Mold, mold assembly and stacking part

Abstract

A mold stack (104, 204, 304, 404, 504) for molding a preform (P), the preform (P) comprising a cavity insert (131, 231, 331, 431, 531), a split mold insert (123, 223, 323, 423, 523), and an interface (140, 240, 340, 440, 540) therebetween. The cavity insert has a molding surface (135, 235, 335, 435, 535) that forms a portion of the body of the preform. The split mold insert has a molding surface (124, 224, 324, 424, 524) forming a portion of the body and a radial flange of the preform. The interface includes a non-mating portion (141, 241, 341, 441, 541) and a mating portion (142, 242, 342, 442, 542), the non-mating portion surrounding and extending from the molding surface, the mating portion surrounding the non-mating portion. When the mold stack is in the molding configuration, the non-mating portion forms a gap (G) between the cavity and the split mold insert when the clamping force is transferred laterally at the mating portion.

Description

Technical Field

[0001] The present invention relates generally to molding apparatus and related methods. More particularly, but not exclusively, the present invention relates to mold stacks and components thereof, mold assemblies, molds, molding systems for molding preforms and other articles (e.g., tubular articles), and related methods. Background Art

[0002] Molding is a process that can form molded articles from a molding material (e.g., a plastic material) using a molding system (e.g., an injection molding system or a compression molding system). Various molded articles can be formed using this molding process, including, for example, preforms that can be formed from polyethylene terephthalate (PET) materials. These preforms can then be blown into containers, such as beverage containers, bottles, cans, and the like.

[0003] As an illustration, the injection molding of preforms involves heating PET material (or other suitable molding materials for this purpose) to a uniform molten state, and injecting the molten material under pressure into a molding cavity at least partially defined by a female cavity member and a male core member. Typically, the female cavity member is mounted on a cavity plate, and the male core member is mounted on the core plate of the mold. The cavity plate and the core plate are pushed together and held together by a clamping force that is sufficient to resist the pressure of the injected material and hold the cavity member and the core member together. The molding cavity has a shape that generally corresponds to the final cold shape of the molded article to be molded. The material injected in this manner is then cooled to a temperature sufficient to enable the molded article thus formed to be removed from the molding cavity. When cooling, the molded article shrinks inside the molding cavity, and therefore when the cavity plate and the core plate are pushed apart, the molded article tends to remain associated with the core member.

[0004] Accordingly, by pushing the core plate away from the cavity plate, the molded article can then be demolded by ejecting the molded article from the core piece. Ejector structures are known to facilitate removal of the molded article from the core halves. Examples of ejector structures include stripper plates, knockout rings and neck rings, ejector pins, and the like.

[0005] When processing moulding can be blown into beverage container preform subsequently, a consideration that needs to be addressed is the formation of so-called " neck region ".Typically and as an example, this neck region comprises (i) engaging feature, such as thread (or other suitable structure), for receiving and holding closure assembly (such as, bottle cap), and (ii) anti-tamper assembly, this anti-tamper assembly cooperates with this closure assembly for example to indicate whether final product (that is, beverage container that has been filled with beverage and is transported to store) has been tampered with in any way.Neck region can comprise other additional elements for various purposes, for example, cooperate with the part (such as, support ledge etc.) of moulding system.As understood in the art, neck region cannot be easily formed by using cavity and core half body.Usually, the neck region is formed using flap-type mould insert (sometimes referred to as " neck ring " by those skilled in the art).

[0006] A typical molding insert stack assembly that can be arranged (in use) within a molding machine includes a pair of flap-fit ​​mold inserts that, together with a mold cavity insert, a gate insert, and a core insert, define a molding cavity. Molding material can be injected from a molding material source into the molding cavity via a receptacle or port in the gate insert to form a molded article. To facilitate forming the neck region of the molded article and subsequent removal of the molded article therefrom, the flap-fit ​​mold insert pair includes a pair of complementary flap-fit ​​mold inserts mounted on adjacent slides of the slide pair. The slide pair is slidably mounted on a top surface of a stripper plate.

[0007] As is generally known, the stripper plate is configured to be movable relative to the cavity insert and the core insert when the mold is arranged in an open configuration. The slide pair and the complementary flap-type mold insert mounted thereon can be laterally driven via a cam arrangement or any other suitable known means to release the molded article from the molding cavity. One of the functions performed by the flap-type mold insert pair is to assist in ejecting the molded article from the core insert by causing the molded article to generally "slide" off the core insert into the cooling tubes of a post-mold cooling unit mounted to downstream processing equipment.

[0008] During the demolding process, the stripper plate and the core plate are held together as the cavity plate and the core plate are pushed apart. The interface between the flap mold insert and the features in the neck region helps to hold the molded article to the core insert, which can be critical for certain preform designs. In the past, the mold stack was designed so that a portion of the support ledge was molded by the flap mold insert and another portion was molded by the cavity insert. While this design approach provides advantages that are understood by those skilled in the art, for certain preform designs this can result in so-called thread pulling (thread deformation). Therefore, encapsulating the support ledge within the flap mold insert is beneficial for avoiding such defects.

[0009] However, enclosing the support ledges within the flap-type mold insert requires it to also mold part of the body of the preform, which, as those skilled in the art will appreciate, can negatively impact ejection performance. Summary of the Invention

[0010] The present invention is particularly intended to provide a device that can minimize the main body portion formed by a flap-type mold insert. The present invention specifically, but not exclusively, relates to a mold stack and its components, molds, mold assemblies, molding systems and related methods for manufacturing tubular articles (such as preforms). The article may have a neck portion, which may have an open end. The article may have a hollow main body portion, which may have a closed end. The neck portion may include one or more radial flanges, which may extend outward. The neck portion may include engaging features, such as threads or snap-on closures. The preform and / or the neck portion may include any one or more other features molded above with respect to known preform designs. In addition, any of the aforementioned features molded with respect to known mold stacks and their components, molds and molding systems may be incorporated into the mold stack, mold and molding system according to the present invention, as long as it is consistent with the disclosure herein.

[0011] According to a first broad aspect of the invention, there is provided a mold stack comprising a cavity insert and a flap mold insert, and having an interface between the cavity insert and the flap mold insert, wherein the interface comprises a non-mating portion and a mating portion, the non-mating portion at least partially surrounding the molding surface of each of the cavity insert and the flap mold insert, and / or being bonded to the molding surface, and / or extending from the molding surface, and the mating portion at least partially surrounding the non-mating portion.

[0012] Providing a non-mating portion surrounding and extending from the molding surface and surrounded by the mating portion enables the non-mating portion to be isolated from clamping loads that might otherwise stress the area of ​​the flap-fit ​​mold insert adjacent the radial flange.

[0013] Another broad aspect of the present invention provides a flap-type mold insert comprising a non-mating portion that at least partially surrounds a molding surface, and / or is bonded to the molding surface, and / or extends from the molding surface, and a mating portion that at least partially surrounds the non-mating portion.

[0014] Another broad aspect of the present invention provides a cavity insert including a non-mating portion that at least partially surrounds a molding surface, and / or is bonded to the molding surface, and / or extends from the molding surface, and a mating portion that at least partially surrounds the non-mating portion.

[0015] A flap-type mold insert and / or a cavity insert can be used in a mold stack for molding a tubular article having a neck portion with a radial flange and an open end and a hollow body portion with a closed end. The molding surface of the flap-type mold insert can be used to mold a portion of the hollow body portion and at least the radial flange of the neck portion. The molding surface of the cavity insert can be used to mold a portion of the hollow body portion.

[0016] Another broad aspect of the present invention provides a mold stack, for example for molding a tubular article having a neck portion with a radial flange and an open end and a hollow body portion with a closed end, the mold stack comprising: a cavity insert having a molding surface for molding a portion of the hollow body portion; a flap-type mold insert having a molding surface for molding a portion of the hollow body portion and at least the radial flange of the neck portion; and an interface between the cavity insert and the flap-type mold insert; wherein the interface comprises a non-mating portion and a mating portion, the non-mating portion at least partially surrounding the molding surface and / or being bonded to the molding surface and / or extending from the molding surface, and the mating portion at least partially surrounding the non-mating portion.

[0017] The non-mating portions may form a gap, such as a force isolating gap. For example, in use, when the mold stack is in a molding configuration, a gap may form between the cavity insert and the flap mold insert when clamping forces are transmitted laterally across the mating portions.

[0018] Another broad aspect of the present invention provides a mold stack, for example for molding tubular articles, the tubular articles having a neck portion with a radial flange and an open end and a hollow body portion with a closed end, the mold stack comprising: a cavity insert having a molding surface for molding a portion of the hollow body portion; a flap-type mold insert having a molding surface for molding a portion of the hollow body portion and at least the radial flange of the neck portion; and an interface between the cavity insert and the flap-type mold insert; wherein the interface comprises a non-mating portion and a mating portion, the non-mating portion at least partially surrounding the molding surface and / or being bonded to the molding surface and / or extending from the molding surface, the mating portion at least partially surrounding the non-mating portion, and in use, when the mold stack is in the molding configuration, when the clamping force is transmitted laterally in the mating portion, the non-mating portion forms a gap, for example a force isolation gap, between the cavity insert and the flap-type mold insert.

[0019] At least a portion of the non-mating portion may be annular or partially annular.At least a portion of the non-mating portion may extend around the moulding surface and / or extend adjacent to the moulding surface and / or circumscribe the moulding surface.

[0020] Additionally or alternatively, at least a portion of the non-mating portion may have a radial dimension that is at least half, for example at least two-thirds or three-quarters or four-fifths or nine-tenths, of the radial dimension of a radial flange formed by the molding surface of the flap-type mold insert.

[0021] The non-mating portion may include one or more non-mating surfaces, such as facing non-mating surfaces. The non-mating portion may include at least one surface of each of the flap-fit ​​mold insert and the cavity insert. The non-mating portion may include facing non-mating surfaces of the flap-fit ​​mold insert and the cavity insert. At least one or each non-mating surface may be planar, but is not required.

[0022] At least a portion of at least one of the non-mating surfaces of the flap-type mold insert may be spaced 5 mm or less, preferably 3 mm or less, and more preferably 2 mm or less from the radial flange portion. In some embodiments, at least a portion of at least one of the non-mating surfaces of the flap-type mold insert is spaced 1 mm or less from the radial flange portion.

[0023] The non-mating portion may include a first portion. The first portion may extend radially from the molding surface. The non-mating portion may include a second portion. The second portion may at least partially surround the first portion and / or may extend at an angle from the first portion or be substantially perpendicular or orthogonal to the first portion.

[0024] The first portion may define, for example, a first gap between a cavity insert and a flap mold insert. The second portion may define, for example, a second gap between a cavity insert and a flap mold insert. The first gap may be larger than the second gap, or the second gap may be larger than the first gap. The second portion may be coupled to and / or extend from the first portion.

[0025] The interface may include one or more or more tapers, such as two or more or more cooperating male and female tapers. The tapers may be used, for example, to align the cavity insert with the flap mold insert when the mold stack is in a molding configuration.

[0026] The flap-type mold insert may include a plurality of flap-type mold insert parts. The flap-type mold insert parts may together provide a molding surface, such as for molding a portion of the hollow body portion and at least a radial flange of the neck portion. The flap-type mold insert may include a male cone, or the flap-type mold insert parts may together provide a male cone. The male cone may be on the cavity side of the flap-type mold insert. The cavity insert may include a female cone. At least a portion of the mating portion may be molded by the male cone and / or the female cone.

[0027] The flap-type mold insert may include, or the flap-type mold insert portion may be provided together with, a cavity side groove, for example, at least partially within the male cone and / or extending from the cavity side. The cavity side groove may include a non-mating portion, which may at least partially surround the molding surface and / or be bonded to the molding surface and / or extend from the molding surface.

[0028] The flap-fit ​​mold insert may include, or the flap-fit ​​mold insert parts may be provided together with, a cavity-fitting portion. The cavity-fitting portion may at least partially surround a non-fitting portion, such as a cavity side pocket.

[0029] The male cone may include a first male cone. The flap-type mold insert may include, or the flap-type mold insert portions may together provide, a second male cone, which may be on the core side of the flap-type mold insert. Alternatively, the flap-type mold insert may include, or the flap-type mold insert portions may together provide, a female cone, which may be on the core side of the flap-type mold insert.

[0030] The flap mold insert may include, or the flap mold insert parts may together provide, a core side pocket, and the core side pocket may be at least partially within the second male cone and / or may extend from the core side to the molding surface.

[0031] The flap-fitting mould insert may be configured such that, in use, when the mould stack is in the moulding configuration, a clamping force is transmitted to the cavity insert through the cavity mating portion, for example, and not through the non-mating portion.

[0032] Another broad aspect of the present invention provides a flap-type mold insert for use, for example, in a mold stack for molding a tubular article having a neck portion with a radial flange and an open end and a hollow body portion with a closed end, the flap-type mold insert comprising a plurality of flap-type mold insert portions that together provide: a molding surface for molding a portion of the hollow body portion and at least the radial flange of the neck portion; a first male cone on a cavity side of the flap-type mold insert; and a cavity side mold insert at least partially within the first male cone and extending from the cavity side. A groove, the cavity-side groove includes a non-mating portion at least partially surrounding the molding surface and extending from the molding surface; a cavity-mating portion at least partially formed by a first male cone, the cavity-mating portion at least partially surrounding the non-mating portion; a second male cone on the core side of the flap-type mold insert; and a core-side groove, the core-side groove is at least partially within the second male cone and extends from the core side to the molding surface; wherein the flap-type mold insert is configured so that in use, when the mold stack is in the molding configuration, the clamping force is transmitted to the cavity insert through the cavity-mating portion rather than through the non-mating portion.

[0033] The mating portion may include one or more planar surfaces. Additionally or alternatively, the mating portion may include one or more frustoconical surfaces. In some embodiments, the mating portion includes one or more planar surfaces and one or more frustoconical surfaces. The planar surfaces may be annular or partially annular. The frustoconical surfaces may be annular or partially annular.

[0034] The mating portion may include one or more annular or partially annular surfaces. At least one of the annular or partially annular surfaces of the mating portion may be planar and / or radially oriented. At least one of the annular or partially annular surfaces of the mating portion may be frustoconical. In some embodiments, the mating portion includes one or more planar annular or partially annular surfaces and one or more frustoconical annular or partially annular surfaces.

[0035] The cooperating male and female cones may include mating frustoconical surfaces. In use, for example, when the mold stack is in a molding configuration, at least a portion of the clamping force may be transmitted through the mating frustoconical surfaces. The cooperating male and female cones may include mating flat surfaces. In use, for example, when the mold stack is in a molding configuration, at least a portion of the clamping force may be transmitted through the mating flat surfaces.

[0036] The first male cone may include a frustoconical surface. The frustoconical surface may at least partially surround the side groove of the cavity. Alternatively, the first male cone may include an extended surface that protrudes from the frustoconical surface and / or at least partially surrounds the side groove of the cavity. The frustoconical surface may shape at least a portion of the mating portion of the cavity.

[0037] The cavity insert may include a female cone. The cavity insert may include a socket, such as a cooperating socket or a socket that cooperates with the cavity side receptacle of the flap mold insert or is formed in the flap mold insert. The female cone may be on the flap mold side of the cavity insert. The socket may include a flap mold side socket. The flap mold side socket may be at least partially circumscribed by the female cone. The flap mold side socket may include a non-matching portion. The non-matching portion may at least partially surround the molding surface and extend from the molding surface. The cavity insert may include a flap mold matching portion. The flap mold matching portion may at least partially surround the non-matching portion.

[0038] The cavity insert may be configured such that, in use, when the mould stack is in the moulding configuration, a clamping force is transmitted to the flap mould insert through the cavity mating portion, for example, rather than through the non-mating portion.

[0039] Another broad aspect of the present invention provides a cavity insert for use, for example, in a mold stack for molding tubular articles, the tubular articles having a neck portion with a radial flange and an open end and a hollow body portion with a closed end, the cavity insert comprising: a molding surface for molding a portion of the hollow body portion; a female cone on the flap-fit ​​mold side of the cavity insert; a flap-fit ​​mold side socket at least partially circumscribed by the female cone, the flap-fit ​​mold side socket comprising a non-mating portion at least partially surrounding the molding surface and extending from the molding surface; a flap-fit ​​mold mating portion at least partially molded by the female cone, the flap-fit ​​mold mating portion at least partially surrounding the non-mating portion; wherein the cavity insert is configured so that in use, when the mold stack is in a molding configuration, a clamping force is transmitted to the flap-fit ​​mold insert through the cavity mating portion rather than through the non-mating portion.

[0040] The female cone of the cavity insert may include a frustoconical surface. The frustoconical surface may at least partially surround the side socket of the flap-type mold. Alternatively, the female cone may include an extension surface. The frustoconical surface may extend from the extension surface. The extension surface may at least partially surround the side socket of the flap-type mold. The frustoconical surface may shape at least a portion of the mating portion of the flap-type mold.

[0041] The male or first male taper of the flap-type mold insert may, for example, be at least partially recessed relative to the peripheral portion of the flap-type mold insert. In other embodiments, the flap-type mold insert may include or the flap-type mold insert parts may together provide a female taper, and / or the cavity insert may include a male taper, in which case the male taper may, for example, be at least partially recessed relative to the peripheral portion of the cavity insert.

[0042] The flap-type mold insert may include a cavity-side groove and / or the cavity-side groove or the cavity-side groove may be formed in the flap-type mold insert. The cavity-side groove may be on the cavity side of the flap-type mold insert. The male taper may be at least partially within the cavity-side groove. The male taper may include the non-mating portion or the non-mating portion, which at least partially surrounds the molding surface and extends from the molding surface.

[0043] Another broad aspect of the present invention provides a flap-type mold insert for use, for example, in a mold stack for molding tubular articles, the tubular articles having a neck portion with a radial flange and an open end and a hollow body portion with a closed end, the flap-type mold insert comprising a plurality of flap-type mold insert portions, the plurality of flap-type mold insert portions together providing: a molding surface for molding a portion of the hollow body portion and at least the radial flange of the neck portion; a cavity side groove on the cavity side of the flap-type mold insert; a male cone at least partially within the cavity side groove, the male cone including a non-mating portion, the non-mating portion at least partially surrounding the molding surface and extending from the molding surface; and a cavity mating portion, the cavity mating portion being at least partially molded by the male cone, the cavity mating portion at least partially surrounding the non-mating portion; wherein the flap-type mold insert is configured so that in use, when the mold stack is in the molding configuration, the clamping force is transmitted to the cavity insert through the cavity mating portion rather than through the non-mating portion.

[0044] Another broader aspect of the present invention provides a flap-type mold insert for use, for example, in a mold stack for molding tubular articles, the flap-type mold insert comprising a plurality of flap-type mold insert portions which together provide a cavity side groove on the cavity side of the flap-type mold insert and a male cone at least partially within the cavity side groove.

[0045] Another broad aspect of the present invention provides a flap-fit ​​mold insert for use, for example, in a mold stack for molding tubular articles, the flap-fit ​​mold insert comprising a plurality of flap-fit ​​mold insert portions that together provide a male cone that is at least partially concave relative to a peripheral portion of the flap-fit ​​mold insert portion.

[0046] The cavity insert may include a raised portion, such as a cooperating raised portion or a raised portion cooperating with a cavity-side recess of the flap-type mold insert or formed in the flap-type mold insert. The raised portion may include, for example, a flap-type mold-side raised portion on the flap-type mold side of the cavity insert. The raised portion may at least partially surround or circumscribe the female cone.

[0047] The cavity insert may include a female cone at least partially within the raised portion of the flap mold side. The female cone may include the non-mating portion or portions thereof, which may at least partially surround the molding surface and / or extend from the molding surface. The cavity insert may include a flap mold mating portion, which may at least partially surround the non-mating portion.

[0048] Another aspect of the present invention provides a cavity insert for use in a mold stack for molding tubular articles, the tubular articles having a neck portion with a radial flange and an open end and a hollow body portion with a closed end, the cavity insert comprising: a molding surface for molding a portion of the hollow body portion; a flap-type mold side protrusion on the flap-type mold side of the cavity insert; a female cone at least partially within the flap-type mold side protrusion, the female cone including a non-mating portion, the non-mating portion at least partially surrounding the molding surface and extending from the molding surface; and a flap-type mold mating portion at least partially molded by the female cone, the flap-type mold mating portion at least partially surrounding the non-mating portion; wherein the cavity insert is configured so that in use, when the mold stack is in a molding configuration, a clamping force is transmitted to the cavity insert through the cavity mating portion rather than through the non-mating portion.

[0049] When the mold stack is in the molding configuration, the protrusion can be separated from the cavity-side groove, for example, by a circumferential gap. The circumferential gap can be between the outer cylindrical surface of the protrusion and the groove. The circumferential gap can be at least 0.01 mm, for example, approximately 0.02 mm. Additionally or alternatively, when the mold stack is in the molding configuration, the protrusion can be separated from the cavity-side groove by an axial gap. The axial gap can be between the facing annular surfaces of the groove and the protrusion. The axial gap can be at least 0.01 mm, for example, approximately 0.02 mm.

[0050] The male cone may include two or more, for example, a plurality of, male cones. The two or more or more male cones may be nested and / or concentric male cones. The plurality of nested and / or concentric male cones may each be at least partially within the cavity side groove or corresponding cavity side grooves.

[0051] Another aspect of the invention provides a flap-fit ​​mold insert, for example for use in a mold stack for molding tubular articles, the flap-fit ​​mold insert comprising a plurality of flap-fit ​​mold insert portions that together provide a plurality of nested and / or concentric cones.

[0052] The mother cone may include two or more, for example, a plurality of, mother cones. The two or more or more mother cones may be nested and / or concentric. The cavity insert may include a plurality of flap-type mold-side projections, which may be on the flap-type mold side of the cavity insert. The plurality of nested and / or concentric mother cones may each be formed within the flap-type mold-side projection or within a corresponding flap-type mold-side projection.

[0053] Another broad aspect of the present invention provides a cavity insert for use, for example, in a mold stack for molding tubular articles, the tubular articles having a neck portion with a radial flange and an open end and a hollow body portion with a closed end, the cavity insert comprising: a molding surface for molding a portion of the hollow body portion; a plurality of flap-type mold side projections on the flap-type mold side of the cavity insert; a plurality of nested and / or concentric female cones, each of the plurality of nested and / or concentric female cones being molded within a corresponding flap-type mold side projection; a flap-type mold non-mating portion, the flap-type mold non-mating portion at least partially surrounding the molding surface and extending from the molding surface; and a flap-type mold mating portion at least partially molded by the female cone, the flap-type mold mating portion at least partially surrounding the non-mating portion; wherein the cavity insert is configured so that in use, when the mold stack is in a molding configuration, a clamping force is transmitted to the cavity insert through the cavity mating portion rather than through the non-mating portion.

[0054] Another broader aspect of the present invention provides a cavity insert, for example for use in a mold stack for molding tubular articles, the cavity insert comprising a plurality of nested and / or concentric female cones.

[0055] At least one of the nested and / or concentric male cones may be annular. At least one of the nested and / or concentric male cones may be partially annular. At least one of the nested and / or concentric female cones may be annular. At least one of the nested and / or concentric female cones may be partially annular.

[0056] The male and female cones, such as the cooperating male and female cones, may include positioning cones. The male and female cones may include positioning cones, such as a plurality of cooperating male and female positioning cones. The cones, such as each of the cooperating male and female positioning cones, may be spaced around and / or adjacent to the non-mating portion and / or centered at a radial distance from the non-mating portion. The cones, such as each of the cooperating male and female positioning cones, may be centered at substantially the same radial distance from the non-mating portion.

[0057] The flap-type mold insert may include a plurality of cones. Each cone may be spaced around and / or adjacent to the non-mating portion. Each cone may be centered at a radial distance from the non-mating portion.

[0058] Another broad aspect of the present invention provides a flap-type mold insert for use in a mold stack for molding tubular articles, the tubular articles having a neck portion with a radial flange and an open end and a hollow body portion with a closed end, the flap-type mold insert comprising a plurality of flap-type mold insert portions, the plurality of flap-type mold insert portions together providing: a molding surface for molding a portion of the hollow body portion and at least the radial flange of the neck portion; a cavity-side non-mating portion at least partially surrounding the molding surface and extending from the molding surface; a cavity-mating portion at least partially surrounding the non-mating portion; and a plurality of cones, each of the plurality of cones being spaced apart around and / or adjacent to the cavity-side non-mating portion and centered at a radial distance from the cavity-side non-mating portion; wherein the flap-type mold insert is configured so that in use, when the mold stack is in a molding configuration, a clamping force is transmitted to the cavity insert through the cavity-mating portion rather than through the cavity-side non-mating portion.

[0059] Another broader aspect of the invention provides a flap-fit ​​mold insert for use in a mold stack for molding tubular articles, the flap-fit ​​mold insert comprising a plurality of cones each spaced about and / or adjacent to a central axis and centered a radial distance from the central axis.

[0060] The cone, for example, each of a plurality of cones, may be provided by a corresponding hole in the flap-fitting mold insert. Alternatively, the cone, for example, each of a plurality of cones, may be provided by a corresponding protrusion or male cone on the flap-fitting mold insert.

[0061] The cavity insert may include a plurality of cones. Each cone may be spaced around and / or adjacent to the non-mating portion. Each cone may be centered at a radial distance from the non-mating portion.

[0062] Another broad aspect of the present invention provides a cavity insert for use in a mold stack for molding tubular articles, the tubular articles having a neck portion with a radial flange and an open end and a hollow body portion with a closed end, the cavity insert comprising: a molding surface for molding a portion of the hollow body portion; a flap-type mold side non-mating portion, the flap-type mold side non-mating portion at least partially surrounding the molding surface and extending from the molding surface; a flap-type mold mating portion, the flap-type mold mating portion at least partially surrounding the non-mating portion; and a plurality of cones, each of the plurality of cones being spaced around and / or adjacent to the flap-type mold side non-mating portion and centered at a radial distance from the flap-type mold side non-mating portion; wherein the cavity insert is configured so that in use, when the mold stack is in a molding configuration, a clamping force is transmitted to the cavity insert through the cavity mating portion rather than through the non-mating portion.

[0063] The cone, for example, each of a plurality of cones, may be provided by a corresponding boss or pin extending from the cavity insert. Alternatively, the cone, for example, each of a plurality of cones, may be provided by a corresponding hole in the cavity insert.

[0064] The mating portion may include one or more (e.g., a pair of) substantially flat surfaces. The mating portion may include a pair of substantially flat surfaces on opposite sides of the non-mating portion. The or each substantially flat surface may taper or slope toward the non-mating portion. The pair of substantially flat surfaces may converge toward the non-mating portion.

[0065] The cavity insert may include a first portion. The first portion may include at least a portion of the molding surface. The cavity insert may include a second portion. The second portion may include at least a portion of the mating portion.

[0066] Another broad aspect of the present invention provides a mould comprising a mould stack or a cavity insert or a flap mould insert as described above.

[0067] The mold assembly or mold can include a stripper plate assembly, for example, to which the flap-type mold insert is mounted or movably mounted. The stripper plate assembly can include a stripper plate and / or one or more (e.g., a pair of) slides movably mounted to the stripper plate. Each flap-type mold insert portion can be mounted to a respective one of the slides.

[0068] The mold assembly can include a plurality of flap-type mold inserts movably mounted to a stripper plate assembly. The stripper plate assembly can include a plurality of slide pairs that can carry the flap-type mold inserts. The stripper plate can include a plurality of core holes, for example, through which the core inserts extend.

[0069] The stripper plate assembly may include one or more wear-resistant surfaces or wear plates. The slides may move along and / or contact the wear-resistant surfaces or plates. The or each slide pair may be movable toward and / or away from each other. Each portion of the or each flap mold insert may be movable toward and / or away from each other, for example, by relative movement of the slides to which they are mounted.

[0070] The mold assembly may include two or more cavity inserts, such as a plurality of cavity inserts. The mold assembly may include a cavity plate, such as the cavity insert or each cavity insert is mounted to or within the cavity plate. The mold assembly may include one or more gate inserts, such as a plurality of gate inserts. The gate insert or each gate insert may include or form a molding surface and / or a gate. The gate insert or each gate insert may be mounted to or within the cavity plate, such as and / or may engage and / or cooperate with the cavity insert or a corresponding one of the cavity inserts.

[0071] The cavity plate may include one or more (e.g., multiple) bases. The or each cavity insert and / or the or each gate insert may be received within a respective one of the bases. The gate insert may include a nozzle receiving recess and / or a molding surface that molds the closed end of the preform. In some embodiments, the cavity insert incorporates features of the gate insert.

[0072] The mold assembly may include a melt stream distributor, which may be mounted to the cavity plate. The melt stream distributor may include one or more (e.g., multiple) nozzles. The nozzle or each nozzle may cooperate and / or engage with the gate of a gate insert or a corresponding one of the gate inserts. The cavity plate may include a melt stream distributor facing side, for example, the melt stream distributor is mounted to the melt stream distributor facing side. The cavity plate assembly may include a core facing side, for example, opposite the melt stream distributor facing side. The mother cone of the cavity insert or each cavity insert may be on the core facing side of the cavity plate.

[0073] The mold stack may include a core insert. The core insert may include a molding surface. The stripper plate assembly may, for example, move along the core insert. The mold assembly or mold may include a core plate, for example, to which the core insert is mounted. The mold assembly may include a plurality of core inserts, each of which may be mounted to the core plate. Each core insert may have a molding surface.

[0074] The stripper plate and / or the stripper plate assembly may include a cavity-facing side and / or a core-facing side, for example, opposite the cavity-facing side. The stripper plate may be located on the core-facing side of the stripper plate assembly. The wear plate and / or the slide and / or the flap-type mold insert may be on the cavity-facing side of the stripper plate or the stripper plate assembly. The core plate may include a mounting side and / or a cavity or stripper plate facing side, for example, opposite the mounting side. The core may be mounted to the core plate so that the core protrudes from the cavity or stripper plate facing side of the core plate. The stripper plate assembly may be mounted (e.g., movably mounted) to the core plate so that the core is accommodated in the core hole and / or can be moved along the core hole. A guide (e.g., a cam) may be mounted (e.g., fixed) to the core plate. Movement of the stripper plate assembly relative to the core plate may cause the cam follower to move along the cam.

[0075] Another aspect of the invention provides a computer program element that includes and / or shapes and / or defines a three-dimensional design for use with a simulation device or a three-dimensional additive or subtractive manufacturing device or equipment (such as a three-dimensional printer or CNC machine), the three-dimensional design including a mold assembly, a mold, a flap mold insert, a core, a pressure plate or any one or more other mold parts described above.

[0076] For the avoidance of doubt, any features described herein are equally applicable to any aspect of the present invention. It is expressly intended that the various aspects, embodiments, examples, and alternatives set forth in the preceding paragraphs, in the claims, and / or in the following description and drawings, and in particular individual features thereof, may be employed independently or in any combination within the scope of this application. That is, all embodiments and / or features of any embodiment may be combined in any manner and / or combination, unless such features are incompatible.

[0077] For the avoidance of doubt, the terms "may," "and / or," "for example," "such as," and any similar terms used herein should be construed as non-limiting, such that any features so formulated need not be present. Indeed, any combination of optional features is expressly contemplated without departing from the scope of the present invention, whether or not such features are expressly claimed. Applicants reserve the right to change any originally filed claim or to file any new claim accordingly, including the right to amend any originally filed claim to reference and / or incorporate any features from any other claim, even though such features were not originally claimed in such manner. BRIEF DESCRIPTION OF THE DRAWINGS

[0078] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0079] Figure 1 depicts a portion of a preform mold incorporating a mold stack according to a first example;

[0080] Figure 2 yes Figure 1 an enlarged view of the mold stack showing the interface between the cavity insert and the flap mold insert;

[0081] Figure 3 Viewed from the side of the flap mold insert Figure 1 and Figure 2 A perspective view of the mold stack and the cavity insert;

[0082] Figure 4 Viewed from the side of the cavity insert Figure 1 and Figure 2 A perspective view of a flap-type mold insert of a mold stack;

[0083] Figure 5 It is an alternative to die stacking similar to Figure 2 , which shows the interface between the cavity insert and the flap mold insert;

[0084] Figure 6 Viewed from the side of the flap mold insert Figure 5 A perspective view of the mold stack and the cavity insert;

[0085] Figure 7 Viewed from the side of the cavity insert Figure 5 A perspective view of a flap-type mold insert of a mold stack;

[0086] Figure 8 is another alternative to the die stack similar to Figure 2 , which shows the interface between the cavity insert and the flap mold insert;

[0087] Figure 9 Viewed from the side of the flap mold insert Figure 8 A perspective view of the mold stack and the cavity insert;

[0088] Figure 10 Viewed from the side of the cavity insert Figure 8 A perspective view of a flap-type mold insert of a mold stack;

[0089] Figure 11 is another alternative to the die stack similar to Figure 2 , which shows the interface between the cavity insert and the flap mold insert;

[0090] Figure 12 yes Figure 11 An enlarged view of area A;

[0091] Figure 13 Viewed from the side of the flap mold insert Figure 11 A perspective view of the mold stack and the cavity insert;

[0092] Figure 14 Viewed from the side of the cavity insert Figure 11 A perspective view of a flap-type mold insert of a mold stack;

[0093] Figure 15 is another alternative to the die stack similar to Figure 2 , which shows the interface between the cavity insert and the flap mold insert;

[0094] Figure 16 Viewed from the side of the flap mold insert Figure 15 a perspective view of the mold stack and the cavity insert; and

[0095] Figure 17 Viewed from the side of the cavity insert Figure 15 A perspective view of a mold stack with a flap-fit ​​mold insert. DETAILED DESCRIPTION

[0096] Reference Figure 1 , depicts a non-limiting embodiment of a portion of a mold assembly 100 including a core plate assembly 101, a stripper plate assembly 102, and a cavity plate assembly 103, which together are incorporated into a plurality of mold stacks 104, only one of which is shown. Figure 1 In the molding configuration shown in , each mold stack 104 forms a cavity, and the cavity forms a preform P. The mold assembly 100 may further include a melt distributor (not shown) fixed to an exposed side of the cavity plate assembly 103 for injecting molten material into the mold stack 104 .

[0097] The core plate assembly 101 includes a core plate 110 to which a core assembly 111 of each mold stack 104 is mounted. Each core assembly 111 includes a hollow core insert 112, a core ring 113 surrounding and engaging the base of the core insert 112, a locking ring 114 surrounding the core insert 112 and the core ring 113, and a core cooling tube 115 housed within the hollow core insert 112. The locking ring 114 is secured to the core plate 110 by bolts B and has an inner taper that engages the outer taper of the core ring 113 to secure the core ring 113 and core insert 112 to the core plate 110 in the usual manner.

[0098] The core insert 112 has a socket 112 a protruding from a first open end thereof and a molding surface 112 b at a second closed end. The socket 112 a is received within the base 110 a of the core plate 110 , and the molding surface 112 b is used to mold the inner surface of the preform P. A core cooling tube 115 is engaged within the base 110 a of the core plate 110 and is used to receive cooling fluid from the network of cooling channels 110 b within the core plate 110 . The cooling fluid then flows along the core cooling tube 115 and is directed to the inner surface of the closed end of the core insert 112 , and is then redirected along the exterior of the core cooling tube 115 back into the network of cooling channels 110 b in a conventional manner.

[0099] The stripper plate assembly 102 includes a stripper plate 120, a wear plate 121 mounted to the stripper plate 120, a slide 122 movably mounted to the wear plate 121, and a flap-type mold insert 123 for each mold stack 104 mounted to the slide 122. More specifically, in the present embodiment, the flap-type mold insert 123 includes two flap-type mold insert portions 123a, 123b, and each flap-type mold insert portion 123a, 123b is mounted to a respective one of the slides 122. Those skilled in the art will appreciate that the stripper plate assembly 102 may include multiple pairs of slides 122, with each slide 122 in each pair carrying a respective one of the flap-type mold insert portions 123a, 123b for each of the plurality of mold stacks 104. Each slide 122 is connected to one of the slides 122 of each of the other pairs of slides 122 , thereby enabling simultaneous separation of all flap-type mould insert parts 123 a , 123 b during demoulding of the preform P in a usual manner.

[0100] The cavity plate assembly 103 includes a cavity plate 130 to which a cavity insert 131 of each mold stack 104 is mounted. In the present embodiment, the cavity insert 131 is divided into a cavity portion 132 and a cavity flange 133, but those skilled in the art will appreciate that these two components can be provided as a single unit. The cavity portion 132 is received within a seat 130a of the cavity plate 130. In the present embodiment, each mold stack 104 also includes a gate insert 134 received within the seat 130a, adjacent to the cavity portion 132. The gate insert 134 includes a nozzle receiving groove 134a and a molding surface 134b that molds the closed end of the preform P.

[0101] Now refer to Figures 2 to 4 The flap-type mold insert 123 forms a molding surface 124 that forms the open-ended neck portion of the preform P. More specifically, the molding surface 124 includes a threaded portion 124a, a radial flange portion 124b, and a hollow body portion 124c. The cavity insert 131, or more specifically, the cavity portion 132 of the cavity insert 131, forms a molding surface 135 for forming a portion of the hollow body portion. The molding surface 134b of the gate insert 134 provides a continuation of the molding surface 135 of the cavity insert 131. However, those skilled in the art will appreciate that the cavity portion 132 may incorporate features of the gate insert 134.

[0102] In this embodiment, the flap-type mold insert 123 includes a cavity-side groove 125 and a male taper 126 within the cavity-side groove 125. The cavity insert 131, or more specifically, the cavity flange 133 of the cavity insert 131, includes a raised portion 136 having a shape complementary to the cavity-side groove 125 of the flap-type mold insert 123. A female taper 137 is formed within the raised portion 136 partially by the cavity flange 133 and partially by the cavity portion 132.

[0103] When the mold stack 104 is in the molding configuration, the male and female tapers 126, 137 form an interface 140 between the clamshell mold insert 123 and the cavity insert 131. The interface 140 includes a non-mating portion 141 and a mating portion 142. The non-mating portion 141 surrounds and extends from the molding surfaces 124, 135, while the mating portion 142 surrounds the non-mating portion 141. In this embodiment, the non-mating portion 141 is formed by facing flat surfaces 141a, 141b of the clamshell mold insert 123 and the cavity insert 131. In this embodiment, the mating portion 142 is formed by frustoconical surfaces 142a, 142b and peripheral flat surfaces 142e, 142f of the clamshell mold insert 123 and the cavity insert 131.

[0104] The non-mating surface 141a of the flap-type mold insert 123 corresponds to the truncated apex of the male cone 126. The non-mating surface 141b of the cavity insert 131 corresponds to the base of the female cone 137 formed by the cavity portion 132. The flap-type mold insert 123 includes a first mating surface 142a corresponding to the exterior of the male cone 126 and a second mating surface 142e surrounding the cavity-side groove 125. The cavity insert 131 includes a first mating surface 142b corresponding to the inner surface of the female cone 137 facing the male cone 126 of the flap-type mold insert 123, and a second mating surface 142f surrounding the protrusion 136 facing the second mating surface 14e of the cavity insert 131. The non-mating surfaces 141 a and 141 b of the flap-type mold insert 123 and the cavity insert 131 circumscribe and extend from their respective molding surfaces 124 and 135 and are not mated with each other by virtue of a gap G therebetween. The mating surfaces 142 a and 142 b of the flap-type mold insert 123 and the cavity insert 131 circumscribe the non-mating surfaces 141 a and 141 b and are in contact with each other.

[0105] The gap G is sized to isolate the non-mating portion 141 from clamping loads applied to the mold assembly 100 during use, while preventing the molded material from passing therethrough. In the present embodiment, the molded material is polyethylene terephthalate (PET), and the gap G is 0.03 mm. Thus, the clamping load passes through the mating surfaces 142a, 142b of the mating portion 142, while the non-mating portion 141 is isolated from the clamping load, which might otherwise stress the area of ​​the flap-fit ​​mold insert 123 adjacent the radial flange portion 124b. This force isolating gap G minimizes the distance between the non-mating surface 141a of the flap-fit ​​mold insert 123 and the radial flange portion 124b, while mitigating the risk of overstressing areas of the flap-fit ​​mold insert 123. For example, the distance between the non-mating surface 141a of the flap-fit ​​mold insert 123 and the radial flange portion 124b can be 2 mm and can be less.

[0106] In this embodiment, when the mold stack 104 is in the molding configuration, the protrusion 136 of the cavity insert 131 is also spaced apart from the facing surface of the cavity-side recess 125 of the flap-type mold insert 123 by an axial gap between the facing annular surfaces of the recess and the protrusion, and a circumferential gap between the protrusion and the outer cylindrical surface of the recess. In this embodiment, both the axial gap and the circumferential gap are approximately 0.02 mm. Thus, substantially all of the clamping force transmitted between the flap-type mold insert 123 and the cavity insert 131 passes through the mating surfaces 142 a, 142 b, 142 e, 142 f of the mating portion 142 of the interface 140.

[0107] Now go to Figures 5 to 7 , shows an alternative mold stack 204 similar to the above-described embodiment, wherein like features are depicted with like reference numerals increased by 100 and are therefore not further described. The mold stack 204 according to this embodiment differs from the mold stacks of the previous embodiments in that the interface 240 incorporates a plurality of nested and concentric cones 226, 237.

[0108] As in the previous embodiment, the interface 240 includes a non-mating portion 241 and a mating portion 242, with the non-mating portion 241 surrounding and extending from the molding surfaces 224, 235, while the mating portion 242 surrounds the non-mating portion 241. The non-mating portion 241 is also formed by the facing flat surfaces 241a, 241b of the flap-type mold insert 223 and the cavity insert 231. The non-mating surfaces 241a, 241b of the flap-type mold insert 223 and the cavity insert 231 also circumscribe their respective molding surfaces 224, 235 and extend from their respective molding surfaces 224, 235, and are not mated by means of a gap G therebetween.

[0109] However, in this embodiment, the mating portion 242 is formed by a plurality of facing frustoconical surfaces 242a, 242b and facing flat surfaces 242c, 242d of the flap-type mold insert 223 and the cavity insert 231. The mating frustoconical surface 242a of the flap-type mold insert 223 corresponds to the exterior of the male cone 226, while the mating surface 242b of the cavity insert 231 corresponds to the facing interior surface of the female cone 237. The mating flat surfaces 242c, 242d of the flap-type mold insert 223 and the cavity insert 231 circumscribe the non-mating flat surfaces 241a, 241b and contact each other. As a result, the innermost male cone 226 has a truncated apex with a shallow step that delimits the mating flat surface 242c of the flap-type mold insert 223 from the non-mating flat surface 241a of the flap-type mold insert 223. However, the base of the innermost female cone 237 of the cavity insert 231 does not have such a step, and therefore, the mating planar surface 242d of the cavity insert 231 is coplanar with its non-mating planar surface 241b. Skilled artisans will appreciate that the base of the innermost female cone 237 of the cavity insert 231 may include a shallow step in addition to or in lieu of the shallow step on the truncated apex of the innermost male cone 226.

[0110] As in the first embodiment, the gap G is sized to isolate the non-mating portion 241 from the clamping load while preventing the molded material from passing therethrough. Thus, the clamping load passes through the mating surfaces 242a, 242b, 242c, 242d of the mating portion 242, while the non-mating portion 241 is isolated from the clamping load, which might otherwise stress the area of ​​the flap-fit ​​mold insert 223 adjacent to the radial flange portion 224b. This force-isolating gap G minimizes the distance between the non-mating surface 241a of the flap-fit ​​mold insert 223 and the radial flange portion 224b, while mitigating the risk of excessive stress on areas of the flap-fit ​​mold insert 223. For example, the distance between the non-mating surface 241a of the flap-fit ​​mold insert 223 and the radial flange portion 224b can be 2 mm or less.

[0111] Similar to the first embodiment, when the mold stack 204 is in the molding configuration, the raised portion 236 of the cavity insert 231 is spaced apart by an axial gap and a circumferential gap from the facing surface of the cavity-side recess 225 of the flap-type mold insert 223. Thus, substantially all of the clamping force transmitted between the flap-type mold insert 223 and the cavity insert 231 passes through the mating surfaces 242a, 242b, 242c, 242d of the mating portion 242 of the interface 240. As will be appreciated by those skilled in the art, other arrangements are also contemplated.

[0112] Now go to Figures 8 to 10, an alternative mold stack 304 is shown that is similar to the first mold stack 104 described above, wherein like features are depicted with like reference numerals increased by 200 and will not be described further. The mold stack 304 according to this embodiment differs from the mold stack of the first embodiment in that the interface 340 includes a cavity-side receiving groove 328 in the male cone 326 of the flap-type mold insert 323, which receives the flap-type mold-side receptacle 338 circumscribed by the female cone 337 of the cavity insert 331. In this embodiment, the male cone 326 protrudes from the body of the flap-type mold insert 323 rather than being located within the cavity-side recess 125.

[0113] As in the previous embodiment, the interface 340 includes a non-mating portion 341 and a mating portion 342, with the non-mating portion 341 surrounding and extending from the molding surfaces 324, 335, while the mating portion 342 surrounds the non-mating portion 341. The non-mating portion 341 is also formed by the facing flat surfaces 341a, 341b of the flap-type mold insert 323 and the cavity insert 331. The non-mating surfaces 341a, 341b of the flap-type mold insert 323 and the cavity insert 331 also circumscribe and extend from their respective molding surfaces 324, 335, and are not mated by means of a gap G therebetween.

[0114] However, in this embodiment, the non-mating surface 341a of the flap-type mold insert 323 corresponds to the base of the cavity-side receptacle 328, and the non-mating surface 341b of the cavity-side receptacle 331 corresponds to the free end of the flap-type mold insert 338. The diameter of the inner circumference of the cavity-side receptacle 328 is also slightly larger than the diameter of the outer circumference of the flap-type mold insert 338. In addition, as in the mold stack 104 of the first embodiment, the mating portion 342 includes not only the facing truncated conical surfaces 342a, 342b and the flat peripheral surfaces 342e, 342f of the cones 326, 337, but also the facing flat surfaces 342c, 342d of the truncated apex of the male cone 326 of the flap-type mold insert 323 and the base of the female cone 337 of the cavity insert 331. The mating planar surfaces 342c, 342d, 342e, 342f and the frustoconical surfaces 342a, 342b of the flap-type mold insert 323 and the cavity insert 331 circumscribe the non-mating planar surfaces 341a, 341b and are in contact with each other.

[0115] As in the previous embodiment, the gap G is sized to isolate the non-mating portion 341 from clamping loads while preventing the molded material from passing therethrough. Thus, the clamping load passes through the mating surfaces 342a, 342b, 342c, 342d, 342e, and 342f of the mating portion 342, while the non-mating portion 341 is isolated from the clamping load, which might otherwise stress the area of ​​the flap-fit ​​mold insert 323 adjacent to the radial flange portion 324b. This force-isolating gap G minimizes the distance between the non-mating surface 341a of the flap-fit ​​mold insert 323 and the radial flange portion 324b, while mitigating the risk of excessive stress on areas of the flap-fit ​​mold insert 323. For example, the distance between the non-mating surface 341a of the flap-fit ​​mold insert 323 and the radial flange portion 324b can be 2 mm or less.

[0116] Now go to Figures 11 to 14 , showing something similar to Figures 8 to 10 An alternative mold stack 404 to the mold stack 304 of FIG. 4 is shown in FIG. 4 , wherein like features are depicted with like reference numerals increased by 100 and are therefore not described further. The mold stack 404 according to this embodiment is similar to the mold stack 304 of FIG. 4 . Figures 8 to 10 The mold stack of FIG. 4 is different in that the male cone 426 includes an axial annular extension 426a that is received in an annular groove 432a in the cavity portion 432. The axial end of the annular extension 426a of the male cone 426 also forms a flat surface 441c spaced from the base of the annular groove 432a, and the annular groove 432a forms a facing flat surface 441d.

[0117] The technicians will also Figure 12 As will be appreciated, the exterior of the annular extension 426a of the male cone 426 is spaced apart from the interior of the annular recess 432a circumscribing the annular extension 426a. Those skilled in the art will appreciate that this gap reduces the risk of the exterior corner of the truncated apex of the male cone 426 of the flap-fit ​​mold insert 423 becoming lodged against the female cone 437. Thus, in this embodiment, the non-mating portion 441 includes all facing surfaces between the flap-fit ​​mold insert 423 and the cavity insert 431, the facing surfaces being circumscribed by the frustoconical mating surfaces 442a, 442b.

[0118] Now go to Figures 15 to 17 , showing something similar to Figures 1 to 4An alternative mold stack 504 to the mold stack 104 is shown, wherein like features are depicted with like reference numerals increased by 400 and are therefore not described further. The mold stack 504 according to this embodiment differs from the mold stack of the first embodiment in that the cooperating cones 126, 137 are replaced by six locating cones 526, 537 spaced about and / or adjacent to the non-mating portion 541 and centered at substantially the same radial distance from the non-mating portion 541.

[0119] More specifically, the cavity flange 533 of the cavity insert 531 includes six stepped holes 527a and six pins 527b, each pin having a male taper 526 projecting from the flap mold side of the cavity flange 533 and a stepped base 527c inserted into one of the stepped holes 527a from the opposite side of the cavity flange 533. The flap mold insert 523 includes six female tapers 537 provided by tapered blind holes extending into the cavity side of the flap mold insert 523.

[0120] The pin 527 can be press-fit into the stepped hole 527a, but the skilled person will understand that when the cavity flange 533 is fixed to the cavity plate 130, the pin 527 will also be captured therein. Other ways of providing the locating cone are also conceivable. Specifically, the stepped base 527 can be omitted, wherein the pin 527b can be inserted from the cavity side of the flap-type mold insert 523 and the pin 527b is fixed in the stepped hole 527a by a corresponding fastener (not shown) that engages in a threaded hole (not shown) in the pin 527b and abuts the step of the stepped hole 527a. Another alternative is to form the male cone 526 integrally with the cavity flange 533. The skilled person will also understand other possible configurations.

[0121] As in the previous embodiment, the interface 540 includes a non-mating portion 541 and a mating portion 542, with the non-mating portion 541 surrounding and extending from the molding surfaces 524, 535, while the mating portion 542 surrounds the non-mating portion 541. The non-mating portion 541 is also formed by the facing flat surfaces 541a, 541b of the flap-type mold insert 523 and the cavity insert 531. The non-mating surfaces 541a, 541b of the flap-type mold insert 523 and the cavity insert 531 also circumscribe their respective molding surfaces 524, 535 and extend from their respective molding surfaces 524, 535, with a gap G therebetween rather than mating.

[0122] However, in this embodiment, the non-mating surface 541a of the clamshell mold insert 523 is not formed on, in, or around the male cone 526, but is simply formed on the cavity-side surface of the clamshell mold insert 523. Furthermore, the mating portion 542 includes facing frustoconical surfaces 543a, 543b of the cones 526, 537 and facing flat surfaces 542c, 542d surrounding and generally adjacent to the non-mating flat surfaces 541a, 541b. The non-mating flat surface 541b of the cavity insert 531 is formed by the cavity portion 532, while the mating flat surface 542d of the cavity insert 531 is formed by the outer portion of the cavity flange 533. The non-mating flat surface 541b formed by the cavity portion 532 may be slightly recessed compared to the mating flat surface 542d formed by the outer portion of the cavity flange 533 to provide a gap G. Additionally or alternatively, the non-mating surface 541a of the flap-fit ​​mold insert 523 may be slightly recessed compared to its mating surface 542c to provide the gap G.

[0123] As in the previous embodiment, the gap G is sized to isolate the non-mating portion 541 from clamping loads while preventing the molded material from passing therethrough. Thus, the clamping load passes through the mating surfaces 542c, 542d, 543a, 543b of the mating portion 542, while the non-mating portion 541 is isolated from the clamping load, which might otherwise stress the area of ​​the flap-fit ​​mold insert 523 adjacent to the radial flange portion 524b. This force-isolating gap G can minimize the distance between the non-mating surface 541a of the flap-fit ​​mold insert 523 and the radial flange portion 524b, while mitigating the risk of excessive stress on areas of the flap-fit ​​mold insert 523. For example, the distance between the non-mating surface 541a of the flap-fit ​​mold insert 523 and the radial flange portion 524b can be 2 mm or less.

[0124] It should be understood that the configuration of the elements of the mold assembly 100 may vary, particularly but not exclusively as described above. Those skilled in the art will also understand that several variations in the construction and / or use of the aforementioned embodiments may be envisioned without departing from the scope of the present invention. Those skilled in the art will also understand that any number of combinations of the aforementioned features and / or features shown in the accompanying drawings provide significant advantages over the prior art and are therefore within the scope of the invention described herein.

Claims

1. A mold stack (104, 204, 304, 404, 504) for molding a tubular article having a neck portion with a radial flange and an open end and a hollow body portion with a closed end, the mold stack (104, 204, 304, 404, 504) comprising: a cavity insert (131, 231, 331, 431, 531) having a molding surface (135, 235, 335, 435, 535) for molding a portion of the hollow body portion; a flap-type mold insert (123, 223, 323, 423, 523) having a molding surface (124, 224, 324, 424, 524) for molding a portion of the hollow body portion and at least the radial flange of the neck portion; and an interface (140, 240, 340, 440, 540) between the cavity insert (131, 231, 331, 431, 531) and the flap-type mold insert (123, 223, 323, 423, 523); wherein the interface (140, 240, 340, 440, 540) includes a non-mating portion (141, 242, 342, 442, 542) at least partially surrounding the molding surface (124, 135, 224, 235, 324, 335, 424, 435, 524, 535) and extending from the molding surface (124, 135, 224, 235, 324, 335, 424, 435, 524, 535) and a mating portion (141, 241, 341, 441, 541) at least partially surrounding the non-mating portion (141, 241, 341, 441, 541) portion (142, 242, 342, 442, 542), and when the mold stack (104, 204, 304, 404, 504) is in a molding configuration, when a clamping force is transmitted laterally across the mating portion (142, 242, 342, 442, 542) in use, the non-mating portion (141, 241, 341, 441, 541) forms a gap (G) between the cavity insert (131, 231, 331, 431, 531) and the flap mold insert (123, 232, 332, 432, 532).

2. The mold stack (104, 204, 304, 404, 504) of claim 1, wherein at least a portion of the non-mating portion (141, 241, 341, 441, 541) is annular and circumscribes the molding surface (141, 241, 341, 441, 541).

3. A mold stack (104, 204, 304, 404, 504) as described in claim 2, wherein the annular non-mating portion (141, 241, 341, 441, 541) has a radial dimension that is at least half of the radial dimension of the radial flange formed by the molding surface (141, 241, 341, 441, 541) of the flap-type mold insert (123, 223, 323, 423, 523).

4. A mold stack (104, 204, 304, 404, 504) as described in any preceding claim, wherein the non-mating portion (141, 241, 341, 441, 541) includes facing non-mating surfaces (141a, 141b, 241a, 241b, 341a, 341b, 441a, 441b, 541a, 541b) of the flap-type mold insert (123, 223, 323, 423, 523) and the cavity insert (131, 231, 331, 431, 531), and at least a portion of the non-mating surface (141a, 241a, 341a, 441a, 541a) of the flap-type mold insert (123, 223, 323, 423, 523) is spaced 2 mm or less from the radial flange portion.

5. A mold stack (104, 204, 304, 404, 504) as described in any preceding claim, wherein the mating portion (142, 242, 342, 442, 542) includes one or more annular or partially annular surfaces (142a, 142b, 142e, 142f, 242a, 242b, 242c, 242d, 342a, 342b, 342c, 342d, 342e, 342f, 442a, 442b, 442e, 442f, 543a, 543b, 542c, 542d).

6. A mold stack (104, 204, 304, 404, 504) as described in claim 5, wherein at least one of the annular or partially annular surfaces (142e, 142f, 242c, 242d, 342c, 342d, 342e, 342f, 442e, 442f, 542c, 542d) of the mating portion (142, 242, 342, 442, 542) is radially oriented.

7. A mold stack (104, 204, 304, 404, 504) as described in claim 5 or claim 6, wherein at least one of the annular or partially annular surfaces (142a, 142b, 242a, 242b, 342a, 342b, 442a, 442b, 543a, 543b) of the mating portion (142, 242, 342, 442, 542) is frustoconical.

8. A mold stack (104, 204, 304, 404, 504) as described in any preceding claim, wherein the interface (140, 240, 340, 440, 540) includes cooperating male and female cones (126, 137, 226, 237, 326, 337, 426, 437, 526, 537), the cooperating male and female cones (126, 137, 226, 237, 326, 337, 426, 437, 526, 537) being used to align the cavity insert (131, 231, 331, 431, 531) and the flap mold insert (123, 223, 323, 423, 523) when the mold stack (104, 204, 304, 404, 504) is in the molding configuration.

9. A mould stack (104, 204, 304, 404, 504) as claimed in claim 8, wherein the cooperating male and female cones (126, 137, 226, 237, 326, 337, 426, 437, 526, 537) comprise mating frustoconical surfaces through which at least a portion of the clamping force is transmitted when the mould stack (104, 204, 304, 404, 504) is in the moulding configuration in use.

10. A mold stack (104, 204) as described in claim 8 or claim 9, wherein the flap-type mold insert (123, 223) includes the male cone (126, 226), and the male cone (126, 226) is at least partially recessed relative to the outer peripheral portion of the flap-type mold insert (123, 223).

11. A mold stack (104, 204) as described in claim 10, wherein the male cone (126, 226) is at least partially within a cavity side recess (125, 225) formed in the flap-type mold insert (123, 223), and the cavity insert (131, 231) includes a cooperating protrusion (136, 236) that circumscribes the female cone (137, 237).

12. The mold stack (104, 204) of claim 11, wherein the protrusion (136, 236) is spaced apart from the cavity side groove (125, 225) by a circumferential gap and an axial gap when the mold stack (104, 204) is in a molding configuration.

13. The mold stack (204) of any one of claims 8 to 12, wherein the male cone (226) comprises one of a plurality of nested and / or concentric male cones (226).

14. The mold stack (504) of claim 8, wherein the cooperating male and female cones (526, 537) comprise locating cones (526, 537).

15. The mold stack (504) of claim 14, comprising a plurality of cooperating male and female locating cones (526, 537), each of the plurality of cooperating male and female locating cones (526, 537) being spaced apart around the non-mating portion (541) and centered at substantially the same radial distance from the non-mating portion (541).

16. The mold stack (104, 204, 304, 404, 504) of any preceding claim, wherein the cavity insert (131, 231, 331, 431, 531) comprises a first portion (132, 232, 332, 432, 532) comprising at least a portion of the molding surface (135, 235, 335, 435, 535) and a second portion (133, 233, 333, 433, 533) comprising at least a portion of the mating portion (142, 242, 342, 442, 542).

17. A mold assembly (100) comprising a mold stack (104, 204, 304, 404, 504) according to any preceding claim.

18. A flap-fit ​​mold insert (323, 423) for use in a mold stack (304, 404) for molding a tubular article having a neck portion with a radial flange and an open end and a hollow body portion with a closed end, the flap-fit ​​mold insert (323, 423) comprising a plurality of flap-fit ​​mold insert parts (323a, 323b, 423a, 423b) that together provide: a molding surface (324, 424) for molding a portion of the hollow body portion and at least the radial flange of the neck portion; a first male cone (326, 426) on the cavity side of the flap-type mold insert (323, 423); a cavity side receiving groove (328, 428), the cavity side receiving groove (328, 428) being at least partially within the first male cone (326, 426) and extending from the cavity side, the cavity side receiving groove (328, 428) including a non-matching portion (341, 441), the non-matching portion (341, 441) at least partially surrounding the molding surface (324, 424) and extending from the molding surface (324, 424); a cavity fitting portion (342, 442) at least partially formed by the first male cone (326, 426), the cavity fitting portion (342, 442) at least partially surrounding the non-fitting portion (341, 441); a second male cone on the core side of the flap-type mold insert (323, 423); as well as a core side receiving groove at least partially within the second male cone and extending from the core side to the molding surface (324, 424); The flap-fitting mold insert (323, 423) is configured so that, in use, when the mold stack (304, 404) is in a molding configuration, a clamping force is transmitted to the cavity insert (331, 431) through the cavity mating portion (342, 442) rather than through the non-mating portion (341, 441).

19. The flap-type mold insert (323, 423) of claim 18, wherein the first male cone (326, 426) includes a frustoconical surface (342a, 442a) at least partially surrounding the cavity side groove (328, 428).

20. The flap-type mold insert (423) of claim 18, wherein the first male cone (426) comprises a truncated conical surface (442a) and an extended surface, the extended surface protruding from the truncated conical surface (442a) and at least partially surrounding the cavity side groove (428).

21. The flap mold insert (323) of claim 19 or claim 20, wherein the frustoconical surface (342a) forms at least a portion of the cavity mating portion (342).

22. A flap-fit ​​mold insert (123, 223) for use in a mold stack (104, 204) for molding a tubular article having a neck portion with a radial flange and an open end and a hollow body portion with a closed end, the flap-fit ​​mold insert (123, 223) comprising a plurality of flap-fit ​​mold insert parts (123a, 123b, 223a, 223b) that together provide: a molding surface (124, 224) for molding a portion of the hollow body portion and at least the radial flange of the neck portion; a cavity side groove (125, 225) on the cavity side of the flap-type mold insert (123, 223); a male cone (126, 226) at least partially within the cavity-side recess (125, 225), the male cone (126, 226) including a non-mating portion (141, 241) at least partially surrounding the molding surface (124, 224) and extending from the molding surface (124, 224); and a cavity fitting portion (142, 242) at least partially formed by the male cone (126, 226), the cavity fitting portion (142, 242) at least partially surrounding the non-fitting portion (141, 241); The flap-fitting mold insert (123, 223) is configured so that, in use, when the mold stack (104, 204) is in a molding configuration, a clamping force is transmitted to the cavity insert (131, 231) through the cavity mating portion (142, 242) rather than through the non-mating portion (141, 241).

23. A flap-type mold insert (223) as described in claim 22, wherein the male cone (226) includes one of a plurality of nested and / or concentric male cones (226), and each of the plurality of nested and / or concentric male cones (226) is at least partially within the cavity side groove (225) or the corresponding cavity side groove (225).

24. A cavity insert (231) for use in a mold stack (204) for molding a tubular article having a neck portion with a radial flange and an open end and a hollow body portion with a closed end, the cavity insert (231) comprising: a molding surface (224) for molding a portion of the hollow body portion; a plurality of flap-type mold side protrusions (236) on the flap-type mold side of the cavity insert (231); A plurality of nested and / or concentric female cones (237), each of which is formed in a corresponding side protrusion (236) of the flap-type mold; a flap-type mold non-mating portion (241) at least partially surrounding the molding surface (224) and extending from the molding surface (224); as well as a flap-type mold matching portion (242) at least partially formed by the female cone (237), the flap-type mold matching portion (242) at least partially surrounding the non-matching portion (241); The cavity insert (231) is configured such that, in use, when the mold stack (204) is in a molding configuration, a clamping force is transmitted to the flap mold insert (223) through the flap mold mating portion (242) rather than through the non-mating portion (241).

25. A flap-fit ​​mold insert (223) for use in a mold stack (204) for molding tubular articles, the flap-fit ​​mold insert (223) comprising a plurality of flap-fit ​​mold insert portions (223a, 223b) that together provide a plurality of nested and / or concentric cones (225).

26. A cavity insert (231) for use in a mold stack (204) for molding a tubular article, the cavity insert (231) comprising a plurality of nested and / or concentric cones (225).

27. A flap-fit ​​mold insert (523) for use in a mold stack (504) for molding a tubular article having a neck portion with a radial flange and an open end and a hollow body portion with a closed end, the flap-fit ​​mold insert (523) comprising a plurality of flap-fit ​​mold insert parts (523a, 523b) that together provide: a molding surface (524) for molding a portion of the hollow body portion and at least the radial flange of the neck portion; a cavity-side non-matching portion (541) at least partially surrounding the molding surface (524) and extending from the molding surface (524); a cavity fitting portion (542), the cavity fitting portion (542) at least partially surrounding the non-fitting portion (541); as well as a plurality of cones (537), each of the plurality of cones (537) being spaced apart around the cavity-side non-mating portion (541) and centered at a radial distance from the cavity-side non-mating portion (541); The flap-fitting mold insert (523) is configured so that, in use, when the mold stack (504) is in a molding configuration, a clamping force is transmitted to the cavity insert (531) through the cavity-fitting portion (542) rather than through the cavity-side non-fitting portion (541).

28. The flap mold insert (523) of claim 27, wherein each of the plurality of cones (537) is provided by a corresponding aperture in the flap mold insert (523).

29. A cavity insert (531) for use in a mold stack (504) for molding a tubular article having a neck portion with a radial flange and an open end and a hollow body portion with a closed end, the cavity insert (531) comprising: a molding surface (524) for molding a portion of the hollow body portion; a flap-type mold-side non-matching portion (541) at least partially surrounding the molding surface (524) and extending from the molding surface (524); a flap-type mold mating portion (542), the flap-type mold mating portion (542) at least partially surrounding the non-mating portion (541); as well as a plurality of cones (526), ​​each of the plurality of cones (526) being spaced around the flap-closed mold side non-mating portion (541) and centered at a radial distance from the flap-closed mold side non-mating portion (541); The cavity insert (531) is configured such that, in use, when the mold stack (504) is in a molding configuration, a clamping force is transmitted to the flap mold insert (523) through the flap mold mating portion (542) rather than through the non-mating portion (541).

30. The cavity insert (531) of claim 29, wherein each of the plurality of cones (526) is provided by a corresponding boss or pin extending from the cavity insert (531).

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