summary of the Invention section and the Abstract of the Specification section, is intended to be used to interpret the claims. The Detailed Description section and the Abstract of the Specification section may provide one or more, but not all, exemplary embodiments of this disclosure as conceived by the inventors, and are therefore not intended to limit this disclosure and the appended claims in any way.

[0069] The present disclosure has been described above using functional building blocks that illustrate the implementation methods of specific functions and their relationships. For the sake of convenience, the boundaries of these functional building blocks are arbitrarily defined herein. Alternative boundaries may be defined as long as the specific functions and their relationships are properly performed.

[0070] The above description of specific embodiments will fully reveal the general nature of this disclosure, enabling others to easily modify and / or adapt these specific embodiments for various applications without departing from the overall conception of this disclosure by applying knowledge of the art, without excessive experimentation. Therefore, based on the teachings and guidance provided herein, such modifications and alterations are intended to be within the meaning and scope of equivalents of the disclosed embodiments. It should be understood that the wording or terminology used herein is for descriptive purposes and not for limiting purposes, and that the terminology or terminology of this specification should be interpreted by those skilled in the art in accordance with the teachings and guidance provided.

[0071] The terms "an embodiment," "an embodiment," "an exemplary embodiment," "some embodiments," etc., used in this specification indicate that the described embodiment may include a specific feature, structure, or characteristic, but each embodiment may not necessarily include that specific feature, structure, or characteristic. Furthermore, such phrases do not necessarily refer to the same embodiment. Additionally, when a specific feature, structure, or characteristic is described in connection with an embodiment, whether explicitly stated or not, it is believed that those skilled in the art can implement such feature, structure, or characteristic in combination with other embodiments.

[0072] The breadth and scope of this disclosure should not be limited by any of the exemplary embodiments described above, but should be defined solely by the appended claims and their equivalents.

Claims

1. A modular system for blow-molded containers, the system comprising: The first part includes: First shell; A first mold, the first mold being removably attached to the first housing; A first top plate, the first top plate being removably connected to the first housing; and A first filling material is disposed in the volume defined by the first housing, the first mold, and the first top plate; The second part, which is removably connected to the first part, includes: Second shell; A second mold, which is removably attached to the second housing; A second top plate, the second top plate being removably connected to the second housing; and A second filling material is disposed in the volume defined by the second housing, the second mold, and the second top plate; The third part includes a base and a base mold, wherein the base is removably coupled to the first housing and the second housing. When the first part is connected to the second part, the first mold, the second mold, and the base mold together define the blow molding cavity.

2. The system of claim 1, further comprising a first cavity retainer removably coupled to the first housing and a second cavity retainer removably coupled to the second housing.

3. The system of claim 2, wherein each of the first mold, the second mold, and the base mold is 3D printed.

4. The system of claim 3, wherein the first housing, the first top plate, the second housing, and the second top plate are made of CNC machined metal.

5. The system of claim 3, wherein each of the first mold, the second mold, and the base mold is isotropic.

6. The system of claim 1, wherein each of the first filler material and the second filler material has an elastic modulus of at least 6300 MPa.

7. The system of claim 1, wherein the first mold, the second mold and the base mold are made of a polymer containing cyanate ester.

8. The system of claim 1, further comprising at least one cooling channel in each of the first mold and the second mold.

9. The system according to claim 1, further comprising: A locking ring, which is removably attached to the first housing. The base is configured to releasably engage with the locking ring to secure the third part.

10. The system of claim 9, further comprising a plurality of vertically aligned recesses configured to receive the locking ring, such that the vertical position of the third portion can be adjusted.

11. An interchangeable mold for blow-molded containers, the mold comprising: First 3D printed mold part; The second 3D printed mold part; and 3D printed base mold part The first 3D printed mold portion, the second 3D printed mold portion, and the 3D printed base mold portion are configured together to define a blow molding cavity. The first 3D printed mold portion, the second 3D printed mold portion, and the 3D printed base mold portion are isotropic, and The first 3D printed mold portion is configured to engage with the first housing, the second 3D printed mold portion is configured to engage with the second housing, and the 3D printed base mold portion is configured to engage with both the first and second housings. Both the first housing and the second housing are compatible with the blow molding system to form a blow-molded container within the blow molding cavity.

12. The mold of claim 11, wherein the first 3D printed mold portion, the second 3D printed mold portion and the 3D printed base mold portion are made of a polymer containing cyanate ester.

13. The mold according to claim 11, further comprising: A first filling material having a first side that contacts the back of the first 3D printed mold portion and a second side configured to contact the inside of the first housing; and The second filler material has a first side that contacts the back of the second 3D printed mold portion and a second side that is configured to contact the inside of the second housing.

14. The mold according to claim 13, wherein both the first filler material and the second filler material are plaster.

15. The mold according to claim 13, the mold further comprising a first cavity retainer and a second cavity retainer for fixing the first filling material and the second filling material, respectively.

16. The mold according to claim 11, wherein the first 3D printed mold portion and the second 3D printed mold portion each include a cooling channel.

17. A method for manufacturing a modular blow molding die system, the method comprising: 3D printing the first mold part, the second mold part, and the base part; The first mold portion is attached to the first housing to form a first half, the first half including a first volume defined by the first mold portion and the first housing; The second mold portion is attached to the second housing to form a second half, the second half including a second volume defined by the second mold portion and the second housing; Pour the filler material into the first volume; Pour the filling material into the second volume; as well as The filler material is cooled to form a solid filler.

18. The method of claim 17, wherein the first mold portion, the second mold portion, and the base portion are made of a polymer comprising a cyanate ester.

19. The method of claim 17, wherein the filler material comprises plaster.

20. The method of claim 19, wherein the gypsum is liquid prior to the cooling.

21. The method of claim 17, wherein the cooling comprises cooling the filler material at room temperature.

22. The method of claim 17, wherein the 3D printing step includes forming at least one channel in the first mold portion and the second mold portion.

23. The method of claim 17, further comprising joining the first half and the second half to form a blow molding die, the blow molding die including a blow molding cavity defined by the first mold portion and the second mold portion.

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