Molding apparatus and method

Abstract

An apparatus and method for conveying molten molding material applied to a molding system that defines a plurality of selectable process paths through a process cell is provided. [Solution] An apparatus for transporting molten molding material includes a container having an internal cavity that receives the molten molding material through an orifice and prevents the molten molding material from flowing out during transport, a coupling assembly configured to selectively couple to a processing station to transfer the molten molding material, and an ejection mechanism operable to extrude the molten molding material from the container, and the container is configured to releasably engage a transport device to move the container to the processing station.

Description

[Technical field]

[0001] Related Applications This application claims priority to U.S. Provisional Patent Application No. 62 / 724,790, filed August 30, 2018, U.S. Provisional Patent Application No. 62 / 770,785, filed November 22, 2018, U.S. Provisional Patent Application No. 62 / 856,833, filed June 4, 2019, and U.S. Provisional Patent Application No. 62 / 866,059, filed June 25, 2019, the disclosures of which are incorporated herein by reference.

[0002] Technical Field The present invention relates to molding, and more particularly to a molding system that defines a plurality of selectable process paths through a process cell. [Background technology]

[0003] Many plastic molding systems are optimized for mass production of products. Such systems typically include complex multi-cavity molds to simultaneously produce multiple identical parts during each molding cycle.

[0004] Typically, successful operation of such processes requires extensive custom tooling. For example, multi-cavity molds are custom designed and fabricated for each unique type of part produced. Complex melt control mechanisms are required to melt the molding material, control the heating, and deliver the molten material to each cavity. The molding material is then directed into the mold via fixed conduits.

[0005] While such systems are capable of producing large volumes of products at a relatively low unit cost, they tend not to be cost-effective for producing small quantities of products and are very inflexible because the product generally cannot be changed without significantly modifying or replacing the tooling. Summary of the Invention

[0006] An exemplary method for use in molding an article includes moving a container holding molten molding material along a track to a molten molding material dispensing cell; dispensing a flowable molten molding material into the container at the molten molding material dispensing cell; following dispensing, moving the container along the track to a molding cell; and injecting the molten molding material from the container into a molding machine in the molding cell at the molding cell.

[0007] In some embodiments, the molding cell comprises a plurality of molding machines, and the method further includes selecting a molding machine from among the plurality of molding machines according to characteristics of the molten molding material to be dispensed into the container by the molten molding material dispensing cell prior to injecting the molten molding material from the container into the molding machine.

[0008] In some embodiments, the property is a volume of molten molding material dispensed into the container.

[0009] In some embodiments, the container is one of a plurality of containers, and the method further comprises tracking a location of each container.

[0010] In some embodiments, the molten molding material dispensing cell comprises a plurality of dispensers and the molding cell comprises a plurality of molding machines, and the method further includes moving each container to a selected dispenser of the molten molding material dispensing cell to receive the molten molding material, and moving each container to a selected molding machine of the molding cell according to characteristics of the molten molding material to be injected into each container.

[0011] In some embodiments, the property is the composition of the molding material.

[0012] In some embodiments, the composition comprises a colorant.

[0013] In some embodiments, the composition is a thermoplastic resin or a thermoset plastic resin.

[0014] In some embodiments, the method further includes, following injecting the molten molding material into the molding machine, returning the container along a return line of the track toward the molten molding material dispensing cell.

[0015] In some embodiments, the method further includes, following pouring the molten molding material from each container, returning each container along a return line of the track toward the molten molding material dispensing cell.

[0016] In some embodiments, the selected dispenser is selected based on the characteristics of the molten molding material that will be dispensed into each container when it was previously in the molten molding material dispensing cell.

[0017] In some embodiments, the method further includes transferring the articles molded in the molding cells to a return line of the truck.

[0018] In some embodiments, the method further includes transporting the article on a return line of the truck to a selected blow molder of the blow molding cell according to the properties of the molten molding material.

[0019] In some embodiments, the track includes two carriages, and the method further includes bringing the two carriages together to trap the container between the carriages; and then keeping the two carriages together while moving the two carriages along the track to transport the container along the track.

[0020] In some embodiments, the method further includes gripping the container with the gripper, then separating the two carriages to release the container from the track, and then manipulating the container with the gripper.

[0021] In some embodiments, the method further includes replacing the container with another container upstream of the molten molding material dispensing cell.

[0022] In some embodiments, the container includes a piston and the injecting comprises moving the piston.

[0023] An exemplary system for use in molding articles includes a truck; a plurality of containers carried on the track; at least one molten molding material dispenser along the track; at least one molding machine along the track; and a controller operatively associated with the truck to selectively move each container along the track to (i) a predetermined dispenser of the at least one molten molding material dispenser where the flowable molten molding material is dispensed into each container, and (ii) a predetermined machine of the at least one molding machine where the molten molding material is dispensed from each container.

[0024] In some embodiments, the system includes a position sensor interconnected with the controller for tracking the position of each container.

[0025] In some embodiments, the at least one dispenser includes a plurality of dispensers and the at least one molding machine includes a plurality of molding machines, and the controller is configured to select a given molding machine from the plurality of molding machines according to a characteristic of the molding material to be dispensed into each container with the given dispenser.

[0026] In some embodiments, the track includes a delivery line that carries the containers to at least one molten molding material dispenser and to at least one molding machine, and a return line that returns the containers to the at least one molten molding material dispenser.

[0027] In some embodiments, the system further includes a transfer device that transfers articles molded in a given molding machine to a return line.

[0028] In some embodiments, the transfer device is a first transfer device, and the system further includes at least one blow molding machine along the return line and a second transfer device that transfers the article on the return line to a predetermined blow molding machine of the at least one blow molding machine.

[0029] In some embodiments, the return line is parallel to the delivery line.

[0030] In some embodiments, the track includes multiple pairs of carriages, the two carriages of each carriage pair equipped with complementary mechanisms that trap each container between the two carriages when the two carriages are brought together, and the controller is further operable to selectively bring the two carriages together and move the two carriages together for a period to move each container on the track.

[0031] In some embodiments, the track includes multiple pairs of carriages, the two carriages of each carriage pair having complementary mechanisms that trap at least one of each container or one of each article between the two carriages when the two carriages are brought together, and the controller is further operable to selectively bring the two carriages together and move the two carriages together for a period to move each container or article along the track.

[0032] In some embodiments, the system further includes a pair of spring-loaded grippers mounted to reciprocate laterally relative to the track such that the grippers can extend and deflect in the direction of the track to grasp each given container trapped by the two carriages.

[0033] In some embodiments, each container is provided with an identifier, and the system further includes a reader for reading the identifier of each container, the controller being operatively linked to an output of the reader.

[0034] In some embodiments, the system further includes a shunt line mounted for movement between a first location coupled to an end of the outflow line and a second location coupled to an end of the return line for transferring the container from the outflow line to the return line.

[0035] In some embodiments, the return lines are parallel to the outgoing lines, with one of the outgoing and return lines directly above the other of the outgoing and return lines.

[0036] In some embodiments, the system further includes at least one container sorting device upstream of the at least one molten molding material dispenser, the at least one sorting device including a reciprocating turntable with a plurality of container grippers.

[0037] In some embodiments, the property is the composition of the molding material.

[0038] In some embodiments, the composition is a thermoplastic resin or a thermoset plastic resin.

[0039] An exemplary plastic molding system includes a feedstock cell including a feedstock station for depositing plastic feedstock into a container, the deposited plastic feedstock defining a workpiece; a pre-molding cell including a plurality of pre-molding stations, each of which molds a predetermined workpiece into a preform shape by injecting it into a pre-molding mold; a molding cell including a plurality of molding stations, each of which molds one workpiece from the preform shape to a final shape in the mold; and a transport subsystem for advancing each workpiece along a selected one of a plurality of process paths to form a molded article from each workpiece, the plurality of process paths being defined by a combination of the feedstock station, the pre-molding stations of the pre-molding cell, and the molding stations of the molding cell.

[0040] In some embodiments, the feedstock cell is a dispensing cell and the feedstock station is a dispensing station that dispenses a dose of the plastic feedstock that defines each workpiece.

[0041] In some embodiments, the dispense cell includes multiple dispense stations, and each of the multiple process paths includes one dispense station.

[0042] In some embodiments, the system further includes a thermal conditioning cell that produces a desired thermal profile at each workpiece between the primary and secondary molding cells.

[0043] In some embodiments, the multiple process paths include a first process path that produces a first molded article having a first characteristic and a second process path that produces a second molded article having a second characteristic that is different from the first characteristic.

[0044] In some embodiments, the characteristic includes a shape.

[0045] In some embodiments, each pre-molding station includes an injection molding apparatus and each molding station includes a blow molding apparatus.

[0046] In some embodiments, each dispensing station includes an extruder that dispenses the plastic feedstock as molten plastic.

[0047] In some embodiments, the system includes a post-molding cell that performs final shape finishing operations on the workpiece.

[0048] In some embodiments, the final shape workpiece is a bottle and the post molding cell includes a filling station.

[0049] In some embodiments, the post molding cell includes a labeling station.

[0050] In some embodiments, the post molding cell includes a capping station.

[0051] An exemplary plastic molding system for a process including dispensing and molding operations includes a dispensing cell including a dispensing mechanism that dispenses multiple doses of a plastic feedstock into a container to produce a workpiece; a molding cell including a plurality of molding stations, each molding station including a mold that receives the plastic feedstock from the container and forms the workpiece into a desired shape; and a transport subsystem that routes each workpiece along a selected one of a plurality of possible process paths through each of the dispensing and molding cells to form a molded article from each workpiece; the plurality of possible process paths being defined by a combination of the dispensing mechanism and different ones of the plurality of molding stations.

[0052] In some embodiments, the system includes a conditioning cell including a plurality of conditioning stations, each for applying a treatment to a workpiece prior to processing the workpiece in the molding cell, and each possible process path includes one of the conditioning stations.

[0053] In some embodiments, the conditioning cell is configured to be under computer control to apply the treatment.

[0054] In some embodiments, the dispense cell includes multiple dispense mechanisms, with each possible process path including one dispense mechanism.

[0055] In some embodiments, the dispensing cell is for dispensing individual doses of the plastic feedstock, each for forming a single molded article.

[0056] In some embodiments, each possible process path includes a different combination of a dispensing mechanism and a molding station.

[0057] In some embodiments, the plurality of possible process paths includes a first process path that produces a first molded article having a first characteristic and a second process path that produces a molded article having a second characteristic that is different from the first characteristic.

[0058] In some embodiments, the characteristic includes a shape.

[0059] In some embodiments, the molding cell is a primary molding cell, each molding station is a primary molding station that performs a primary molding operation to form a pre-molded article, and the system further includes a secondary molding cell that performs a secondary molding operation to form each molded article by remolding each pre-molded article.

[0060] In some embodiments, each primary molding station includes an injection molding apparatus and the secondary molding cell includes multiple secondary molding stations each including a blow molding apparatus.

[0061] In some embodiments, the dispensing cell includes an extruder that dispenses the plastic feedstock as molten plastic.

[0062] In some embodiments, the transport subsystem includes a guide mechanism, and the multiple process paths are at least partially defined by the guide mechanism.

[0063] In some embodiments, the guide mechanism includes a loop and multiple branches, each connecting a station of the cell with the loop.

[0064] In some embodiments, the guide mechanism includes a track and a carriage mounted for movement on the track.

[0065] In some embodiments, the guide mechanism includes a plurality of carriages and the transport subsystem includes a plurality of sorting devices that selectively initiate redirection of the carriages to individual stations of the cell.

[0066] In some embodiments, the primary molding cell is for performing a primary molding operation to form a pre-molded article, and the transport subsystem includes a plurality of pre-molded carriages mounted for movement along a track for receiving the pre-molded article from the primary molding cell and for transporting the pre-molded article to a next processing station.

[0067] In some embodiments, the system includes a post-molding cell that performs final shape finishing operations on the workpiece.

[0068] In some embodiments, the final shape workpiece is a bottle and the post molding cell includes a filling station.

[0069] In some embodiments, the post molding cell includes a labeling station.

[0070] In some embodiments, the post molding cell includes a capping station.

[0071] An exemplary method for molding a plastic article in a molding system including a plurality of raw material providing stations and a plurality of molding stations includes: forming a first molded article by transporting a first amount of raw material through the molding system in a first process path, where the transporting includes moving the first amount into a container; and forming a second molded article by transporting a second amount of raw material through the molding system in a second process path different from the first process path and overlapping with the first process path, where the transporting includes moving the second amount into an additional container; each of the first process path and the second process path includes a raw material providing station of the plurality of raw material providing stations and a molding station of the plurality of molding stations.

[0072] In some embodiments, the molding system includes at least one conditioning station, and each of the first and second process paths includes one dosage dispensing station, one molding station, and one conditioning station.

[0073] In some embodiments, the molding station is a primary molding station, and each of the first and second process paths includes one dispensing station, a primary molding station, one conditioning station, and a secondary molding station.

[0074] In some embodiments, the first process path includes a first molding station and the second process path includes a second molding station that is different from the first molding station.

[0075] In some embodiments, transporting the first dose of the ingredient includes dispensing the first dose of the ingredient into a first container, and transporting the second dose of the ingredient includes dispensing the second dose of the ingredient into a second container.

[0076] In some embodiments, transporting the first dose of ingredient includes dispensing the first dose from a first dispensing station, and transporting the second dose of ingredient includes dispensing the second dose from a second dispensing station different from the first dispensing station.

[0077] In some embodiments, the first molded article and the second molded article have different shapes.

[0078] In some embodiments, the first molded article and the second molded article comprise different sizes.

[0079] In some embodiments, the first molded article and the second molded article are formed of different materials.

[0080] In some embodiments, each one of the first process path and the second process path includes an injection molding apparatus and a blow molding apparatus.

[0081] In some embodiments, conveying the first dose of the ingredient and conveying the second dose of the ingredient include conveying a carriage along a track.

[0082] In some embodiments, conveying the first dose of raw material and conveying the second dose of raw material include operating a sorting device to initiate a redirection from the track loop toward an individual one of the molding stations.

[0083] In some embodiments, the molding system includes a post-molding station and the method further includes performing finishing operations at the post-molding station.

[0084] In some embodiments, the finishing operations include filling.

[0085] In some embodiments, the finishing operations include labeling.

[0086] In some embodiments, the finishing operation includes capping.

[0087] An exemplary method for use in molding an article includes dispensing a dose of molten plastic material into a container; moving the container with the dose to a selected one of a plurality of available forming stations; transferring the dose of molten material from the container to a forming device at the selected forming station; and forming a molded article from the dose in the forming device.

[0088] In some embodiments, the molded article is a pre-molded molded article, and the method further includes moving the pre-molded molded article to one of a plurality of available finishing stations, and forming a finished molded article from the pre-molded molded article at the finishing station.

[0089] An exemplary system for molding an article includes means for dispensing a dose of molten plastic material into a container; means for moving the container with the dose to a selected one of a plurality of available forming stations; means for transferring the dose of molten material from the container to a forming device at the selected forming station; and means for forming a molded article from the dose in the forming device.

[0090] In some embodiments, the means for dispensing includes a plurality of dispensers, each dispenser for dispensing molten plastic material having a different composition.

[0091] An exemplary apparatus for transporting molten molding material includes a container having an internal cavity for receiving the molten molding material through an orifice and for preventing flow of the material during transport; a coupling assembly for selectively mating with a processing station to transfer the molding material; and an ejection mechanism operable to extrude the molten molding material from the container.

[0092] In some embodiments, the ejection mechanism includes a piston received within the cavity.

[0093] In some embodiments, the container includes an orifice that receives the molding material from the melter, and the coupling assembly includes a seal assembly that selectively seals the orifice.

[0094] In some embodiments, the orifices are fill orifices that mate with a melter to receive the molten molding material and discharge orifices that mate with a mold to force the molten molding material from a container into the mold.

[0095] In some embodiments, the apparatus includes a thermal regulation assembly in the container to control the thermal profile of the molten molding material.

[0096] In some embodiments, the thermal regulation assembly includes an insulator.

[0097] In some embodiments, the thermal regulation assembly includes a heat sink.

[0098] In some embodiments, the thermal regulation assembly includes a sleeve around the vessel.

[0099] In some embodiments, the thermal regulation assembly includes a heating element.

[0100] In some embodiments, the coupling assembly is a seal assembly that selectively seals the orifice.

[0101] In some embodiments, the seal assembly includes a valve stem.

[0102] In some embodiments, the valve stem extends within the interior cavity along the axis of the container.

[0103] In some embodiments, the seal assembly includes a sliding gate.

[0104] In some embodiments, the container is configured to releasably engage a transport device to move the container relative to the processing station.

[0105] In some embodiments, the container includes a handling mechanism for releasably securing the container to a delivery device.

[0106] In some embodiments, the delivery device includes a guide and the handling mechanism includes an adapter configured to engage the container and the guide.

[0107] In some embodiments, the seal assembly is part of the adapter.

[0108] An exemplary method of conveying the molten molding material includes receiving the molten molding material into an interior cavity of a container through an orifice; moving the container along a conveying path; preventing material flow during movement; mating the container with a mold; and transferring the molten molding material to the mold by extruding the molten molding material from the container.

[0109] In some embodiments, forcing the molten molding material from the container includes moving a piston within the internal cavity.

[0110] In some embodiments, preventing the flow includes sealing the orifice.

[0111] In some embodiments, the transferring comprises forcing the material out of the container through an orifice.

[0112] In some embodiments, the method includes regulating heat transfer through the vessel.

[0113] In some embodiments, regulating heat transfer includes insulating the container to regulate heat loss.

[0114] In some embodiments, regulating heat transfer includes removing heat from the container by a heat sink.

[0115] In some embodiments, regulating heat transfer includes introducing heat into the container after receiving with a heating element.

[0116] In some embodiments, the method includes releasably engaging the container with a transport device for moving.

[0117] In some embodiments, the delivery device includes a guide and releasably engaging includes attaching the container to the guide with an adapter.

[0118] In some embodiments, the method includes sealing the orifice with an adapter.

[0119] An exemplary apparatus for transferring flowable molding material between a container and a processing station includes a holder supporting a container having an internal cavity for holding the flowable molding material, the holder including a nest configured to matingly receive the container; a coupling device for selectively engaging the container with the processing station, thereby establishing a flow path of the flowable molding material between the container and the processing station; and a flow actuator for passing a flow of the flowable molding material through the flow path.

[0120] In some embodiments, the nest includes an interlocking mechanism that maintains the position of the container.

[0121] In some embodiments, the apparatus includes a locking actuator that biases the container against the interlocking mechanism.

[0122] In some embodiments, the apparatus includes a seal actuator that operates a seal on the container.

[0123] In some embodiments, the seal actuator is in a nested relationship with one or more of the flow actuator and the locking actuator.

[0124] In some embodiments, the holder includes a trigger structure that releases the seal on the container.

[0125] In some embodiments, the trigger structure includes a guide and releasing the seal includes receiving the locking protrusion in the guide and moving the locking protrusion across the guide.

[0126] In some embodiments, the processing station includes a dispensing station that transfers the flowable molding material to a container.

[0127] In some embodiments, the processing station includes an injection molding station, and the flow actuator is operable to force flowable molding material from a container into a mold by displacement of a piston. The drawings show example embodiments. [Brief description of the drawings]

[0128] [Figure 1] FIG. 1 is a schematic diagram of a molding system. [Diagram 2] FIG. 1 is a schematic diagram of the molding system with process cells defining multiple paths through the system. [Diagram 3] FIG. 1 is an isometric view of a molding system. [Figure 4A] FIG. 4 is an isometric view of a dispensing station of the system of FIG. [Figure 4B] FIG. 4 is an isometric view of a dispensing station of the system of FIG. [Figure 4C] FIG. 4B is an isometric view of a subassembly of the dispensing station of FIG. 4A. [Figure 4D] FIG. 4B is an isometric view of a subassembly of the dispensing station of FIG. 4A. [Figure 4E]FIG. 4B is an isometric view of a subassembly of the dispensing station of FIG. 4A. [Figure 4F] FIG. 2 is a partial enlarged isometric view of the barrel unit. [Figure 4G] FIG. 2 is a partial enlarged isometric view of the barrel unit. [Figure 4H] FIG. 4C is a schematic diagram of a coupling holding the barrel unit of FIGS. 4F and 4G to the drive unit. [Figure 4I] FIG. 4F is a partial enlarged isometric view of the drive unit and barrel unit of FIG. [Figure 4J] FIG. 4F is a partial enlarged isometric view of the drive unit and barrel unit of FIG. [Figure 4K] FIG. 13 is a schematic diagram of a removal tool for removing the barrel unit from the drive unit. [Figure 4L] 11A-11C are partial enlarged cross-sectional views showing a process of coupling the barrel unit to the drive unit. [Figure 4M] 11A-11C are partial enlarged cross-sectional views showing a process of coupling the barrel unit to the drive unit. [Figure 4N] 11A-11C are partial enlarged cross-sectional views showing a process of coupling the barrel unit to the drive unit. [Figure 4O] 11A-11C are partial enlarged cross-sectional views showing a process of coupling the barrel unit to the drive unit. [Figure 4P] 11A to 11C are partial enlarged cross-sectional views showing a process of removing the barrel unit from the drive unit. [Figure 4Q] 11A to 11C are partially enlarged cross-sectional views showing a process of removing the barrel unit from the drive unit. [Figure 4R] 11A to 11C are partial enlarged cross-sectional views showing a process of removing the barrel unit from the drive unit. [Figure 4S] FIG. 4K is a schematic diagram of a removal tool for attaching the barrel unit to the drive unit. [Diagram 5] FIG. 5 is a longitudinal cross-sectional view of the dispensing station of FIG. 4. [Figure 6A] 1A and 1B are isometric and isometric cross-sectional views, respectively, of a container for carrying molding material. [Figure 6B]1A and 1B are isometric and isometric cross-sectional views, respectively, of a container for carrying molding material. [Figure 7A] FIG. 6C is an isometric view of the material container and carrier of FIGS. 6A and 6B. [Figure 7B] FIG. 6C is an isometric view of the material container and carrier of FIGS. 6A and 6B. [Figure 8A] 5A and 5B are side and cross-sectional views showing stages of a dispensing operation at the dispensing station of FIG. 4. [Figure 8B] 5A and 5B are side and cross-sectional views showing stages of a dispensing operation at the dispensing station of FIG. 4. [Figure 8C] 5A and 5B are side and cross-sectional views showing stages of a dispensing operation at the dispensing station of FIG. 4. [Figure 8D] 5A and 5B are side and cross-sectional views showing stages of a dispensing operation at the dispensing station of FIG. 4. [Figure 9] FIG. 2 is an exploded view of the gate assembly. [Figure 10A] 10 is an enlarged cross-sectional view showing the operation of the gate assembly of FIG. [Figure 10B] 10 is an enlarged cross-sectional view showing the operation of the gate assembly of FIG. [Figure 11] FIG. 4 is an isometric view of a molding station of the system of FIG. 3. [Figure 12A] 12A and 12B are cross-sectional and isometric views of the molding station of FIG. 11. [Figure 12B] 12A and 12B are cross-sectional and isometric views of the molding station of FIG. 11. [Figure 12C] 12A and 12B are cross-sectional and isometric views of the molding station of FIG. 11. [Figure 12D] 12A and 12B are cross-sectional and isometric views of the molding station of FIG. 11. [Figure 13A] 1A and 1B are isometric and side views, respectively, of a linkage of a clamp assembly. [Figure 13B] 1A and 1B are isometric and side views, respectively, of a linkage of a clamp assembly. [Figure 13C] FIG. 14 is a diagram of the forces on the linkage of FIGS. 13A and 13B. [Figure 14A] 11A and 11B are isometric and side views, respectively, of another linkage of the clamp assembly. [Figure 14B] 11A and 11B are isometric and side views, respectively, of another linkage of the clamp assembly. [Figure 15A] 11A and 11B are isometric and side views, respectively, of another linkage of the clamp assembly. [Figure 15B] 11A and 11B are isometric and side views, respectively, of another linkage of the clamp assembly. [Figure 16] FIG. 13 is a side view of another linkage of the clamp assembly. [Figure 17] FIG. 12 is an isometric view of a core actuation assembly of the molding station of FIG. [Figure 18A] 18A and 18B are isometric and cross-sectional views, respectively, of a core deployment actuator of the core actuation assembly of FIG. 17. [Figure 18B] 18A and 18B are isometric and cross-sectional views, respectively, of a core deployment actuator of the core actuation assembly of FIG. 17. [Figure 19] FIG. 18 is an isometric view of the load actuator of the core actuation assembly of FIG. [Figure 20] FIG. 20 is a partial cross-sectional view of the load actuator of FIG. 19. [Figure 21A] FIG. 18C is a schematic diagram showing the interlocking between the core placement actuator of FIGS. 18A and 18B and the load actuator of FIG. 17. [Figure 21B] FIG. 18C is a partial cross-sectional view of the core-located actuator of FIGS. 18A and 18B and the load actuator of FIG. 17, showing interlocking. [Figure 22] FIG. 18 is an isometric view of a secondary mold opening actuator of the core actuation assembly of FIG. [Figure 23A] 12A-12C are side, isometric, enlarged top and enlarged perspective views, respectively, of a shaper module of the molding station of FIG. [Figure 23B] 12A-12C are side, isometric, enlarged top and enlarged perspective views, respectively, of a shaper module of the molding station of FIG. [Figure 23C]12A-12C are side, isometric, enlarged top and enlarged perspective views, respectively, of a shaper module of the molding station of FIG. [Figure 23D] 12A-12C are side, isometric, enlarged top and enlarged perspective views, respectively, of a shaper module of the molding station of FIG. [Figure 24A] 14A-14C are front isometric and top elevation views of another molding station; [Figure 24B] 14A-14C are front isometric and top elevation views of another molding station; [Figure 24C] FIG. 24B is a rear isometric view of the molding station of FIG. 24A. [Figure 24D] FIG. 24B is a front isometric view of the support structure of the molding station of FIG. 24A. [Figure 24E] 24D is an isometric view of the support structure of FIG. 24D and a cross-sectional view taken along lines EE and FF of FIG. 24B. [Figure 24F] 24D is an isometric view of the support structure of FIG. 24D and a cross-sectional view taken along lines EE and FF of FIG. 24B. [Figure 24G] FIG. 24B is an isometric view of the molding station of FIG. 24A with a cross-sectional view showing the internal components. [Fig. 24H] 24B is an enlarged partial cross-sectional view of the molding station of FIG. 24A. [Figure 24I] 24B is an isometric view and a cross-sectional view of the molding station of FIG. 24A in an open state. [Figure 24J] 24B is an isometric view and a cross-sectional view of the molding station of FIG. 24A in an open state. [Figure 24K] 24B is an isometric view and a cross-sectional view of the molding station of FIG. 24A in a mold open state, with the mold core in molding position. [Figure 24L] 24B is an isometric view and a cross-sectional view of the molding station of FIG. 24A in a mold open state, with the mold core in molding position. [Figure 24M] 24B is an isometric view and a cross-sectional view of the molding station of FIG. 24A in a closed state. [Figure 24N]24B is an isometric view and a cross-sectional view of the molding station of FIG. 24A in a closed state. [Fig. 24O] 24B is an isometric view and a cross-sectional view of the molding station of FIG. 24A in a closed state with a preload applied to the mold core. [Figure 24P] 24B is an isometric view and a cross-sectional view of the molding station of FIG. 24A in a closed state with a preload applied to the mold core. [Figure 24Q] 24B is an isometric view and a cross-sectional view of the molding station of FIG. 24A in an open state. [Figure 24R] 24B is an isometric view and a cross-sectional view of the molding station of FIG. 24A in an open state. [Figure 24S] 24B is an isometric and cross-sectional view of the molding station of FIG. 24A during mold removal. [Figure 24T] 24B is an isometric and cross-sectional view of the molding station of FIG. 24A during mold removal. [Figure 25A] FIG. 2 is a side perspective view of one embodiment of a portion of a mold assembly. [Figure 25B] FIG. 25B is a front view of a portion of the mold assembly of FIG. 25A. [Figure 25C] FIG. 25B is a side perspective view of an embodiment of a portion of a part of the mold assembly of FIG. 25A. [Figure 25D] FIG. 25B is a side perspective view similar to FIG. 25C of a portion of the mold assembly of FIG. 25A. [Figure 25E] FIG. 25B is a side perspective view similar to FIG. 25C of a portion of the mold assembly of FIG. 25A. [Figure 25F] FIG. 25B is a side perspective view similar to FIG. 25C of a portion of the mold assembly of FIG. 25A. [Figure 25G] FIG. 2 is a top perspective view of an embodiment of a mold cavity block. [Fig. 25H] FIG. 25F is a top perspective view of one embodiment of a cavity plate that includes the mold cavity block of FIG. [Figure 25I] FIG. 13 is a top perspective view of an alternative embodiment of a mold cavity block. [Figure 25J] FIG. 25I is a top view of the mold cavity block of FIG. [Figure 25K] FIG. 25I is another top perspective view of the mold cavity block of FIG. [Figure 26A] FIG. 13 is a side perspective view of an alternative embodiment of a portion of a mold assembly. [Figure 26B] FIG. 13 is a side perspective view of an alternative embodiment of a portion of a mold assembly. [Figure 26C] FIG. 26C is a top cross-sectional view of a portion marked 26C in FIG. 26A. [Figure 26D] FIG. 26C is a side perspective view of a portion of an embodiment of a portion of the mold assembly of FIGS. 26A and 26B. [Figure 26E] FIG. 26E is a perspective view of some of the disconnected components shown in FIG. 26D. [Figure 26F] FIG. 26E is a perspective view of some of the disconnected alternative components shown in FIG. 26D. [Figure 26G] FIG. 26E is a rear elevational view of some of the disconnected components shown in FIG. 26D. [Fig. 26H] FIG. 26E is a plan view of a mold cavity block used in part of FIG. 26D. [Figure 26I] FIG. 26E is a top perspective view of a portion of a mold cavity block of FIG. 26D. [Figure 26J] FIG. 26E is a top perspective view of an alternative mold cavity block that may be employed in the portion of FIG. 26D. [Figure 27A] FIG. [Figure 27B] FIG. 27B is a rear perspective view of the base block of FIG. 27A. [Figure 28A] FIG. 1 is an assembled view of a portion of a mold assembly. [Figure 28B] FIG. 2 is a schematic diagram of a cooling fluid circuit. [Figure 28C] FIG. 2 is a schematic diagram of a cooling fluid circuit. [Figure 29] 12 is a cross-sectional view of the mold and container of the molding station of FIG. 11. [Diagram 30]1 is a sequence of overhead and isometric views illustrating a container sealing process. [Diagram 31] FIG. 13 is an isometric view showing another container sealing process. [Diagram 32] FIG. 12 is an isometric view of an actuator assembly of the molding station of FIG. [Figure 33A] 12A-12C are isometric, cross-sectional, and cross-sectional views, respectively, of the container and actuation assembly at the molding station of FIG. 11. [Figure 33B] 12A-12C are isometric, cross-sectional, and cross-sectional views, respectively, of the container and actuation assembly at the molding station of FIG. 11. [Figure 33C] 12A-12C are isometric, cross-sectional, and cross-sectional views, respectively, of the container and actuation assembly at the molding station of FIG. 11. [Figure 34A] 12A-12C are cross-sectional and partial cross-sectional views showing stages of the molding operation at the molding station of FIG. 11. [Figure 34B] 12A-12C are cross-sectional and partial cross-sectional views showing stages of the molding operation at the molding station of FIG. 11. [Figure 34C] 12A-12C are cross-sectional and partial cross-sectional views showing stages of the molding operation at the molding station of FIG. 11. [Fig. 34D] 12A-12C are cross-sectional and partial cross-sectional views showing stages of the molding operation at the molding station of FIG. 11. [Figure 34E] 12A-12C are cross-sectional and partial cross-sectional views showing stages of the molding operation at the molding station of FIG. 11. [Fig. 34F] 12A-12C are cross-sectional and partial cross-sectional views showing stages of the molding operation at the molding station of FIG. 11. [Figure 34G] 12A-12C are cross-sectional and partial cross-sectional views showing stages of the molding operation at the molding station of FIG. 11. [Fig. 34H] 12A-12C are cross-sectional and partial cross-sectional views showing stages of the molding operation at the molding station of FIG. 11. [Fig. 34I] 12A-12C are cross-sectional and partial cross-sectional views showing stages of the molding operation at the molding station of FIG. 11. [Fig. 34J] 12A-12C are cross-sectional and partial cross-sectional views showing stages of the molding operation at the molding station of FIG. 11. [Figure 34K] 12A-12C are cross-sectional and partial cross-sectional views showing stages of the molding operation at the molding station of FIG. 11. [Figure 35A] 17A-17C depict cross-sectional views of the container and actuation assembly, illustrating operation of the container and actuation assembly. [Figure 35B] 17A-17C depict cross-sectional views of the container and actuation assembly, illustrating operation of the container and actuation assembly. [Figure 35C] 17A-17C depict cross-sectional views of the container and actuation assembly, illustrating operation of the container and actuation assembly. [Figure 35D] 17A-17C depict cross-sectional views of the container and actuation assembly, illustrating operation of the container and actuation assembly. [Figure 35E] 17A-17C depict cross-sectional views of the container and actuation assembly, illustrating operation of the container and actuation assembly. [Fig. 35F] 17A-17C depict cross-sectional views of the container and actuation assembly, illustrating operation of the container and actuation assembly. [Diagram 36] FIG. 2 is an exploded view of the gate assembly. [Figure 37A] 37 is an enlarged cross-sectional view showing the operation of the gate assembly of FIG. 36. [Figure 37B] 37 is an enlarged cross-sectional view showing the operation of the gate assembly of FIG. 36. [Figure 38] FIG. 4 is an isometric view of the conditioning station and molding station of the system of FIG. 3. [Figure 39] FIG. 39 is a side cross-sectional view of the conditioning station of FIG. 38. [Figure 40A] 39A and 39B are side and cross-sectional views showing stages of the conditioning operation at the conditioning station of FIG. 38; [Figure 40B] 39A-39C are side and cross-sectional views showing stages of the conditioning operation at the conditioning station of FIG. 38; [Figure 40C]39A-39C are side and cross-sectional views showing stages of the conditioning operation at the conditioning station of FIG. 38; [Figure 41A] FIG. 2 is an isometric view of a molding station. [Figure 41B] FIG. 42 is a side view of the press of the molding station of FIG. 41. [Diagram 42] FIG. 13 is a side view of another molding station. [Diagram 43] FIG. 43 is a top view of the molding station of FIG. 42. [Diagram 44] FIG. 43 is an exploded view of the mold and service plate of the molding station of FIG. 42. [Diagram 45] FIG. 45 is an exploded view of the mold of FIG. 44. [Diagram 46] FIG. 45 is a cross-sectional view of the mold of FIG. 44. [Figure 47A] 43A and 43B are schematic top and side views of the molding station of FIG. 42 during mold removal. [Figure 47B] 43A and 43B are schematic top and side views of the molding station of FIG. 42 during mold removal. [Figure 48A] 43A-43C are top and side schematic views of the molding station of FIG. 42 during mold removal. [Figure 48B] 43A and 43B are schematic top and side views of the molding station of FIG. 42 during mold removal. [Figure 49A] 43A-43C are top and side schematic views of the molding station of FIG. 42 during mold removal. [Figure 49B] 43A and 43B are schematic top and side views of the molding station of FIG. 42 during mold removal. [Figure 50] FIG. 1 is a schematic diagram showing mold components at a molding station. [Figure 51A] 51 is a schematic diagram showing stages of a molding operation by the mold component of FIG. 50. [Figure 51B] 51 is a schematic diagram showing stages of a molding operation by the mold component of FIG. 50. [Figure 51C] 51 is a schematic diagram showing stages of a molding operation by the mold component of FIG. 50. [Fig. 51D] 51 is a schematic diagram showing stages of a molding operation by the mold component of FIG. 50. [Figure 52] FIG. 4 is a top view of the molding system of FIG. 3, showing the transfer subsystem. [Figure 53] FIG. 2 is a plan view of an injection molding system according to another embodiment. [Figure 54] 54 is a cross-sectional view taken along line II in FIG. 53. [Figure 55A] FIG. 2 is a side view of a track section. [Figure 55B] 55B is a cross-sectional view taken along line II-II of FIG. 55A. [Figure 55C] FIG. 55B is a partial perspective view of a portion of the track of the system of FIG. 55A. [Figure 56] FIG. 54 is a side view of a portion of the system of FIG. 53. [Figure 57] FIG. 54 is a partial perspective view of another portion of the system of FIG. 53. [Figure 58] FIG. 54 is a partial perspective view of yet another portion of the system of FIG. 53. [Figure 59] FIG. 54 is a partial perspective view of yet another portion of the system of FIG. 53. [Figure 60] FIG. 59 is a detailed perspective view of a portion of FIG. 58. [Figure 61] FIG. 2 is a top view of a conditioner and shaper station and associated transport system. [Figure 62] FIG. 62 is a side view of the station and transfer system of FIG. [Figure 63A] 62A and 62B are isometric and side views, respectively, of a carriage of the transport system of FIG. 61. [Figure 63B] 62A and 62B are isometric and side views, respectively, of a carriage of the transport system of FIG. 61. [Figure 64] FIG. [Figure 65] FIG. 2 is a partial perspective view of a portion of a modified system. [Figure 66] FIG. 64 is a detailed perspective view of a portion of FIG. 63. [Figure 67]1 is a flow chart illustrating a method of conveying a molding material. [Figure 68] 1 is a flow chart illustrating a method for producing a plastic molded part. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0129] 1 illustrates generally an exemplary plastic molding system 100 for producing plastic molded articles. As described in more detail below, the plastic molding system 100 is capable of performing a molding process that includes dispensing, conditioning, and molding operations.

[0130] Plastic molding system 100 includes a plurality of process cells, each including one or more process stations in which operations of the molding process may be performed. Specifically, the illustrated embodiment includes dispensing cell 102, molding cells 104, 106, and conditioning cell 108. Other embodiments may include more or fewer cells and may perform the molding process with more or fewer process steps. Alternatively or additionally, plastic molding system 100 may include cells for other operations. For example, plastic molding system 100 may include cells for post-molding operations such as container filling, labeling, or capping.

[0131] The process cells of the plastic molding system 100 are linked by a transport subsystem 110 .

[0132] Any of the process cells 102, 104, 106, 108 may include two or more stations of a given type. A transport subsystem 110 selectively interconnects the stations of the process cells. The transport subsystem 110 may be configurable to define a number of possible process paths through the process cells of the molding system 100. For example, the transport subsystem 110 may be capable of transporting an article from a given station in one process cell 102, 104, 106, 108 to a selected one of a number of possible stations in another process cell 102, 104, 106, 108.

[0133] FIG. 2 illustrates, in schematic form, an exemplary embodiment having a dispensing cell 102 with four dispensing stations 102-1, 102-2, 102-3, 102-4; a molding cell 104 with eight molding stations 104-1, 104-2, 104-3, 104-4, 104-5, 104-6, 104-7, 104-8; a molding cell 106 with two molding stations 106-1, 106-2; and a conditioning cell 108 with two conditioning stations 108-1, 108-2.

[0134] 2, the transport subsystem 110 is capable of coupling any of the dispensing stations 102-1, 102-2, 102-3, 102-4 to any of the molding stations 104-1, 104-2, ... 104-8; coupling any of the molding stations 104-1, 104-2, ... 104-8 to any of the conditioning stations 108-1, 108-2; and coupling any of the conditioning stations 108-1, 108-2 to any of the molding stations 106-1, 106-2. This defines a large number of possible paths through the molding system 100. As shown, there are 128 unique combinations of one dispensing station 102, one molding station 104, one conditioning station 108, and one molding station 106, with each unique combination corresponding to one possible path. In some embodiments, one or more of the process cells may be excluded from some paths, thereby allowing additional paths. For example, conditioning in conditioning cell 108 or molding in molding cell 106 may not be required in all cases.

[0135] In other embodiments, there may be more or fewer stations in each process cell and more or fewer paths through the molding system may be possible.

[0136] In some embodiments, the process cells or stations of the process cells may be physically separated from one another. The transport subsystem 110 may include an apparatus for moving the molding material through the spaces between the process cells or stations thereof. The apparatus may include one or both of a container 124 (FIGS. 6A and 6B) for holding the molding material and a carrier 125 (FIG. 7) for moving the container through the spaces between the process cells or stations, e.g., along a guide or track. In the embodiments described in detail herein, the container is selectively coupled to the carrier, so that the container can be coupled and decoupled from the carrier at one or more process stations. In another embodiment not shown, the container may be otherwise secured to the carrier and a process station configured to receive the container while it remains coupled to the carrier. In either case, the container may be thermally insulated from the carrier.

[0137] In the illustrated embodiment, the molding cell 104 includes an injection molding station and the molding cell 106 includes a blow molding station. The conditioning cell 108 includes a station for thermally conditioning an article to prepare it for blow molding. For example, an injection molded article formed in the molding cell 104 may be cooled after molding and then warmed to a temperature suitable for blow molding. Alternatively or additionally, the stations of the conditioning cell 108 may be configured to generate a particular desired thermal profile in the article. For example, some molding operations may require an input article with a non-uniform temperature distribution. The stations of the conditioning cell 108 may generate such a temperature distribution by selectively heating certain areas with or without a net transfer of heat into or out of the article. In some embodiments, the article may experience a net loss of heat in the conditioning cell 108 despite the warming of certain areas. Thus, the stations of the conditioning cell 108 may achieve a thermal profile not easily achieved by heat input at the dispensing cell 102.

[0138] As described in more detail below, each station may have the same or unique characteristics. For example, the dispense stations of dispense cell 102 may each be configured to dispense the same or different feedstock (e.g., different materials and / or colors). The molding stations of molding cells 104, 106 may each be configured to mold articles with the same or different shapes, characteristics, or the like. The conditioning stations of conditioning cell 108 may each be configured to condition parts in a common state or in a different state. Thus, molding system 100 may be configured to be capable of simultaneously producing up to 128 identical or unique parts at any one time. Alternatively or additionally, molding system 100 may be configured to be capable of producing multiple passes of the same part. For example, a single dispense station may produce multiple shots of feedstock to feed multiple stations of molding cells 104, 106. In some embodiments, cells may be rapidly reconfigured. Thus, the number of system resources used to produce a given type of part may vary.

[0139] Each unique path through molding system 100 includes a unique combination of selected stations of dispensing cells 102, molding cells 104, 106, and possibly other process cells, such as, for example, conditioning cell 108. Similarly, each unique combination of stations may produce finished articles having the same or unique characteristics. For example, various stations of dispensing cells 102 may produce articles with different colorant types or weights. Various stations of molding cells 104, 106 may produce articles with different shapes. Various stations of conditioning cell 108 may produce articles with different shapes or other characteristics.

[0140] FIG. 3 is a perspective view of a molding system 100. In the illustrated embodiment, the molding system 100 is for forming hollow plastic articles such as bottles or other containers. The molding system 100 includes two molding cells. Specifically, the molding cell 104 is an injection molding cell that molds a dose of raw material into a molded preform shape. The molding cell 106 is a blow molding cell (specifically a stretch blow molding cell) that transforms a preform of a particular shape into a finished hollow container having another shape (e.g., a further expanded shape). The conditioning cell 108 prepares the workpiece for the operations performed in the molding cell. The transport subsystem 110 links the stations of each of the cells 102, 104, 106, 108. The links between the cells are flexible. For example, in some embodiments, the transport subsystem 110 links all the stations of each cell to all the stations of an adjacent cell. In other examples, some or all of the stations of a given cell are each linked to multiple stations of an adjacent cell. In some instances, some stations may be linked 1:1 to stations in adjacent cells, such as in the embodiment of FIGURE 3, where each station in dispensing cell 102 is linked to multiple stations in molding cell 104, which is linked to multiple stations in conditioning cell 108, with each station in conditioning cell 108 linked to one corresponding station in molding cell 106.

[0141] Dispensing of ingredients 4A-4S, details of an exemplary dispensing cell 102 are described.

[0142] Each station 102-1, 102-2, 102-3, 102-4 of the dispensing cell 102 includes one or more devices for melting a feedstock, such as a plastic feedstock, and for transferring the feedstock. In the embodiment shown, the dispensing devices output multiple doses of a particular size of the molding material, although in other embodiments the dispensing devices may simply perform a bulk transfer of the molding material without precisely metering the dose size.

[0143] In the embodiment shown, each station of the dispensing cell 102 includes an extruder 112; however, other types of dispensing devices are possible. For example, melting and dispensing multiple doses of raw material can be accomplished through the use of a conduction melter. In the example shown, the extruder 112 receives the raw material in the form of polyethylene terephthalate (PET) pellets; however, other raw materials and other shapes are possible. For example, the raw material can be provided as a filament (e.g., on a spool), or as a bar or block.

[0144] The extruder 112 may dispense different raw materials. In some examples, the extruder 112 may dispense raw materials of different volumes, colors, different material types or grades, or different temperatures. In some embodiments, the extruder may be capable of injecting or blending additives, such as dyes or oxygen scavengers, into the raw materials. In some embodiments, the extruders 112 may be of different sizes or may be configured to dispense raw materials at different speeds or different dose sizes. For example, the system 100 may be configured to form containers of different sizes with the extruders 112 configured to dispense raw materials in doses corresponding to each particular size.

[0145] 4A and 4B are isometric and exploded views, respectively, of extruder 112, detailing its components. As shown, extruder 112 includes a barrel 114 housing a screw 116 (FIG. 5) and a drive unit 115 for driving rotation of screw 116. Rotation of screw 116 is driven by a drive train 130 within drive unit 115, which may include an electric motor. Barrel 114 includes an inlet opening for supplying feedstock and an outlet orifice 122 (FIG. 5) for dispensing molten feedstock into a vessel 124.

[0146] 4B, in the illustrated embodiment, the extruder 112 is mounted on supports 162 in the dispensing cell 102. One set of supports 162 may be provided for each dispensing station 102-1, 102-2, 102-3, 102-4. As shown, the barrel 114 and the screw 116 therein (collectively referred to as barrel unit 117) are releasably coupled to the drive unit 115. Specifically, a coupling 161 rotatably couples the screw 116 to the drive train 130, and one or more positioning mechanisms 163 are received in corresponding recesses in the supports 162 to position and secure the barrel 114 relative to the supports 162. Alternatively, the alignment mechanisms 163 may be part of the supports 162 and may be received in corresponding recesses in the barrel 114. The supports 162 may include actuators for selectively engaging or disengaging the positioning mechanisms 163. This allows the barrel 114 and screw 116 to be released and removed as a unit and replaced with another barrel 114 and screw 116. The coupling 161 and positioning mechanism 163 are located in one or both of the coupling block 4010 of the barrel unit 117 and the frame 4012 of the drive unit 115. Reference herein to removing, replacing or installing the extruder 112 is intended to include removing, replacing or installing the barrel 114 and screw 116 as an assembly. In this manner, extruder characteristics or feedstock characteristics can be quickly and easily changed.

[0147] In some embodiments, removal, replacement, or installation of extruder 112 may be done automatically. For example, extruder 112 may be grasped and removed from support 162 and moved by one or more robots under computer control. The computer control may be part of an overall control system for system 100, and the release or engagement of a positioning mechanism, such as positioning mechanism 163 on barrel 114, may be coordinated with the operation of the robot, such that extruder 112 is held securely during installation by the robot and until subsequent removal by the robot.

[0148] 4C and 4D show the barrel unit 117 and drive unit 115 of the extruder 112 in more detail. In the configuration of FIG. 4C, the barrel unit 117 is coupled to the drive unit 115. In the configuration of FIG. 4D, the barrel unit 117 is disengaged from the drive unit 115.

[0149] As shown, the barrel unit 117 includes a barrel 4002 and a screw 116 within the barrel 4002. A nozzle assembly 4006 is disposed at a distal end of the barrel 4002, which defines an exit orifice 122 thereat. Rotation of the screw 116 within the barrel 4002 results in a heated and melted barrel of molding material, conveying the molding material toward the exit orifice 122 of the nozzle assembly 4006. A shroud 4008 is disposed around the barrel 4002. The barrel 4002 can become very hot during operation. The shroud 4008 acts as a barrier to prevent damage to surrounding components and to protect the operator from injury.

[0150] The barrel 4002 is attached to a mating block 4010. For example, the barrel 4002 may include a flange (not shown) that interfaces with the block 4010 and is secured thereto by a fastener. As will be described in more detail, the screw 116 is received in and supported by the barrel 4002.

[0151] The nozzle assembly 4006 includes a thermal regulating element 4007 proximate the outlet 122. The thermal regulating element 4007 maintains the nozzle assembly 4006 at a desired temperature, which in turn controls the temperature of the molding material in the nozzle assembly 4006 and exits the nozzle assembly 4006 via the outlet 122. One or more temperature measuring devices, such as thermocouples, may be disposed in the nozzle assembly 4006, and the thermal regulating element 4007 may be controlled based on measurements of such devices.

[0152] The drive unit 115 and the barrel unit 117 are coupled via a coupling system operated by one or more actuators. The one or more actuators may couple and decouple the drive unit 115 and the barrel unit 117 using the coupling system. That is, the coupling system is operable to physically fix the barrel unit 117 in a position relative to the drive unit 115. The coupling system is further operable to couple the screw 116 with the drive unit 115 for driving rotation of the screw 116. In the illustrated embodiment, the coupling system includes a retaining mechanism 4014 and a driving mechanism 4016. The retaining mechanism 4014 is operable to physically hold the barrel unit 117 in a position relative to the drive unit 115. The driving mechanism 4016 rotatably couples the drive unit 115 to the screw 116 for rotating the screw.

[0153] In the embodiment shown, the retention mechanism 4014 and the drive mechanism 4016 are operated by separate actuators. In other embodiments, a single actuator may operate both the retention mechanism 4014 and the drive mechanism 4016. In other embodiments, a single mechanism may provide both retention and drive functions.

[0154] In the embodiment shown, the actuators for the holding mechanism and for the drive mechanism 4016 are pneumatic, although other types of actuators may be used, including electromechanical actuators such as solenoids, magnetic actuators, or hydraulic actuators.

[0155] The barrel unit 117 further includes one or more service ports 4018 each coupled to a corresponding port of the drive unit 115 or an adjacent drive unit 115. The service ports may include, for example, conduits for circulating a coolant, such as water, to and from the barrel unit 117, conduits for supplying air, such as pressurized air, to the pneumatic actuation system, and electrical connections. The electrical connections may include, for example, any of power, control, and signal wiring. The drive unit 115 also includes a resin feed port 4076 (FIG. 4I). The resin feed port 4076 receives a feed of molding material, such as pelletized molding material, and communicates with the barrel unit 117 to supply molding material to the barrel. The service ports 4018 may be configured for quick coupling and decoupling with corresponding ports of the drive unit 115. In one example, the service ports 4018 may be coupled using a push-fit pneumatic or hydraulic connector, a magnetic connector, a barbed fitting, or the like. Thus, the service ports 4018 may be automatically coupled or decoupled from their corresponding ports by application of force, for example, by movement of the barrel unit 117 or in response to a control signal.

[0156] FIG. 4E shows the barrel unit 117 with the mating block 4010 and shroud 4008 removed to show internal features. The barrel unit 117 includes a resin input port 4074 that communicates with the interior of the barrel 4002 to deliver molding material to the interior of the barrel 4002. The molding material is typically input to the barrel 4002 in a granular solid state and may be delivered, for example, from a hopper (not shown). The hopper may be attached to the drive unit 115 or an adjacent drive unit 115 and may deliver molding material to the resin input port 4074 via a corresponding resin feed port 4076 in the drive unit 115. In some embodiments, the resin input port 4074 and the resin feed port 4076 abut one another. In other embodiments, one of the input port 4074 and the feed port 4076 may be received in the other port. In some embodiments, the input port 4074 and the feed port 4076 may be securely coupled to one another using quick connect fittings, such as, for example, push-fit pneumatic or hydraulic connectors, magnetic connectors, barbed fittings, or the like. Coupling and uncoupling of such fittings may be accomplished automatically by application of force, for example, by movement of the barrel unit 117 or in response to a control signal.

[0157] As best illustrated in FIG. 4F and FIG. 4G, one or more positioning devices may be provided to position the drive unit 115 and the barrel unit 117. The positioning devices position the barrel unit relative to the drive unit 115 as the barrel unit moves toward the coupled position. Specifically, the positioning devices guide the barrel unit 117 so that it seats in the coupled position relative to the drive unit 115, where the retaining mechanism 4014 and the drive mechanism 4016 may engage. That is, in the coupled position, the components of the retaining mechanism 4014 and the drive mechanism 4016 on the barrel unit 117 are aligned with the corresponding components on the drive unit 115. The positioning devices may gradually urge the barrel unit 117 into precise alignment as the barrel unit 117 moves toward the drive unit 115. In the illustrated embodiment, the positioning devices include a leader pin 4020 and a mating recess 4022 (FIG. 4D). As shown, the leader pin 4020 protrudes from the coupling block 4010 of the barrel unit 117 and is received in a recess 4022 in the frame member 4012 of the drive unit 115 .

[0158] The leader pin 4020 and the recess 4022 engage with each other as the barrel unit 117 moves towards the drive unit 115. Such engagement aligns the barrel unit 117 relative to the drive unit 115 so that the barrel unit 117 and the drive unit 115 can be coupled by actuation of the retention mechanism 4014. In the example shown, the alignment devices engage with each other prior to engagement of the coupling system.

[0159] 4H shows the retention mechanism 4014 in more detail. In the embodiment shown, the retention mechanism 4014 includes a stud 4024 and a socket 4026 that can selectively interface with the stud 4024. As shown, the stud 4024 is part of the barrel unit 117 and the socket 4026 is part of the drive unit 115. For example, the stud 4024 can be screwed into the coupling block 4010. The socket 4026 can be a recess cut into the frame 4012 or an insert attached (e.g., screwed) to the frame 4012. However, the socket 4026 can instead be part of the barrel unit 117 and the stud 4024 can instead be part of the drive unit 115.

[0160] The stud 4024 includes an inner flange and an outer flange 4028 that define a channel 4032 therebetween. The socket 4026 includes an opening 4034 sized to receive the stud 4024, and a gripping device 4036. The gripping device 4036 is configured to be received in the channel 4032 and to interlockingly engage the flanges 4028.

[0161] The gripping device 4036 is movable between an engaged state and a disengaged state. In the disengaged state, the gripping device 4036 disengages from the flange 4028 of the stud 4024 so that the stud 4024 can be freely inserted into or withdrawn from the socket 4026. In the engaged state, the gripping device interfaces with the stud 4024 and prevents the stud 4024 from being withdrawn from the socket 4026.

[0162] In the embodiment shown, the gripping device 4036 includes a series of balls 4038 and a moveable locking collar 4040. In the engaged state, the locking collar 4040 holds the ball 4038 against the channel 4032. The ball 4038 abuts against the distal flange 4028 of the stud 4024, urging the stud 4024 (and barrel unit 117) against the drive unit 115. In the disengaged state, the locking collar 4040 is withdrawn, allowing the ball 4038 to move away from the stud 4024.

[0163] As shown, the locking collar 4040 is spring biased into engagement. An actuator is provided to selectively overcome the spring bias, thereby releasing the locking collar 4040 and ball 4038. In the embodiment shown, the spring bias is overcome by air pressure provided through a retention control line 4044, which is controlled by a valve (not shown).

[0164] The drive mechanism 4016 is shown in detail in Figures 4I and 4J. The drive mechanism 4016 includes a drive shaft 4050 that is driven by an electric motor (not shown). The drive shaft 4050 has an end with a toothed connector, such as, for example, spline 4052. The connector interfaces with a mating connector on the screw 116 or spline 4054. The spline 4052 of the drive unit 115 and the spline 4054 of the screw 116 interface via a spline insert 4056 as shown.

[0165] The spline insert 4056 mates with both splines 4052, 4054. The spline insert 4056 is movable along the axis of rotation of the drive shaft 4050 between an engaged position and a retracted position.

[0166] In the engaged position, the spline insert 4056 meshes with the splines 4052, 4054 to rotatably couple the drive shaft 4050 and the screw 116. In the retracted position, the spline insert 4056 retracts along the axis of the drive shaft 4050 and disengages from the splines 4054 of the screw 116. This causes the drive shaft 4050 and the screw 116 to be decoupled from one another in the retracted position of the spline insert 4056. Retraction of the spline insert 4056 can occur without any movement of the drive shaft 4050. That is, the spline insert can move relative to and disengage from both the drive shaft 4050 and the splines 4054 of the screw 116 along its longitudinal axis.

[0167] The position of the splined insert 4056 is controlled by an actuator or drive actuation assembly 4060. As shown, the drive actuation assembly 4060 includes a pneumatic cylinder 4062. A piston of the pneumatic cylinder 4062 is coupled to the splined insert 4056 via a link 4064. Movement of the piston stroke in a first direction moves the splined insert 4056 to an engaged position. Movement of the piston stroke in the reverse direction moves the splined insert 4056 to a disengaged position.

[0168] The shroud is also coupled to the link 4064 and moves with the link 4064 and the splined insert 4056. In the engaged position, the shroud is disposed near the mating interface between the splined insert 4056 and the splines 4054 of the screw 116. The shroud prevents the ingress of objects, i.e., contaminants such as dust or other particles, that can cause premature wear and degrade the performance of the splines 4052, 4054.

[0169] The splines 4052, 4054 and the spline insert 4056 define a mating interface, i.e., an interface between mating teeth through which torque can be transmitted. The mating surfaces have a relatively large axial length such that the mating interface can accommodate some movement of the drive shaft 4050 and the screw 116 along the longitudinal axis. In other words, the screw 116 and the drive shaft 4050 can shift axially relative to one another without interfering with the meshing of the splines 4052, 4054 and the spline insert 4056.

[0170] The screw 116 is rotatably supported by a bearing 4070, which is in turn supported by a flange 4071 on the coupling block 4010. A support ring 4072 is secured to the screw 116 over the bearing 4070 by a press fit or other suitable technique.

[0171] In operation, the screw 116 may be supported vertically at least in part by friction between the spline insert 4056 and the splines 4054 and by the pressure of the molding material in the barrel 114. In this state, there may be a clearance between the support ring 4072 and the bearing 4070. When operation is terminated, the screw 116 may be lowered until the support ring 4072 abuts the bearing 4070. The support ring 4072 is positioned such that when the screw 116 is thus lowered, there is a clearance gap between the ends of the screw 116 and the drive shaft 4050. In this state, the drive unit 117 may move without the drive shaft 4050 and the screw 116 rubbing against each other and, as a result, wearing each other.

[0172] Advantageously, in the illustrated embodiment, engagement and disengagement of the drive mechanism 4016 and the retaining mechanism 4014 may occur independently of one another. That is, the drive mechanism 4016 may engage or disengage without changing the state of the retaining mechanism 4014. Engagement of the drive mechanism 4016 occurs by movement of the screw 116 along its longitudinal axis, and the barrel unit 117 is physically positioned relative to the drive unit 115 by vertical movement. Similarly, physical fixation of the barrel unit 117 to the drive unit 115 occurs by fixation in a direction perpendicular to the axis of the screw 116, i.e., perpendicular to the direction in which engagement of the drive mechanism 4016 occurs. Alignment of the barrel unit 117 to the drive unit 115 also occurs by movement along an axis perpendicular to the axis of the screw 116. That is, the leader pin 4020 extends in a direction perpendicular to the axis of the screw 116. Independent movement of the drive mechanism 4016 and the retaining mechanism 4014 may also be achieved in other configurations. For example, the mechanisms may be configured to engage by movement along parallel axes, but the movements may be independent of one another.

[0173] The coupling block 4010 includes at least one mating surface 4076. When the barrel unit 117 is coupled to the drive unit 115, the mating surface 4076 abuts a corresponding surface of the drive unit 115 (i.e., a corresponding surface of the frame 4012). The mating surface 4076 may abut against the frame 4012 to hold the barrel unit 117 to the drive unit 115 square.

[0174] In some embodiments, the mating surface 4076 can be positioned to limit stress on the drive mechanism 4016. For example, as shown in FIG. 4F, the mating surface 4076 is located in a central plane C of the connector block 4010. The longitudinal axis L of the screw 116 lies within the central plane C.

[0175] In operation, forces can be applied to the tip of the barrel 114. Such forces can include axial forces, i.e., forces parallel to the longitudinal axis L, and lateral forces perpendicular to the longitudinal axis L. For example, the lateral forces can result from misalignment. The length 114 of the barrel can act as a moment arm, such that the lateral forces act as a torque on the barrel 114.

[0176] The contact between the mating surface 4076 and the frame 4012 can resist torque applied to the barrel 114. That is, the frame 4012 can exert a reaction force on the mating surface 4076, which resists movement or twisting of the barrel unit 117.

[0177] The alignment of plane C and longitudinal axis L can limit the stresses on the barrel 114 and splines 4054. Conversely, if location C and longitudinal axis L were spaced apart, lateral forces would also act near second moment arms perpendicular to the longitudinal axis L. The alignment of mating surface 4076 and longitudinal axis L prevents such second moment arms, and therefore limits the torque that the splines 4054 and barrel 114 can be subjected to.

[0178] The coupling block 4010 includes a back surface 4078 opposite the mating surface 4076. When the barrel unit 117 is coupled to the drive unit 115, the back surface 4078 faces outward, away from the drive unit 115. At least one pull stud 4080 is fixedly attached (e.g., screwed) to the coupling block 4010. Each pull stud 4080 pops out of the coupling block 4010 for engagement by a removal tool to remove the barrel unit 117 from the drive unit 115.

[0179] FIG. 4K illustrates an exemplary removal tool 4082. The removal tool 4082 is an automated (e.g., robotic) transport device. The removal tool 4082 comprises a base 4084 and a rack 4086 supported by the base. The rack 4086 comprises a number of nests 4088, each capable of engaging and holding a barrel unit 117. Two nests 4088-1 and 4088-2 are shown in FIG. 4K, although any number of nests may be present.

[0180] Each nest 4088 includes one or more couplings 4090 operable to selectively engage the pull studs 4080. In some embodiments, the couplings 4090 may be identical to the gripping devices 4036 of the drive unit 115 and the pull studs 4080 may be identical to the studs 4024 of the barrel unit 117. The couplings 4090 are controlled by an actuator (not shown). The actuator may be, for example, an electronic actuator, a pneumatic actuator, or a hydraulic actuator.

[0181] The rack 4086 may be attached to the base 4084 by a movable arm 4092. The arm 4092 is operable to extend to engage the barrel unit 117 for removal from the drive unit 115, and to retract for transport once the barrel unit is secured in the nest 4088. The arm 4092 may be driven, for example, by an electric servo motor or by a hydraulic or pneumatic cylinder.

[0182] As mentioned above, plastic molding system 100 may include multiple barrel units 117, which may be interchangeably attachable to one or more drive units 115. For example, each barrel unit 117 may include a different type of molding material, such as a different resin type, a different color of material, or the like.

[0183] The interchangeability of the barrel units 117 may allow for rapid setup of the molding system 100 to produce a variety of specific molded parts. The removal tool 4082 may allow for automation of changing of the barrel units 117 on the drive unit 115. That is, the removal tool 4082 may be capable of automatically approaching the drive unit 115, engaging the barrel unit 117 mounted on that drive unit 115, removing the barrel unit 117, holding it, and mounting a new barrel unit 117. The removal tool 4082 may then be capable of automatically transporting the removed barrel unit to a storage or cleaning area.

[0184] 4L to 4O show the process of mounting barrel unit 117 to drive unit 115.

[0185] As shown in FIG. 4L, the barrel unit 117 is brought to a position opposite the drive unit 115 by the removal tool 4082. In some embodiments, the removal tool 4082 may be guided to a position relative to the drive unit 115. For example, a beacon, such as an infrared or other light-based beacon, or a radio frequency (RF) beacon, may be mounted on the drive unit 115 or the barrel unit 117, and a corresponding sensor may be mounted on the removal tool 4082. The removal tool 4082 may be programmed to detect a signal from the beacon and approach the detected signal. In other embodiments, the removal tool 4082 may be programmed to monitor and record its location. For example, the removal tool 4082 may initially manually move to a particular drive unit 115 location and record the coordinates corresponding to that location. Thereafter, upon receiving a specific command, the removal tool 4082 may automatically return to the recorded location. In some embodiments, the removal tool 4082 can thus be programmed to hold multiple transfer positions, each for engaging a respective drive unit 115 .

[0186] With the removal tool 4082 aligned with the drive unit 115 , the arm 4092 extends to move the barrel unit 117 towards the drive unit 115 .

[0187] As the barrel unit 117 approaches the drive unit 115, the gripping device 4036 of the barrel unit 117 opens. In the embodiment shown, the gripping device is energized as the gripping device 4036 opens, overcoming the spring bias towards a closed state. The energization can be by providing a pressurized air or water stream, or by an electrical signal.

[0188] The alignment devices on the barrel unit 117 and the drive unit 115 engage with each other to position the barrel unit 117 relative to the drive unit 115. Specifically, the leader pin 4020 is received in the recess 4022 to guide the barrel unit 117 onto the drive unit 115.

[0189] 4M, the stud 4024 is received in a socket 4026. The tapered tip of the stud 4024 abuts the walls of the socket 4026 or a gripping device 4036, finely aligning the stud 4024.

[0190] Whatever barrel unit 117 is fitted, the screw 116 is supported by a support ring 4072 that sits atop a bearing 4070. In this condition, with the barrel unit 117 positioned so that the stud 4024 is aligned with the socket 4026 of the drive unit 115, there is a clearance gap between the screw 116 and the end of the drive shaft 4050. Thus, when the barrel unit 117 is moved into position, the screw 116 passes under the drive shaft 4050 and spline insert 4056 without contacting the drive shaft or spline insert.

[0191] 4N, the barrel unit 117 moves closer to the drive unit 115 until the stud 4024 is fully received within the socket 4026. The retention actuator is actuated to close the gripping device 4036, thereby locking the stud 4024 and barrel unit 117 in place relative to the drive unit 115. Engagement of the stud 4024 by the gripping device 4036 pulls the stud 4024 and barrel unit 117 towards the drive unit 115. Such engagement of the stud 4024 causes the mating surface 4076 of the coupling block 4010 to be tightly secured to the drive unit 115. In some embodiments, the gripping device 4036 remains closed and engaged with the stud 4024 unless energy, such as in the form of hydraulic or pneumatic pressure, is applied to cause it to move away.

[0192] 4O, the barrel unit 117 is physically secured to the drive unit 115 such that the drive mechanism 4016 can be actuated to rotatably couple the screw 116 to the motor via the drive shaft 4050. A signal is provided to the drive actuation assembly 4060 to extend the pneumatic cylinder 4062, which moves the spline insert 4056 to an engaged position. The extension of the spline insert 4056 causes it to mesh with the splines 4054, thereby rotatably coupling the screw 116 to the drive shaft 4050, which in turn drives the drive shaft 4050.

[0193] 4P-4R and 4S show the process of removing barrel unit 117 from drive unit 115.

[0194] 4P, the drive actuation assembly 4060 disengages the drive mechanism 4016 prior to movement of the barrel unit 117. The drive actuation assembly 4060 receives a signal to retract the cylinder 4062, thereby retracting the splined insert 4056. Retraction of the splined insert 4056 releases the engagement between the splined insert 4056 and the splines 4054, such that the screw 116 and the drive shaft 4050 can rotate independently of one another.

[0195] The screw 116 may be lowered such that the support ring 4072 supports the drive screw 116 on the bearing 4070. The screw 116 may be lowered immediately after the spline insert 4056 retracts, or may be lowered after the pressure of the molding material in the barrel 114 is reduced. When the screw is supported by the support ring 4072 on the bearing 4070 and the spline insert 4056 retracts, the screw 116 does not contact the drive shaft 4050 or the spline insert 4056, and the barrel unit 117 separates from the drive shaft 4050 and the spline insert 4056 for removal.

[0196] As shown in FIG. 4S, the removal tool 4082 approaches the barrel unit 117 and the arm 4092 extends to contact or nearly contact the barrel unit 117.

[0197] The gripping device 4036 of the drive unit 115 is energized, causing the gripping device to release the stud 4024. The coupling 4090 of the removal tool 4082 is placed on the pull stud 4080 of the barrel unit 117 and locked in a closed position engaging the pull stud. The locking of the coupling 4090 holds the barrel unit 117 to the nest 4088 and rack 4086 of the removal tool 4082.

[0198] With the barrel unit 117 engaged with the arm 4092, the removal tool 4082 retracts the arm to pull the barrel unit 117 from the drive unit 115. The stud 4024 is withdrawn from the socket 4026, and the service port 4018 and the resin input port 4076 are decoupled from the corresponding ports of the drive unit 115. The alignment mechanism is also decoupled (not shown) as the leader pin 4020 is withdrawn from the recess 4022.

[0199] After the barrel unit 117 is removed from the drive unit 115, a new barrel unit may be installed. In some examples, the removal tool 4082 moves the new barrel unit to align it with the drive unit 115. Specifically, the removal tool 4082 may shift the nest 4088 that carries the new barrel unit to align it with the drive unit 115.

[0200] With the new barrel unit aligned, the removal tool 4082 extends the arm 4092 to couple the new barrel unit to the drive unit 115, as described above with respect to Figures 4L-4O.

[0201] In some examples, the removed barrel unit 117 can remain in the nest 4088 of the arm 4092 while a new drive unit in another nest 4088 is attached to the drive unit 115. A removal tool can arrive at the drive unit 115 carrying the first barrel unit, automatically remove the second barrel unit from the drive unit 115, and replace the second barrel unit with the first barrel unit.

[0202] Once a barrel unit is removed from the drive unit 115, it may be stored. The barrel unit may be transported from the removal tool 4082 to a rack or other storage area, for example. Alternatively, the barrel unit may simply remain in the removal tool 4082 for storage. In some examples, there may be multiple removal tools 4082, and each stored barrel unit may be stored in a removal tool with at least one empty nest 4088. Thus, any stored barrel unit may be loaded by delivering the respective removal tool to the drive unit, which may also remove the previous barrel unit from the drive unit.

[0203] The interchangeability, and especially the automated interchangeability, of barrel units 117 may allow for rapid configuration and reconfiguration of molding system 100. In particular, various barrel units for different molding materials (e.g., different material types or colors) may be used. Thus, molding system 100 may be reconfigured for molding parts of different materials by simply replacing barrel units 117.

[0204] Transport container Details of the transfer vessel, in which the molten raw material may be transferred between the process stations, will now be described with reference mainly to Figures 5 to 12, as will the relevant features of the process stations.

[0205] FIG. 5 is an enlarged cross-sectional view of extruder 112 and vessel 124 showing the components in greater detail.

[0206] Feedstock, such as PET pellets, are introduced into a cavity of barrel 114 and forced towards an exit orifice 122 by the rotation of screw 116. The rotation of screw 116 compresses the feedstock, which causes it to be heated and ultimately melted for dispensing into container 124.

[0207] The extruder 112 includes a nozzle assembly 113 disposed at the dispensing end of the barrel 114. As will be described in further detail, a container 124 may be disposed opposite the nozzle assembly 113 to receive the molten feedstock. A gate assembly 1130 may be sandwiched between the extruder and the nozzle assembly.

[0208] In some embodiments, only a subset of the available extruders may be loaded at any time. For example, molding system 100 may have four or more extruders 112 available, of which only one subset may be loaded or active at any time.

[0209] In such an embodiment, each extruder 112 may be used for a specific feedstock (e.g., a particular combination of color and material). Advantageously, this may reduce or eliminate the need to change feedstocks at any given extruder 112. That is, switching from a first feedstock to a second feedstock may be accomplished by removing the extruder containing the first feedstock and replacing it with another extruder containing the second feedstock. Optionally, the first feedstock may be left in the extruder 112 for the next time that feedstock is needed. Alternatively, the extruders may undergo a cleaning process, which may be automated to remove the first feedstock and prepare the extruder for its next use.

[0210] On the other hand, changing the feedstock within a particular extruder 112 is relatively difficult, time consuming, burdensome (waste of molding material), and labor intensive. Typically, the existing feedstock must be thoroughly purged from the extruder before the new feedstock can be introduced.

[0211] The vessel 124 is carried by the conveying subsystem 110 and positioned adjacent to the extruder 112 to receive the molten feedstock. In the embodiment shown, the vessel 124 is a cartridge having an outer wall 132 that defines an interior cavity 134. The outer wall 132 may be insulated or may be formed of a relatively heat resistant material. In some embodiments, temperature control elements, such as heating and / or cooling devices, may be attached to or integrated with the wall 132 to maintain thermal control of the feedstock within the interior cavity 134.

[0212] The vessel 124 may be thermally conditioned so that prior to receiving the molten feedstock, the vessel is provided with a thermal profile consistent with a desired feedstock temperature. For example, the vessel 124 may be heated prior to receiving the feedstock to limit head loss from the feedstock to the vessel 124.

[0213] A buffering area may be defined, for example, within or adjacent to the dispensing cell 102, where one or more containers 124 may be collected and prepared for receiving ingredients, for example by thermal conditioning, such as heating. The containers may be transported to and from the buffering area by the transport subsystem 110.

[0214] 6A and 6B show isometric and isometric cross-sectional views, respectively, of the container 124. The container includes a gate orifice 136 designed to matingly engage and receive flow from the exit orifice 122 of the extruder 112. As will be further shown below, in the illustrated embodiment, the gate orifice 136 also matingly engages a die of one of the molding stations 104-1, 104-2, ... 104-8 to deliver the molten feedstock into the die. In other embodiments, another orifice may be provided to allow feedstock to exit the container 124. In such an embodiment, the container 124 may be configured such that feedstock is handled in a first-in, first-out manner. That is, the first feedstock that enters the container 124 via the gate orifice 136 may also be the first feedstock that is extruded from the container 124 through the exit orifice. This may limit degradation of the material within the container 124.

[0215] The container 124 includes a barrel 1320 and a tip 1322. The tip 1322 fits over and seals at an end of the barrel 1320, and the barrel and tip cooperate to define an interior cavity 134. The barrel 1320 and the tip 1322 may be formed of different materials. For example, the barrel 1320 may be formed of a hard metal alloy for durability. The tip 1322 may be formed of a highly thermally conductive metal alloy.

[0216] A sealing member 140 (FIG. 6B) is disposed within the cavity 134. The sealing member 140 is operable to control flow through the gate orifice 136. The sealing member 140 is sized to cover and substantially seal one or both of the extruder exit orifice 122 and the container gate orifice 136. As shown, the sealing member 140 includes a shoulder 1402 that contacts and forms a seal with a corresponding shoulder 1404 on the inner wall of the tip 1322. This allows the sealing member 140 and the tip 1322 to seal with each other at their axially opposed surfaces rather than, or in addition to, a sealing arrangement between the container gate orifice 136 and the complementary circumferential surfaces of the end of the sealing member 140. Such an axial sealing arrangement may reduce the risk of leakage and wear.

[0217] The sealing member 140 includes an elongated stem, also referred to as a valve stem, that may move axially relative to the gate orifice 136. The sealing member 140 may be moved by manipulation of the stem. Specifically, the sealing member 140 may retract from the gate orifice 136 to allow flow therethrough, or may extend to block and seal the gate orifice 136. In some embodiments, if the sealing member 140 is stretched sufficiently, it may pop out of the container 124 and into the exit orifice 122 of the extruder 112. In such embodiments, the sealing member 140 may form a seal with both the orifices 136 and 122.

[0218] The container 124 also includes a discharge mechanism that extrudes material from the cavity 134. As shown, the discharge mechanism includes a piston 182 received within the cavity 134, movable between an extended position in which the piston 182 is proximate to the orifice 136 and a retracted position (shown in FIG. 6B ) in which the piston 182 is displaced from the orifice 136 and the cavity 134 is occupied by the molding material. The piston 182 is configured to seal against an inner wall of the container 124 as the piston moves between the extended and retracted positions. This allows the piston 182 to scrape molding material from the inner wall as it moves toward the orifice 136.

[0219] A thermal regulation assembly 1324 can be disposed over at least a portion of the barrel 1320 and the tip 1322. As shown, the thermal regulation assembly 1324 includes a metal sleeve 1326 and a heating device, i.e., a heating coil 1328.

[0220] In the embodiment shown, the sleeve 1326 is a thermal insulator and inhibits heat loss through the underlying surfaces of the barrel 1320 and tip 1322. The sleeve 1326 may be formed, for example, from an alloy with relatively low thermal conductivity. In other embodiments, the sleeve 1326 may act as a heat sink such that it tends to facilitate heat transfer from the molding material in the cavity 134.

[0221] Heating coil 1328 is configured to selectively introduce heat to barrel 1320 and tip 1322, and thereby to molding material in cavity 134. Heating coil 1328 may include contacts 1330, which may be external to sleeve 1326. Contacts 1330 are configured to interface with an external power source to activate heating coil 1328. The external power source may be provided at separate locations. For example, contacts 1330 may be coupled to corresponding contacts at stations of dispensing cell 102, molding cells 104, 106, or conditioning cell 108, or to corresponding contacts at heating stations between stations of cells 102, 104, 106, 108. Alternatively, contacts 1330 may interface with corresponding power lines along the entire length of track 144, such that container 124 is heated continuously or throughout the entire portion of the container's travel between stations.

[0222] The sleeve 1326 and heating coil 1328 can be configured to produce a desired thermal profile in the molding material within the cavity 134. The sleeve 1326 is disposed proximate the tip 1322 and the inlet end of the barrel 1320 and extends toward the base of the container 124, i.e., toward the retracted position of the piston 182. In some embodiments, the sleeve 1326 does not reach the retracted position of the piston 182. That is, in some embodiments, the sleeve 1326 does not overlie the piston 182 or a portion of the barrel 1320 surrounding the piston 182 in the retracted position of the piston 182.

[0223] In an alternative embodiment (not shown), heating of the vessel 124 may be indirect. For example, the vessel 124 may be inductively heated, with the vessel including a heating jacket formed of a suitable material (e.g., brass, aluminum, copper, or steel) for coupling with an applied electromagnetic field radiating from coils located at a heating station or otherwise arranged along the path of travel.

[0224] In the embodiment shown, the container 124 includes an insulator 1332 disposed at the end of the tip 1322. A cap 1334 fits tightly onto the insulator 1332. An orifice 136 is defined by the cooperation of holes in the tip 1322, the insulator 1332, and the cap 1334, with these mutually aligned holes sized to receive a sealing member 140.

[0225] The insulator 1332 is formed of a material selected to have sufficient mechanical strength and low thermal conductivity, and may be, for example, plastic, ceramic, or metal. The cap 1334 is formed of a material selected to have relatively high thermal conductivity. As will be described in more detail, the cap 1334 interfaces with the mold plate of a station of the molding cell 104 such that the cap 1334 is sandwiched between the mold and the tip 1322 of the container 124. The high thermal conductivity of the cap 1334 facilitates heat transfer from the cap to the mold. Thus, the cap 1334 tends to be cooler than the tip 1322. The cap 1334 cools the distal tip of the sealing member 140, which in turn facilitates solidification of the molding material. Thus, the relatively cool cap 1334 and sealing member 140 at the end of the injection operation tend to facilitate solidification of the remaining material in the orifice 136. Such solidification may cause the molded articles to separate cleanly. The insulation 1332 tends to inhibit heat transfer between the tip 1322 of the container 124 and the mold. Because of this, a portion of the tip 1322, as well as the insulation 1332 surrounding the orifice 136, may remain at a temperature close to that of the molten molding material, which in turn experiences a large temperature gradient as it passes through the cap 1334. In some embodiments, the cap 1334 may include an interior profile configured to limit the surface area of ​​contact between the cap 1334 and the tip 1322. For example, the cap 1334 may include ridges or castellations (not shown) to position the cap 1334 relative to the tip 1322 without continuous contact between the components.

[0226] The tip 1322, insulator 1332, cap 1334, orifice 136, and sealing member 140 cooperate to define a mating assembly for mating the container 124 with stations of the dispensing and molding cells. External features such as the outer diameter of the cap 1334 and a shoulder on the tip 1322 engage corresponding positioning features on the molding or injection station to position the orifice 136 into alignment with a mold or extruder. The mating assembly may also serve to seal the container 124, for example, by the orifice 136 sealing against the sealing member 140.

[0227] In the illustrated embodiment, the transport subsystem 110 includes a track 144. The container 124 is received in a carriage 125, which is slidably received on the track 144. The container 124 and carriage 125 may move along the track, for example, by pneumatic or electromagnetic actuation, or by a mechanical device such as a belt or chain. The transport subsystem 110 is capable of precisely indexing the position of each carriage 125 mounted on the track 144. Thus, the transport subsystem 110 can align a particular carriage 125 and container 124 with a particular extruder 112 such that the gate orifice 136 of the container 124 is aligned with the exit orifice 122 of the extruder 112.

[0228] The container 124 is movable with the carriage 125 in a direction toward or away from the extruder 112. In the embodiment shown, movement of the container 124 in the carriage 125 is in a direction perpendicular to the track 144. The carriage 125 may include channels that define seats for the containers and other channels to define paths of movement of the containers 124.

[0229] Movement of the container 124 within the carriage 125 and operation of the sealing member 140 are effected by an actuator assembly 172 .

[0230] The actuator assembly 172 includes a container positioning actuator, a piston actuator 176 , and a sealing member actuator 178 .

[0231] With the container 124 in a dispensing (i.e., fill) position aligned with the extruder 112, the container-positioning actuator is likewise aligned with the container 124 and operable to extend into contact with the container 124 and urge the container 124 into engagement with the nozzle assembly 113 of the extruder 112. Upon such engagement, the exit orifice 122 of the extruder 112 and the gate orifice 136 of the container 124 are aligned in fluid communication with each other.

[0232] The piston 182 is movable by the piston actuator 176 between an empty position in which the piston 182 is adjacent to the orifice 136 and a full position in which the piston 182 is displaced by the ingredient in the cavity 134. The piston 182 is biased toward the empty position, for example, by a spring or by a mechanical force from the actuator assembly 172.

[0233] The sealing member actuator 178 is operable to engage the sealing member 140 and retract the sealing member from the gate orifice 136, thereby allowing the flow of molten raw material through the gate orifice 136 and into the cavity 134 of the container 124. In the embodiment shown, the sealing member 140 includes a detent 180 for gripping by the sealing member actuator 178 such that the sealing member actuator 178 can push the sealing member 140 into sealing engagement with the gate orifice 136 or withdraw the sealing member 140 to allow flow.

[0234] 7A and 7B show isometric views of the container 124 and the carriage 125. The carriage 125 includes a base 1250 configured for mounting to the track 144 and a retention mechanism 1252 that releasably engages the container 124 to retain the container 124 to the base 1250.

[0235] The retention mechanism 1252 includes grips (e.g., tongs 1254) configured to securely hold the container 124. In the embodiment shown, the retention mechanism 1252 includes two sets of tongs 1254; however, there may be more or less than two sets. The tongs 1254 are attached to a carrier plate 1262, which is in turn attached to the base 1250.

[0236] The tongs 1254 are movable between an open position (FIG. 7A) and a closed position (FIG. 7B). In the closed position, the tongs 1254 hold the container 124. Such holding can be achieved, for example, by friction or by interlocking or a combination thereof. In the illustrated embodiment, one set of tongs 1254 interlocks with corresponding detents 1255 on the surface of the container 124. A second set of tongs 1254 grips the outer surface of the barrel 1320 of the container 124 by friction. The second set of tongs 1254 is positioned on a second detent 1256 in the container 124. As will be described in more detail below, the detent 1256 is for engaging a positioning mechanism at a processing station. The tongs 1254 are therefore positioned to prevent interference with the positioning mechanism. In the open position, clearance is provided between the tongs 1254 and the container 124 so that the container 124 can freely pass between the tongs 1254 or be removed from the tongs 1254 .

[0237] The tongue 1254 may be biased toward the closed position. For example, the tongue 1254 may be biased by a spring assembly 1260. In some embodiments, the spring assembly 1260 may be double acting, such that if the tongue 1254 is partially open, for example, by a threshold amount, the spring assembly 1260 instead biases the tongue 1254 to the open position. The tongue 1254 may be configured such that insertion of the container 124 between the tongues 1254 switches the tongue 1254 to the closed position. For example, the tongue 1254 may include a profile such that insertion of the container 124 moves the tongue to an intermediate position between the open and closed positions, where the spring assembly 1260 biases the tongue 1254 to snap into the closed position. The profile of the tongue 1254 may be such that it tends to center the container 124 when the container is inserted between the tongues. Because of this, some lateral misalignment of the container 124 can be tolerated and can be corrected while the container is seated inside the tongs 1254 and the tongs are closed.

[0238] The tongues 1254 and carrier plate 1262 are suspended above the base 1250 such that the tongues and carrier plate have some freedom to move vertically relative to the base 1250. For example, the tongues 1254 may be free to move vertically to align with the detents 1255. Such freedom of movement may compensate for vertical misalignment of the container 124.

[0239] The carrier 125 further includes a closure assembly 1270. In the embodiment of Figures 7A and 7B, the closure assembly 1270 is attached adjacent to the bottom of the base 1250.

[0240] The closure assembly 1270 includes a movable arm 1272 that is movable between a sealed position, shown in Figures 7A and 7B, and an open position. In the embodiment of Figures 7A and 7B, in the sealed position, the arm 1272 contacts an end of the sealing member 140 and urges that end upwardly toward the tip 1322 of the container 124 to seal the orifice 136.

[0241] 8A-8D, the operational sequence for dispensing ingredient from extruder 112 to container 124 is shown in detail. FIG. 8A shows a side elevational view of extruder 112 and container 124 prior to engagement of those parts. FIG. 8B shows a side elevational view of extruder 112 and container 124 after engagement and immediately prior to dispensing ingredient. FIGs. 8C and 8D show longitudinal cross-sectional views of extruder 112 and container 124 before and during dispensing.

[0242] As shown in Figure 8A, container 124 is carried by carriage 125 and movably mounted on track 144. Carriage 125 and container 124 move on track 144 to a dispensing position between a dispensing nozzle of extruder 112 and actuator assembly 172. A container positioning actuator (not shown) extends to move container 124 into abutment with nozzle assembly 113 of extruder 112, as shown in Figure 8B.

[0243] As shown in FIG. 8C, the sealing member actuator 178 retracts the sealing member 140 to allow the flow of material from the extruder 112 to the container 124. The piston 182 is displaced from the extruder 112, increasing the volume of the cavity 134 as the molten material flows into the container 124. In the embodiment shown, the container 124 includes a stop (not shown) that limits the displacement of the piston 182, thereby controlling the amount of material that can flow into the container 124. The stop may be adjustable. Alternatively, the extruder 112 may include a metering mechanism. For example, the extruder 112 may include a pumping device to dispense a specific, pre-set volume of material. The screw 116 may itself function as such a pumping device. For example, the rotation of the screw 116 may be controlled to dispense a specific volume. Alternatively, the screw 116 may translate axially to dispense a specific volume.

[0244] A dose of raw material is deposited in a container 124. The dispensed dose may be referred to as a workpiece 101. In this disclosure, workpiece 101 refers to a dose of raw material throughout processing in system 100. The prime designation of the workpiece, i.e., 101', 101'', refers to the change in morphology of the raw material dose that occurs as it is processed.

[0245] When filling of the container 124 is complete, the sealing member actuator 178 extends the sealing member 140 to seal the gate orifice 136, as shown in Figure 8C. The container positioning actuator then retracts, moving the container 124 away from the extruder 112 and into the carriage 125.

[0246] The container 124 filled with the raw material may be transported to a molding station of the molding cell 104 for the molding operation.

[0247] In some embodiments, the gate assembly 1130 may be sandwiched between the nozzle assembly 113 and the vessel 124. FIG. 9 shows an exploded view of the gate assembly 1130 with the nozzle assembly 113 and the vessel 124. The gate assembly has special utility when used in combination with a vessel without a sealing member 140 (FIG. 8B). The gate assembly 1130 may serve to position the orifice 136 of the vessel 124 with the nozzle assembly 113. The gate assembly 1130 may further serve to cut the feed stream between the nozzle assembly 113 and the vessel 124 when filling of the vessel 124 is complete.

[0248] The gate assembly 1130 includes a guide block 1132 and a blade 1134. The guide block 1132 includes respective recesses 1136 for receiving and aligning each of the tips of the nozzle assembly 113 and the container 124. The blade 1134 may extend through a pocket in the guide block to cut the feed stream. As shown, the blade 1134 includes an arched cross-sectional shape and is compressed within the pocket of the guide block 1132 such that the blade 1134 is biased against the nozzle 113. A scraper 1133 is positioned opposite the blade 1134 such that the scraper 1133 contacts the blade 1134 to remove molding material from the blade.

[0249] The blade 1134 may be extended to cut the feed stream when filling of the vessel 124 is complete. Figures 10A and 10B are enlarged cross-sectional views of the nozzle assembly 113, vessel 124, and gate assembly 1130 during cutting of the feed stream.

[0250] As shown in Figure 1OA, the feed stream is dispensed from nozzle assembly 113 via orifice 136 into vessel 124. When vessel 124 is complete, blade 1134 advances in the direction of the stream.

[0251] 10B, the blade 1134 is biased against the nozzle assembly 113. As the blade 1134 advances into the feed stream, the blade 1134 divides the stream. The blade 1134 fits tightly against the nozzle assembly 113 so that the feedstock is substantially prevented from leaking between the blade 1134 and the nozzle assembly 113. The blade 1134 includes a tab 1138 that extends downward to contact the container 124. As the blade 1134 advances across the container 124, the tab 1138 scrapes the feedstock to limit or remove any residue on the outside of the container.

[0252] Primary molding 11-24, the features and operation of exemplary stations of molding cell 104 will now be described in detail. In the embodiment shown, the exemplary stations are for injection molding of plastic articles, although many features of the described embodiment are expressly not limited to injection molding.

[0253] 11-12 show an enlarged isometric view and a side cross-sectional view, respectively, of molding station 104-1 of molding cell 104. Molding station 104-1 cycles between an open state in which it ejects a molded workpiece, and a closed state in which it receives a dose of feedstock to form molded workpiece 101'. As shown in FIGURES 11-12, molding station 104-1 is in an open state.

[0254] The molding station 104-1 comprises a mold defined by a core assembly 190 and a cavity assembly 192. The cavity assembly 192 comprises two cavity plates 194-1, 194-2 (individually and collectively, cavity plates 194) attached to platens 196-1, 196-2 (individually and collectively, platens 196). Platen 196-1 is attached to a clamping mechanism, such as a hydraulic or electromechanical piston. Platen 196-1 is movable relative to platen 196-2, the latter of which is fixedly attached to a base structure.

[0255] 12A, platen 196-1 is withdrawn from platen 196-2 in the open position of molding station 104-1, cavity plate 194-2 is aligned with mold axis MM, and core assembly 190 is aligned with discharge axis EE.

[0256] 12B-12D show the components of molding station 104-1 in detail. In the example shown, molding station 104-1 includes a mold subassembly 3040, a clamp subassembly 3042, and a core actuation subassembly 3044, the latter of which includes a core placement actuator 3046 and a load actuator 3050. For simplicity, the core actuation assembly has been omitted from FIG. 12D.

[0257] Each of the mold subassembly 3040, the clamp subassembly 3042, and the core actuation subassembly 3044 are mounted to a shaper frame 3052. The mold subassembly 3040, the clamp subassembly 3042, the core actuation subassembly 3044, and the shaper frame 3052 collectively define a shaper module 3054. The shaper frame 3052 may be removably mounted to a support base 3056 of the molding station 104-1 such that the shaper module 3054 may be installed or removed as a single assembly.

[0258] As best shown in FIG. 12C, the mold subassembly 3040 may be opened and closed along multiple axes. That is, the platen 196, along with the cavity plate 194, may be opened and closed along the clamp axis C1-C1. The core assembly 190 may be moved toward and away from the cavity plate 194 along the core axis C2-C2. Opening and closing along the clamp axis C1-C1 may be accomplished by a clamp subassembly 3042. Movement of the core assembly 190 along the core axis C2-C2 may be accomplished by a core actuation subassembly 3042.

[0259] Figure 12D shows details of the connection between the clamp subassembly 3042 and the shaper frame 3052. For simplicity, the core actuation subassembly 3044 has been omitted from Figure 12D.

[0260] The platen 196 may be supported by a shaper frame 3052. The platen 196 and shaper frame 3052 may include mating guide mechanisms that maintain the position and alignment of the platen 196 during opening and closing. In the embodiment shown, the guide mechanisms include guide rails 3062 on the shaper frame 3052 that receive and mate with pins (not shown) on the platen 196. In other embodiments, the guide mechanisms may be interlocking tracks. Other guide configurations are obviously possible.

[0261] As shown, platen 196-1 is slidably mounted to support frame 3052 using a guide mechanism. Platen 196-2 is rigidly mounted to support frame 3052 in a fixed position. In this embodiment, the clamp subassembly 3042 is opened and closed by movement of platen 196-1 relative to platen 196-2 along clamp axis C1-C1. In other embodiments, opening and closing is accomplished by moving both platens toward and away from each other.

[0262] The clamp subassembly 3042 includes a multi-bar linkage 3070. The linkage 3070 includes an anchor block 3072 rigidly attached to the support frame 3052 and a plurality of pivotally connected links that couple the platen 196 to the anchor block 3072. In the embodiment shown, the links include a drive link 3074 and first and second rockers 3076, 3078. The drive link 3074 is coupled to a crosshead 3080.

[0263] The crosshead 3080 may be reciprocated by a suitable linear actuator, such as a ball screw. The drive link 3074 may pivot relative to the crosshead 3080 and relative to the rockers 3076, 3078 as the crosshead goes through its stroke, which in turn causes the rockers 3076, 3078 to pivot relative to one another to drive the platen 196 in either direction along the clamping axis C1-C2.

[0264] The clamp subassembly 3042 includes a number of pivotable connections 3082, each of which may be formed by pressing a pin and bushing (not shown) through a hole into the link or support frame 3052. Other connection types may be used if they have sufficient strength and provide an appropriate range of motion.

[0265] The anchor block 3072 is attached to the support frame 3052 so that the central axis of the anchor block 3072 is aligned with the central axis of the support frame 3052. The guide rail 3062 maintains the position of the platen 196 so that the central axis of the platen 196 is aligned with the central axis of the support frame 3052. This couples the anchor block 3072 and the platen 196 to the linkage 3070 at the central axes of the anchor block 3072, the platen 196, and the support frame 3052. In other words, the pivotable connection 3082 between the anchor block 3072 and the rocker 3076 is located along the central axis of the anchor block 3072 and along the central axis of the support frame 3052. Similarly, the pivotable connection 3082 between the platen 196 and the rocker 3078 is located along the central axis of the anchor block 3072 and along the central axis of the support frame 3052.

[0266] Movement of the crosshead 3080 moves the platen 196 between an open position and a closed position. In the closed (forming) position, a clamping force may be applied via the crosshead 3080 and linkage 3070 to urge the platens together. The clamping force may be significant (in some embodiments, the clamping force may be on the order of 300 kN). As is apparent, a reaction force is applied to the support frame 3052. In the embodiment shown, the platen 196 and anchor block 3072 are loaded in substantially pure compression, and the support frame 3052 is loaded in substantially pure tension, because the linkage 3979 is coupled to the platen 196 and anchor block 3072 at the central axis of the platen 196, anchor block 3072, and frame 3052. On the other hand, the location of any of the pivotable connections away from the center of a given component may create significant shear forces or bending moments. For example, the platens of conventional injection molding machines tend to be closed by rams (e.g., hydraulic rams or ball screws) located close to the corners of the platen. Applying a clamping force in such a configuration can create bending moments in the platen, and in some cases can cause the platen to distort.

[0267] In some embodiments, the stroke length between the open and closed positions of the platen 196 is relatively short. The stroke length is influenced by the amount of clearance required to remove (demold) the finished part. Demolding may be possible with a relatively small opening along an axis perpendicular to the longitudinal axis of the part. For this reason, some exemplary embodiments have a mold opening stroke on the order of 60-120 mm. Conversely, if the part is to be demolded by opening along the longitudinal axis of the part, a longer opening stroke may be required to create a larger amount of clearance.

[0268] Other linkage configurations are possible. For example, in some embodiments, the linkage can include one or more rockers that are pivotally coupled to the support frame 3052. Figures 13A-13C show an example linkage 3070' of such a configuration.

[0269] The linkage 3070' comprises a drive link 3074' fixed to a linear actuator 3088 (as shown, a ball screw driven by an electric motor) with one or more intermediate links 3086. The drive link 3074 is attached to a linear guide 3090. As shown, the linear guide constrains the drive link 3074' to move in a single direction, namely vertically. Specifically, the linear actuator 3088 reciprocates horizontally and the intermediate link 3086 pivots to move the drive link through a reciprocating vertical path II defined by the linear guide 3090 (FIG. 13B).

[0270] The drive link 3074' is pivotally connected to two rockers 3076', 3078' via a further intermediate link 3086. Each rocker 3076', 3078' is attached to a respective platen 196 for driving the platen in a reciprocating opening and closing motion. Each rocker 3076', 3078' is pivotally attached to the support frame 3052. Reciprocating motion of the drive link in direction II (FIG. 13B) causes the rockers 1-76', 3078' to pivot about their connections with the support frame 3052, i.e., in direction II-II. Such pivoting motion then drives the reciprocating motion of the platen 196 along direction III-III. The position and orientation of the platen 196 during such reciprocating motion is maintained by the guide rails 3062 on the support frame 3052. 13C illustrates an exemplary loaded state of the linkage 3070' and support frame 3052 when the platen 196 is in the mold closed position. As shown, the drive link 3074' applies a force to the rockers 3076', 3078', which pivot about their connections to drive the platen 196 together and apply a clamping force to the platen. Because the rockers 3076', 3078' pivot about their midpoints, the clamping force and the force applied by the drive link 3074 are substantially equal in magnitude. An equal reaction force is applied to the rockers 3076', 3078', which are resisted by the support frame 3052. The transfer of force between the rockers 3076', 3078' and the support frame 3052 occurs at a pivotable connection 3082, which is located at the central axis of the support frame 3052. Application of a clamping force therefore places a substantially pure tension force on the support plate 3052 .

[0271] The length of the opening and closing stroke of the platen may be determined by the geometric specifications of the linkage 3070'. Specifically, the stroke may be determined by the length of the drive link 3074', the rockers 3076', 3078', the intermediate link 3086 in combination with the stroke length of the linear actuator 3088.

[0272] In some embodiments, the linkage can be configured to maintain the position and alignment of the platen 196 without the use of a guide structure such as a guide rail 3082. Figures 14A and 14B show an example of such a linkage 3070''.

[0273] Linkage 3070'' is generally identical to linkage 3070', except that linkage 3070'' further includes secondary rockers 3096, 3098, and support plate 3052' is somewhat larger than support plate 3052 to accommodate the extra rockers.

[0274] The secondary rocker 3096 cooperates with rocker 3076' to control the first platen 196, and the secondary rocker 3098 cooperates with rocker 3078' to control the second platen 196. Each rocker pair constrains the position and alignment of the platen 196 during opening and closing. The secondary rockers 3096 and 3098 are connected at one end to a drive link 3074' and at the other end to an intermediate link 3086 which is also connected to the corresponding rocker 3076' / 3078' and platen 196. Multiple connections between the platen 196 and the support frame 3052 hold the platen 192 square relative to the support frame 3052 and relative to each other. Similarly, the rockers 3076' / 3078' and secondary rockers 3096 / 3098 cooperate to align the position of the platen 196 at the end of the closing stroke.

[0275] In some embodiments, the clamp assembly 3042 may be driven by a rotary actuator rather than a linear actuator. For example, the clamp assembly 3042 may be driven by the crank of an electric motor. FIGS. 15A and 15B show an example linkage 3070''' for such an embodiment. The linkage 3070''' is generally similar to the linkage 3070', but the drive link 3074' is replaced by a rotor 3100. The rotor 3100 is driven by a crankshaft, for example, the crankshaft of an electric motor. The rotor 3100 may be coupled to the crankshaft via a gear set, such as a planetary gear set, to provide a suitable speed reduction.

[0276] The rotor 3100 is driven to rotate about its midpoint, the ends of which are coupled to the rockers 3076', 3078' via intermediate links 3086 such that rotation of the rotor 3100 causes the rockers 3076', 3078' to pivot about their connections 3082 to the support frame 3052. When the mold is closed and clamping pressure is applied to the platen 196, the rockers 3076', 3078' and support frame 3052 are subjected to loading conditions similar to Figure 13C. That is, the clamping force corresponds to the force applied to the rockers 3076', 3078' by the rotor 3100 and intermediate links 3086, and the support frame 3052 is loaded in substantially pure tension.

[0277] The linkage 3070''' may be relatively easily adjustable. For example, the length of the rotor 3100 and its associated intermediate link 3086 may be changed to adjust the length of the opening and closing stroke of the platen 196. Increasing the length of the rotor 3100 may increase the stroke. The clamping force may be adjusted by changing the length of the rockers 3076', 3078' or by changing the torque applied to the rotor 3100 (e.g., by changing the ratio of the coupled sets). The linkage 3070''' may thus be relatively easily adapted for use with a variety of molds.

[0278] Embodiments may include combinations of the crank assembly and linkage mechanisms described above. For example, Figure 16 shows a linkage including a crank driven clamp assembly with multiple rockers connected to each platen to provide positional stability.

[0279] In the embodiment shown in Figures 12-15, the rockers 3076', 3078' are attached to the support frame 3052 at their midpoints so that the rockers rotate symmetrically. In some embodiments, the pivot points may be off-center. For example, to increase the clamping force or to increase the length of the opening and closing stroke, the pivot points may be moved closer to the drive ends of the rockers 3076', 3078'. Conversely, the pivot points may be moved closer to the opposite ends to decrease the clamping force or stroke length.

[0280] As shown in FIGS. 13-16 , the linkages 3070′, 3070″, and 3070′″ of the clamp subassembly 3042 act on both platens 196 to move the platens away from or towards each other. In other embodiments, the clamp subassembly may be configured to act on a single moveable platen 196 while the other platen 196 is fixed. For example, the drive link 3074′ or rotor 3100 may be coupled to only a single rocker and platen 196.

[0281] 17, 18A, 18B, 19, 20, 21A and 21B, the components of the core actuation subassembly 3044 are shown in detail. The core actuation subassembly 3044 is configured to move the core assembly 190 along the core axis. In the illustrated embodiment, the core actuation subassembly 3044 includes a core placement actuator 3046 operable to move the core assembly 190 through a first stroke between a molding (closed) position and a separation (open) position. The core placement actuator 3046 may be attached to a secondary mold opening actuator 3180. The core actuation subassembly 3044 further includes a load actuator 3050 operable to apply a force to the core assembly 190 to cause the core assembly 190 to pass a short stroke to initiate separation after molding and resist the molding force. FIGS. 18A and 18B show isometric and cross-sectional views of the core placement actuator 3046, respectively.

[0282] The core placement actuator 3046 comprises a primary frame 3102 for fixing to the support frame 3052. The core placement actuator further includes a loading frame 3104 disposed atop the primary frame 3102. In the embodiment shown, the loading frame 3104 is attached to the primary frame 3102 using locating pins such that the loading frame 3104 can move vertically relative to the primary frame 3102 while maintaining alignment.

[0283] The core placement actuator 3046 may include one or more pneumatic pistons 3108 to move the loading frame 3104 relative to the primary frame 3102. As best shown in FIG. 18B, the pneumatic pistons 3108 are attached to the loading frame 3104 and act against the primary frame 3102 to move the loading frame 3104 toward or away from the primary frame 3102. As shown, the pistons 3108 are coupled to an intermediate structure, i.e., pins 3110. In other embodiments, the pistons 3108 may be directly coupled to the primary frame 3102. Although two hydraulic pistons 3108 are shown in FIG. 18B, there may be any number of pneumatic pistons. In some embodiments, other suitable linear actuators may be used in place of or in addition to the pneumatic pistons. The primary frame 3102 includes a central opening sized to receive the core assembly 190. The core assembly 190 is attached to the loading frame 3104 and extends through the central opening. The core assembly 190 includes an inner core 3112 and an outer core 3114. During molding, the inner core 3112 defines the inner surface of the part being molded. The outer core 3114 seals the top of the mold defined by the core assembly 190 and the cavity assembly 192.

[0284] The inner core 3112 is attached to the loading frame 3104 and received within the outer core 3114 such that the inner core 3112 is movable relative to the outer core 3114. Specifically, the inner core 3112 is movable relative to the outer core 3114 along the core axis by movement of the loading frame 3104. The outer core 3114 is fixedly attached to the primary frame 3102 by a retention assembly 3116, which engages a flange 3118 of the outer core. Thus, relative movement of the frames 3102, 3104 also causes relative movement of the inner core 3102, outer core 3104. After molding of the part, the loading frame 3104 can be pulled away from the primary frame 3102, causing the inner core 3112 to retract and release the molded part.

[0285] The pin positioning assembly 3120 is disposed on the primary frame 3102 to align the loading frame 3104 and the primary frame 3102 (and thereby align the inner core 3112 with the outer core 3114 and the core assembly 190 with the central opening 3106).

[0286] The pin positioning assembly 3120 includes a pin 3122 and a pneumatic piston 3124. When the loading frame 3104 is spaced from the primary frame 3102, the piston 3124 may extend the pin 3122. The loading frame 3104 may include a recess (not shown) sized and positioned to align with the pin 3122, so that when the loading frame 3104 is lowered against the primary frame 3102 for molding, the pin 3122 aligns with the recess, guiding the frame 3104 into precise alignment.

[0287] 18A, the loading frame 3104 defines an interlocking aperture 3130. The locking aperture 3130 is sized and positioned to engage a corresponding interlocking feature of the load actuator 3050.

[0288] 19 shows the load actuator 3050 in detail. The load actuator 3050 includes a base plate 3140 and a movable plate 3142. The movable plate 3142 is movable relative to the base plate 3140, and one or more guide rods 3144 are attached to the base plate 3140 and received in corresponding openings in the movable plate 3142 to guide movement of the movable plate.

[0289] The load actuator 3050 includes a drive assembly 3146 that includes a motor 3148, a gear set 3150, and a rocker 3152. The motor 3148 is coupled to the rocker 3152 via the gear set 3150 and a camshaft 3154 to cause rotation of the rocker 3152 and impart a torque to the rocker 3152. The movable plate 3142 is attached to one end of the rocker 3152 and the base plate 3140 is attached to the other end of the rocker 3152.

[0290] The rocker 3152 may be rotated by a motor 3148 via a gear set 3150 and a camshaft 3154 to move the movable plate 3142 relative to the base plate 3140. A guide rod 3144 constrains the movement relative to the vertical or core axis.

[0291] 20 is a detailed cross-sectional view of the load actuator 3150 showing the coupling of the motor 3148, gear set 3150 and camshaft 3154 to move the rockers 3152 and plates 3140, 3142. As shown, the camshaft 3154 is supported on the moving plate 3142. The camshaft 3154 is received through one end of the rockers 3152. Both ends of the camshaft 3154 are received in fittings 3155 in the moving plate 3142. The rockers 3152 support the moving plate 3142 via the camshaft 3154 and fittings 3155.

[0292] The opposite end of the rocker 3152 is attached to the base plate 3140 by a retainer shaft 3160. The retainer shaft 3160 is received by a block pair 3162, which is rigidly fixed to the base plate 3140.

[0293] The camshaft 3154 is supported by bearings 3164 in the rocker 3152 and in the mounting bracket 3155. Similarly, the retainer shaft 3160 is supported by bearings 3166 in the block 3162. The camshaft 3154 and retainer shaft 3160 can therefore rotate relative to the plates 3140, 3142 with relatively little resistance.

[0294] The camshaft 3154 is rotatably coupled to a gear set 3150 (not shown) via a coupling 3156. The gear set 3150 can be configured to drive the camshaft to rotate at a relatively low speed and with a relatively high torque. The camshaft 3154 includes an offset lobe such that the radius from the center of rotation of the shaft 3154 to the outside of the offset lobe is greater than the radius from the center of rotation to any other portion on the circumferential surface of the crankshaft. As the crankshaft 3154 orbits with the gear set 3150, the offset lobe engages a bearing 3166 in the rocker 3152. As the offset lobe descends, the camshaft 3154 impinges on the rocker 3152 and urges the movable plate 3142 upward. As the offset lobe descends, the rocker 3152 and the movable plate 3142 can descend.

[0295] 19, a measurement device, or proxy bracket 3170, may be mounted to provide an indication of the position of the camshaft 3154. The proxy bracket 3170 is secured to the base plate 3140 and extends upwardly beyond the camshaft 3154. A sensor 3172 is attached to the proxy bracket 3170 and provides a signal representative of the rotational position of the camshaft 3154. Alternatively or additionally, the sensor may provide a signal representative of the vertical position of the moving plate 3142. Alternatively or additionally, one or more position transducers may be mounted between the base plate 3140 and the moving plate 3142 to provide a signal representative of the relative positions of the plates.

[0296] As best seen in Figures 19, 21A and 21B, the movable mold plate 3142 includes a protrusion 3174 for engaging the loading frame 3104 of the core placement actuator 3046. The protrusion 3142 is sized, shaped and positioned to engage an interlocking recess 3130 defined by the loading frame 3104. With the mold in the closed position, the protrusion 3174 is received in the recess 3130. The protrusion 3174 includes an upwardly facing surface 3176 that abuts a corresponding surface of the loading frame 3104 in the mold closed position. In the embodiment shown, the upwardly facing surface 3176 is angled so that it may abut against a corresponding surface of the loading frame 3104 during closure to guide the protrusion 3174 into engagement with and alignment with the recess 3130. The projection 3174 further includes a downwardly facing surface 3178 which abuts a corresponding surface of the loading frame 3104 .

[0297] While the protrusion 3174 is received in the aperture 3130, movement of the movable plate 3142 causes the protrusion 3174 to abut against the frame 3104. Specifically, upward movement of the movable plate 3142 causes the surface 3176 to abut against the frame 3104, urging the frame upward. Downward movement of the movable plate 3142 causes the surface 3178 to abut against the frame 3104, urging the frame downward.

[0298] Rotation of the camshaft 3154 can therefore selectively create an upward or downward force that is applied to the frame 3104, which then moves the frame 3104 a short stroke. Rotation of the camshaft 3154, which urges the plate 3142 upward via the rocker 3152 (FIG. 20), creates a short upward movement of the frame 3104 and therefore the inner mold core 3112 (FIG. 18B). Such upward movement can serve to dislodge or break the seal between the molded part and the mold core 190.

[0299] The illustrated configuration may eliminate the need for a separate stripper plate to remove the molded article, thereby reducing the mechanical complexity of the molding apparatus associated with typical configurations that include a stripper plate.

[0300] Rotation of the camshaft 3154, which urges the plate 3142 downward via the rocker 3152 (FIG. 20), generates a downward force that is applied to the frame 3104, causing a short downward movement of the frame 3104. The force and short movement can be transmitted to the inner mold core 3112 and act as a preload to resist the pressure applied by the molding material to the mold core 190 during molding.

[0301] The core placement actuator 3046 may be attached to one of the platens 196. The load actuator 3050 may be attached to the other of the platens 196. The load actuator 3050 may be rigidly mounted so that the base plate 3140 does not move relative to the platen 196 to which it is attached.

[0302] The core placement actuator 3046 may be attached via a secondary mold opening actuator 3180 as shown in Figures 17 and 22. The secondary mold opening actuator 3180 includes one or more blocks 3182 rigidly attached to the platen 196. The secondary mold opening actuator 3180 further includes a pneumatic cylinder 3186 carried on a plate 3184 attached to the block 3182. The pneumatic cylinder 3186 includes a coupling 3190 for securing the core placement actuator 3046 to the primary frame 3102. The pneumatic cylinder 3186 is operable to move the core placement actuator between a retracted position where the mold core 190 is in a molding position relative to the mold cavity portion, and an extended position where the mold core is spaced from the mold cavity portion for removal of the molded part.

[0303] As mentioned above, the shaper module 3054 may be mounted as a unitary assembly to or removable from the support base 3056 of the molding station 104-1. The mounting and removal mechanism for the shaper module 3054 is shown in detail in Figures 23A-23C.

[0304] In the embodiment shown, the shaper module 3054 includes a drive unit, i.e., an electric motor 3190. When mounted in the operating position, the clearance between the components of the shaper module 3054 and the support base 3056 may be insufficient to remove the shaper module 3054. Similarly, the clearance may be insufficient to remove the mold components. Thus, the shaper module 3054 includes a position adjustment mechanism 3192 operable to move the shaper module 3054 relative to the support base 3056 along an adjustment axis, shown as AA in FIG. 23A. The shaper module 3054 may be moved between an operating position and a removal position, as shown in FIGS. 12A-12D, in which the shaper module 3054 may pass through a removal opening 3194 defined by the support base 3056 without interference. As shown, the adjustment axis AA is parallel to the longitudinal axis of the shaper frame 3052. However, in some embodiments, the shaper module 3054 may be adjustable along a different axis or multiple axes. Similarly, the mold may be removed or replaced in the removal position, i.e., the mold may be removed from the shaper module without contacting the support base 3056. Thus, such removal and replacement may be performed automatically, for example, using a robot.

[0305] Once in the removal position, the shaper module 3054 may be removed from the base 3056. For example, a lifting tool, such as a crane or lift truck, may engage a coupling on the shaper module 3054. In one example, the coupling may be a hook rigidly attached to the shaper frame 3052 for secure engagement by a crane. The lifting tool may remove the shaper module by vertical or horizontal translation, or a combination thereof.

[0306] 23C, the support base 3056 may include one or more guide blocks 3196 to position the shaper module 3054 in its operating position. The shaper module 3054 may include a corresponding locking pin 3195 rigidly attached to the shaper frame 3052. The locking pin 3195 may selectively engage the guide block 3196 to prevent movement of the shaper module 3054 relative to the support base 3056. The locking pin may be actuated, for example, by an electric motor or using a hand tool. Other modes of actuation, such as pneumatic, are also possible.

[0307] 23C illustrates the adjustment mechanism 3192 in detail. As shown, the adjustment mechanism includes a linear actuator, such as a ball screw 3197, disposed between two anchor plates 3198. One anchor plate 3198 abuts the support base 3056, while the other anchor plate is rigidly coupled to the shaper frame 3052. Actuation of the ball screw 3197 in a first direction causes the anchor plates 3198 to push against each other, resulting in the shaper module 3054 moving in a first direction along the adjustment axis relative to the support base 3056. Actuation of the ball screw 3197 in the opposite direction causes the shaper module 3054 to move in the opposite direction along the adjustment axis relative to the support base 3056.

[0308] In some embodiments, the adjustment mechanism 3192 may be configured such that at maximum or minimum extension of the ball screw 3197, the shaper module is in the operating position, and at other than maximum and minimum extension of the ball screw 3197, the shaper module 3054 is in the removed position. Alternatively or additionally, the adjustment mechanism may include a sensor that reports the position of the shaper module 3054 for confirmation when it is in the operating and removed positions. For example, the ball screw 3197 may be driven by an electric motor using a position encoder, or its position may be measured by a sensor, such as an optical, mechanical, or magnetic sensor.

[0309] The installation and removal of the shaper module 3054 as a single assembly may allow for relatively easy fixture changes at the molding station 104-1. For example, if a mold change is desired, the associated clamp assembly, drive unit, and core actuation assembly may be removed with the mold as a unit and a new unit may be installed on the base 3056. Mold-specific setup may be minimized or eliminated entirely. For example, the clamp assembly may remain assembled to the mold after removal from the base 3056, so that the clamp assembly may be reinstalled without having to adjust the mold shut height or the like.

[0310] In the closed position of molding station 104-1 (FIGS. 12B, 29B-29F), core assembly 190 is aligned with axis MM and cavity plates 194-1, 194-2 are secured together by platens 196-1, 196-2. Core assembly 190 and cavity plates 194-1, 194-2 collectively form a mold 200 for producing a molded workpiece from molten feedstock material. Core assembly 190 defines an inner surface of the molded workpiece. Cavity plates 194-1, 194-2 collectively define an outer surface of the molded workpiece. Mold 200 includes an entry gate 202 aligned with axis MM.

[0311] The track 144 of the transport subsystem 110 passes an injection location that is aligned with the mold axis MM.

[0312] Figures 24A-24T show an alternative shaper module 3054'. As shown in Figures 12-23, the shaper module 3054 is configured such that opening and closing of the mold is effected by linkages 3070, 3070', 3070'', 3070''', which pivot about a horizontal axis. As shown in Figures 24A-24L, the shaper module 3054' is configured such that the shaper module linkages lie generally in a horizontal plane and pivot about a vertical axis.

[0313] As shown in detail in Figures 24C-24F, the shaper module 3054' is supported by a tower structure 7000. The shaper module 3054' comprises a support plate 3052' that is structurally identical to the support plate of the shaper module 3054, but is mechanically suspended from the tower structure 7000 and oriented in a vertical plane.

[0314] The shaper module 3054' includes a mold subassembly 3040', a clamp subassembly 3042' that includes a linkage 3070'''', and a core actuation subassembly 3044'.

[0315] Like the mold subassembly 3040, the mold subassembly 3040' can be opened and closed along multiple axes, namely vertical and horizontal. Specifically, the platen 196 and mold cavity plate 194 open and close along the clamping axis C1-C1, and the core assembly 190 is movable along the core axis C2-C2. In the illustrated embodiment, the core axis C2-C2 is vertical. Thus, with respect to this embodiment, "up" refers to a direction away from the mold cavity plate 194 along the core axis C2-C2, and "down" refers to a direction toward the cavity plate 194 along the core axis C2-C2. However, other orientations of the shaper module 3054' are possible. For example, in some embodiments, the shaper module 3054' can be rotated 90 degrees, such that the clamping axis C1-C1 and the core axis C2-C2 are in a common horizontal plane.

[0316] The mold cavity plate 194 and mold core 190 are within a bounding envelope E between the platens 196. The ends of the bounding envelope are defined by the platens 196. The top and bottom of the bounding envelope are defined by the top and bottom edges of the platens 196, and the sides of the bounding envelope are defined by the sides of the platens 196.

[0317] During molding, and during the opening and closing stroke movements of the platen 196, the mold cavity plate 194 is entirely within the bounding envelope.

[0318] The tower structure 7000, shaper frame 3052', and linkage 3070'''' are located on one side of the boundary envelope E. That is, the tower structure 7000, shaper frame 3052', and linkage 3070'''' are all adjacent to the same side of the boundary envelope E. Advantageously, the opposite side of the boundary envelope E is substantially unobstructed, and the bottom of the boundary envelope E is also unobstructed.

[0319] 24B is a top front view of the shaper module 3054' detailing the linkage 3070''''. The linkage 3070'''' includes a drive link pair 3074 and rocker pairs 3076, 3078.

[0320] Each drive link 3074 is pivotally supported at one end by a tie bar 7002 of the tower structure 7000 and pivotally connected at the other end to a rocker 3076 or 3078. The drive links 3074 are coupled to and reciprocate through a stroke by a drive system 7006. The drive system 7006 is supported on the tower structure 7000 and may include an electric motor and one or more gear reductions.

[0321] Each of the rockers 3076, 3078 is pivotally attached at one end to one of the drive links 3074 and at the other end to a respective platen 196. In the embodiment shown, the rockers 3076, 3078 are coupled to the platen 196 via an intermediate link 3086. The rockers 3076, 3078 are supported at pivotable connections 3082 to tie bars 7002 of the tower structure 7000 such that the drive links 3074 cause the rockers 3076, 3078 to rotate about the pivotable connections 3082. As shown, the pivotable connections 3082 are approximately at the midpoint of the rockers 3076, 3078, but may be located at various positions along the length of the rockers. Moving the pivotable connections 3082 toward the connection with the drive links 3074 will lengthen the stroke of the platen 196 while the rockers rotate. Conversely, movement of the pivotable connection 3082 away from the drive link 3074 will shorten the stroke of the platen 196.

[0322] Figures 24C-F show the tower structure 7000 in detail. Figure 24C is an isometric view of the shaper module 3054' from a rear perspective opposite the mold. Figure 24D is an isometric view of the shaper module 3054' from a front perspective (components other than the tower structure 7000 and shaper frame 3052' are omitted). Figures 24E and 24F are cross-sectional views of the tower structure 7000 taken along planes EE and FF shown in Figure 24B.

[0323] The tower structure 7000 includes a pair of vertical columns 7010. The columns 7010 are supported on a base (not shown) and support the weight of the components of the tower structure 7000, the mold assembly 3040', the clamp assembly 3042', and the core actuation assembly 3044'.

[0324] The shaper frame 3052' is coupled to the column 7010 via the mounting blocks 7012. The shaper frame 3052' faces a vertical plane. The tracks 7024 are attached to the shaper frame 3052'. The tracks 7024 are configured to slidably support the platen 196. The tracks 7024 face a vertical plane such that the connection between the platen 196 and the shaper frame 3052' is similar in the vertical plane.

[0325] As can be seen, the platen 196 is suspended from the track 7024. The track 7024 is therefore configured to interface with the platen 196 to maintain the position of the platen. For example, the platen 196 can include runners having a cross-sectional shape that interfaces with the cross-sectional shape of the track 7024.

[0326] The tower assembly 7000 further includes a tie bar 7002. Components of the linkage 3070'''' of the clamp assembly 3042' are coupled to the tie bar 7002. For example, the drive train 7006 is supported in part by the tie bar 7002. The rotor 7007 of the drive train 7006 (which is directly coupled to the drive link 3074) is rotatably mounted between the tie bars 7002. The rockers 3076, 3078 are also rotatably mounted between the tie bars 7002. The pivotable connections 3082 that connect the rockers 3076, 3078 to the tie bar 7002 allow the rockers to rotate but prevent translational movement of the rockers in substantially any direction. Thus, stresses, such as tensile and compressive stresses, can be transferred between the rockers and the tie bars.

[0327] In the embodiment shown, the tie bars 7002 are not directly coupled to the column 7010. Rather, the tie bars 7002 are attached to support blocks 7020. As shown in Figures 24E and 24F, the support blocks 7020 are disposed between the tie bars 7002 and abut both the tie bars 7002 and the shaper frame 3052. The support blocks 7020 reinforce the tie bars 7002 against each other and against the shaper frame 3052'. Fasteners 7022 are inserted into the tie bars 7002 and received in the support blocks 7020 to secure the tie bars relative to the support blocks. A second set of fasteners 7024 are inserted into the shaper frame 3052' to secure the tie bars relative to the shaper frame 3052'. The shaper frame 3052' is then coupled to the tower 7010 via the mounting blocks 7012 as described above. Thus, the tie bars 7002 are coupled to the shaper frame 3052 ′ via the support blocks 7020 , and are coupled to the columns 7010 via the support blocks 7020 and the shaper frame 3052 .

[0328] 24G and 24H are detailed cross-sectional and cross-sectional views, respectively, of the mold assembly 3040', the clamp assembly 3042', and the core actuation assembly 3044'.

[0329] The mold assembly 3040' includes a pair of platens 196 that can be moved toward and away from each other on a closing and opening stroke, respectively, by a linkage 3070''''. The platens 196 are supported by tracks 7024 on the shaper frame 3052. The platens 196 and the tracks 7024 can be configured to interlock such that the platens 196 are securely suspended from the tracks 7024 and can move freely therealong. For example, the platens 196 can include runners that interlock with the tracks.

[0330] Attached to each platen is a mold cavity plate 194. With the platens 196 in the mold closed position (FIG. 24A), the mold cavity plates 194 abut against one another and cooperate to define a mold cavity.

[0331] During molding, the rockers 3076, 3078 apply a clamping pressure to the platen 196 and mold assembly 3040' via the intermediate link 3086. The clamping pressure generally acts along the clamping axis C1-C1. A reaction force is applied via the rockers 3076, 3078 to the tie bar 7002 at the pivotable connection 3082. This then transfers the load to the shaper frame 3052' at the pivotable connection 3082.

[0332] Because the linkage 3070'''' is symmetrical, equal forces are applied to the shaper frame 3052' by the rockers 3076, 3078. The shaper frame 3052' experiences a strain due to the tension applied by the rockers, i.e., the shaper frame 3052' tends to stretch in the direction of the clamping axis C1-C1 due to the tension.

[0333] On the other hand, the columns 7010 generally do not distort during molding, and therefore the shaper frame 3052' is coupled to the columns 7010 to limit distortion of the shaper frame 3052' relative to the columns 7010 in the attached position.

[0334] For example, the stretching of the shaper frame 3052' associated with tensile stress during clamping is most pronounced at the ends of the shaper frame 3052'. In other words, a feature when at one end of the shaper frame 3052' can move more between the stressed and unstressed states of the shaper frame 3052' than when the feature is located in the center of the shaper frame 3052'.

[0335] Thus, fasteners 7024 connect the shaper frame 3052 to the support block 7020 near the center of the shaper frame 3052 to limit stresses due to the connection.

[0336] The mold core assembly 190 is disposed between mold cavity plates 194 and defines a mold core when the cavity plates 194 are in a closed position. The mold core assembly 190 does not move substantially in the direction of the clamp axis C1-C1, but can move along a vertical core axis C2-C2.

[0337] The mold core assembly 190 includes an outer core 7030 and an inner core 7032. The outer core 7030 is generally annular in cross-section, and the inner core 7032 is received through the outer core and is movable relative to the outer core 7030 along the core axis C2-C2.

[0338] The core cap 7034 is placed atop the inner core 7032 and coupled to the inner core 7032 via a mounting block 7035. The coupling between the inner core 7032 and the core cap 7034 is achieved using a quick-connect coupling 7037 (FIGS. 24R and 24S). For example, the quick-connect coupling 7037 may be controlled by a locking device (not shown). When the locking device is engaged, the coupling 7037 holds the core such that it cannot move relative to the core cap 7034. The locking device may, however, be disengaged to release the coupling between the core and the core cap 7034. Movement of the core cap 7034 selectively applies or releases a preload force to the outer core 7030 and the inner core 7032.

[0339] As best shown in FIG. 24G, in the illustrated embodiment, the locking device 7031 includes an actuator, or piston 7038, that can be selectively extended or retracted (e.g., by electronic or pneumatic control). Extension or retraction of the piston 7038 causes extension or retraction of the locking block 7039. In the extended (locked) position, the locking block 7039 interfaces with a flange of a retention device 7041 that is secured to a mounting block 7035. The interface of the block 7039 with the retention device 7041 prevents movement of the core cap 7034, the mounting block 7035, and the retention device 7041 relative to the locking device 7031.

[0340] The inner core 7032 and outer core 7030 mate with a core support block 7042 , which is in turn fixedly attached to the shaper frame 3052 .

[0341] The core cap 7034 is movable by an actuator 7046. In the example shown, there are two actuators 7046, although in other embodiments, more or fewer actuators may be used.

[0342] In the example shown, the actuator 7046 is a roller screw driven by an electric motor, although other types of linear actuators could be used, such as pneumatic or hydraulic cylinders.

[0343] Each actuator 7046 includes a housing 7048 and an output shaft 7050. The housing 7048 is rigidly coupled to a floating support plate 7052. The output shaft 7050 is coupled to the housing 7048 and to a fixed support plate 7054.

[0344] Each fixed support plate 7054 is rigidly coupled (e.g., bolted) to a respective platen 196. Each floating support plate 7052 is free to move relative to the corresponding fixed support plate 7054 in both directions along the core axis C2-C2.

[0345] Movement of the floating plate 7052 relative to the fixed plate 7054 is caused by operation of the actuator 7046. Specifically, extension of the output shaft 7050 pushes the housing 7048 and the floating plate 7052 away from the fixed plate 7054 and the platen 196 to which it is attached. Conversely, retraction of the output shaft 7050 pulls the floating plate 7052 toward the corresponding fixed plate 7054 and the platen 196 to which it is attached. One or more guide rods 7056 may be attached to each fixed plate 7054 and may extend through corresponding slots in the floating plate 7052 to constrain movement of the floating plate 7052 relative to the fixed plate 7054. Specifically, the guide rods 7056 are parallel to the core axis C2-C2 and constrain movement of the floating plate 7052 to be parallel to that axis.

[0346] Because the actuator 7046 and fixed plate 7054 are attached to the platen 196, they move with the platen as the clamp assembly 3042' is opened and closed. This causes the actuator 7046 to move relative to the core assembly 190 and core cap 7034 along the clamp axis C1-C1.

[0347] The lifter 7058 may extend between the floating plate 7052 and the core cap 7034. The lifter 7058 couples the floating plate 7052 and the core cap 7034 in the direction of the core axis. In other words, the lifter 7058 and the floating plate 7052 engage with each other, such that movement of the lifter in either direction along the core axis C2-C2 causes movement of the core cap 7034 in the same direction. The connection between the lifter 7058 and the floating plate 7052 is slidable, such that the floating plate 7052 may move along the clamp axis C2-C2 while the lifter and floating plate remain engaged with each other.

[0348] 24A , the lifter 7058 includes a pair of arms 7059 that are received between and vertically interlock with the extension of the floating plate 7052. In other embodiments, the lifter 7058 may be permanently fixed to the floating plate 7052 and may protrude toward the core cap 7034. In the embodiment shown, the lifter 7058 is a discrete structure that is coupled to the core cap 7034. However, the lifter 7058 may be integrally formed with one of the core cap 7034 or the floating plate 7052.

[0349] Movement of the floating plate 7052 can cause the floating plate to contact the lifters 7058, which can then push the core cap 7034 upwards or downwards. In the example shown, the lifters 7058 make interlocking contact with the floating plate 7052.

[0350] Retraction of the output shaft 7050 causes the floating plate 7052 to move downward toward the fixed plate 7054. The lifters 7058 contact and abut the core cap 7034, pushing the core cap 7034 downward against the inner core 7032 and outer core 7030.

[0351] Extension of the output shaft 7050 causes the floating plate 7052 to move upward and away from the fixed plate 7050. The lifters 7058 contact and impinge on the core cap 7034, pushing the core cap 7034 upward and away from the inner core 7032 and outer core 7030.

[0352] Guide structures are provided to maintain alignment between the floating plates 7052 and the fixed plates 7054. Specifically, a guide pin 7060 projects upwardly from each fixed plate 7054 and extends through the corresponding floating plate 7052. The guide pins 7060 constrain the movement of the floating plate 7052 such that the floating plate may only move along the axis of the guide pin.

[0353] 24H details the attachment of the inner core 7032 and outer core 7030 to the core support block 7042. The core support block 7042 is rigidly attached so that it does not move during operation of the shaper module 3054'. For example, the core support block 7042 may be attached to the shaper frame 3052 or a fixed platen.

[0354] The inner core 7032 and outer core 7030 are received through a core support block 7042 and supported thereon by a core reset assembly 7070. During molding, the core reset assembly 7070 is compressed with a preload force that urges the inner core 7032 and outer core 7030 into the mold cavity to resist molding pressures. Upon mold opening, the core reset assembly 7070 urges the inner core 7032 and outer core 7030 into a neutral position to release the molded part.

[0355] The core reset assembly 7070 includes a retainer ring 7072 and a core load spring 7074. The retainer ring 7072 cooperates with the outer core 7030 and the core support block 7042 to define a pocket in which the core load spring 7074 is received. When the inner core 7032 and outer core 7030 are urged downward by the core cap 7034, the retainer ring 7072 impinges on and compresses the load spring 7074. The downward (closing) force applied to the inner core 7032 and outer core 7030 may be referred to as a preload and exceeds the opening force due to pressure in the mold cavity during molding, such that the closing force on the inner core 7032 and outer core 7030 is sufficient to resist the injection pressure.

[0356] When the preload on the inner core 7032 and outer core 7030 is released, the load spring 7074 rebounds and abuts against the retainer ring 7072 which in turn abuts against the flange 7080 of the outer core 7030, causing the outer core 7030 to move slightly upward. Such movement causes the outer core 7030 to lose contact with the mold cavity plate 194 so that the plate 194 can be opened without the outer core 7030 and plate 194 rubbing against one another.

[0357] 24I to 24L show the operation sequence of the shaper module 3054'.

[0358] 24I and 24J are isometric and cross-sectional views, respectively, of the shaper module 3054' in the mold open state. The drive link 3074 and rockers 3076, 3078 are positioned such that the platens 196 (and thus the cavity plate 194) are spaced apart from one another.

[0359] As can be seen, the shaper module 3054' provides relatively unobstructed access to the mold area when the mold is open. Specifically, with the mold open, an operator or machine may access the mold core assembly 190, cavity plate 194, or other components between the platens 196 lateral to the clamp axis C1-C1 and lateral to the core axis C2-C2. Such access may simplify operations such as molded part removal, maintenance, or mold changes.

[0360] 24I and 24J, the core actuation assembly 3042' is also in an open state and the mold core assembly 190 is withdrawn from its molding position. The actuator 7046 is extended, thereby urging the floating plate 7052 away from the fixed plate 7054. The floating plate 7052 then moves the linkage 7058 upwardly, thereby urging the core cap 7034 upwardly and away from the inner core 7032 and the outer core 7030.

[0361] The core reset assembly 7070 is in an unloaded state and the load spring 7074 is extended. The extension of the load spring 7074 causes the retaining ring 7072 to abut against the outer core 7030, thereby pushing the core along the core axis C2-C2 and away from the molded position.

[0362] After removing the finished part, the shaper module 3054' returns to the molding configuration for a new molding cycle. Figures 24K and 24L are isometric and cross-sectional views, respectively, showing the shaper module 3054' in an intermediate configuration, the open cavity plate 194 and platen 196, and the mold core 190 approximately in the molding position.

[0363] The transition of the shaper module 3054' from the open state to the closed (molding) state is initiated by movement of the core assembly 190 toward the molding position. Specifically, the actuator 7046 of the core actuation assembly 3042' retracts the output shaft 7050. Retraction of the output shaft 7050 moves the floating plate 7052 downward toward the fixed plate 7054. The floating plate 7052 then impinges on the lifter 7058, urging the lifter and the core cap 7034 downward.

[0364] As the lifter 7058 and core cap 7034 are pulled downward, the core cap 7034 abuts against the inner core 7032 and the outer core 7030. Thus, the downward movement of the core cap 7034 also causes the inner core 7032 and the outer core 7030 to move downward.

[0365] The position of the core cap 7034 may be measured by an optical sensor, a physical probe, or another suitable sensor. Additionally or alternatively, the position of the core cap 7034 may be determined based on the state of the actuator 7046. For example, the actuator 7046 may include an encoder to communicate the position of the output shaft 7050.

[0366] When the core assembly 190 reaches the molding position, as shown in Figures 24K and 24L, the clamp assembly 3042' is actuated to move the platen 196 and cavity plate 194 into the molding position. The drive link 3074 is extended by the drive train 7006, causing the rockers 3076, 3078 to urge the platen 196 toward each other.

[0367] The cavity plates 194 contact each other in their molded position, i.e., the closed position of the clamp assembly 3042'. In the closed position, the core assembly 190 is sealed within the cavity defined by the cavity plates.

[0368] When the cavity plate 194 reaches the closed position, as shown in Figures 24M and 24N, the core cap 7034 is again biased downward by the actuator 7046 to apply a preload to the core assembly 190. The core cap 7034 is biased against the inner core 7032 and the outer core 7030. The outer core 7030 then abuts against the retainer ring 7072 and load spring 7074 of the core reset assembly 7070. The load spring 7074 is compressed by the retainer ring 7072. A compressive force is applied to the load spring 7074. As the load spring 7074 is compressed, the shoulder 7033 of the outer core 7030 is pressed into sealing contact with the corresponding surface of the cavity plate 194. The preload force is sufficient to resist movement of the core assembly 190 due to the pressure of the injection molding material and to prevent leakage of the molding material at the sealing surface. The applied preload force is typically determined using the product of the injection pressure at which the mold was operated and the stamping area of ​​the mold cavity. The applied preload force can be measured, for example, using a load cell, or can be inferred, for example, based on the current applied by actuator 7046.

[0369] The drive system 7006 applies a closing pressure to the platen 196 and cavity plate 194 via the drive link 3074 and rockers 3076, 3078. The drive pressure exceeds the pressure expected for injection of molding material into the mold cavity and maintains the cavity plate 194 in tight abutment during molding. As previously described, application of closing pressure to the platen 196 results in a reaction force being transmitted through the linkage 3070''''. Such force transmission results in tension in the tie bars 7002 via the pivotable connections 3082.

[0370] The molten molding material is injected into the mold cavity defined by the cavity plate 194 and the core assembly 190. After injection, the molding material is allowed to cool and harden.

[0371] 24O-24V show the operation of the shaper module 3054' after formation of the molded article.

[0372] As shown in Figures 24O and 24P, the mold assembly 190 is moved by the mold actuation subassembly 3044' while the clamp subassembly 3042' is maintained in a closed position. The actuator 7046 extends the output shaft 7050, thereby urging the floating plate 7052 away from the fixed plate 7054.

[0373] As the floating plate 7052 is pushed upward, it forces the lifter 7058 and the core cap 7034 upward. When the core cap 7034 moves slightly upward, the core reset assembly 7070 is no longer constrained. The load spring 7074 therefore expands back to its uncompressed state, urging the retainer plate 7072 upward. The retainer plate 7072 may abut against the outer core 7030 and force it upward. Such upward movement causes the outer core 7030 to lose contact with the mold cavity plate 194. Thus, the platen 196 and core plate 194 may be withdrawn without damage associated with friction between the outer core 130 and the cavity plate 194.

[0374] As the outer core 7030 is lifted out of contact with the cavity plate 194, the linkage 3070'''', the platen 196, and the mold cavity plate 194 move to their open positions, as shown in Figures 24Q and 24R.

[0375] Once the platen 196 and cavity plate 194 are in the mold open position, the mold core assembly 190 is moved to the mold open position and the molded part is removed, as shown in Figures 24I and 24J. As shown, the cavity plate 194 is opened and the molded part is lightly held to the inner core 7032. The released part may be removed from the mold using a handling device. In other embodiments, the part may be completely removed from the core assembly 190 prior to opening the cavity plate 194, so that the part falls upon opening.

[0376] The core cap 7034 pulls the inner core 7032 upward, causing the inner core 7032 to move back along the core axis C2-C2 relative to the outer core 7030. Such relative movement of the inner core 7032 and the outer core 7030 removes the molded part from the core assembly 190.

[0377] The molded part tends to resist removal from the core assembly somewhat; that is, the part tends to remain in the mold inner core 7030. However, when the inner core 7032 is pulled upward, the top edge of the molded part abuts the annular edge of the outer core 7030. The annular edge of the outer core prevents the molded part from being pulled out with the inner core, removing the part from the inner core 7032.

[0378] The retraction of the inner core 7032 may occur in two stages: an initial short movement followed by a longer movement. The initial movement may be fast to free the molded part from the inner core 7032. For example, the initial movement may overcome suction that may develop between the molded part and the inner core 7032. The second, longer movement of the inner core 7032 further withdraws the inner core from the molded part until the molded part can fall freely or be easily removed from the core.

[0379] Advantageously, the configuration of the shaper station 3054' provides flexibility in part removal. Because the linkage 3070'''', drive train 7006, shaper frame 3052', and tower structure 7000 are disposed on the same side of the mold, i.e., one side of the bounding envelope E (FIG. 24A), the opposite side of the bounding envelope E is substantially unobstructed and the bottom is also unobstructed. Thus, material handling devices may freely access the space between the platens 196 from the bottom or from the unobstructed side to remove parts.

[0380] Additionally, the access provided by the configuration of the shaper module 3054' facilitates the process of modifying or performing maintenance on a mold component.

[0381] 24S and 24T show the shaper module 3054' in a configuration to remove the mold cavity plate 194. The clamp assembly 3042' includes a wedge block (not shown) that is operable to selectively lock the cavity plate 194 in its closed position. The wedge block may be attached to the shaper frame 3052', for example, and extended into contact with the cavity plate 194 to bias the cavity plate into its closed position. Some embodiments may include multiple wedge blocks (e.g., one wedge block per cavity plate).

[0382] 24S, the engagement of the wedge blocks causes the cavity plate 194 to remain in a closed position when the platen 196 opens. The connection (not shown) between the cavity plate 194 and the platen 196 is configured to release upon application of a force away from the platen such that opening of the platen by the engaged wedge blocks disconnects the mold cavity plate 194 from the platen.

[0383] As shown, the cavity plate 194 is removed from the platen 196 while the core assembly 190 is positioned between the cavity plates. This allows the mold to be removed intact from the shaper module 3054', i.e., the cavity plate 194 can be removed with the mold core assembly 190 captive between the cavity plates.

[0384] To allow removal of the core assembly 190, it is decoupled from the core cap 7034. Specifically, the coupling 7037 is released so that the mounting block 7035 and the core cap 7034 can be separated from one another. After the coupling is released, the actuator 7046 extends the drive shaft 7050 to push the floating plate 7052, the lifter 7058, and the core cap 7034 upward. Maximum extension of the drive shaft 7050 is sufficient to raise the core cap 7034 and decouple it from the mounting block 7035.

[0385] Once the core cap is decoupled from the mounting block 7035, the cavity plate 194 and core assembly 190 may be removed from the shaper module 3054' as a single assembly. Advantageously, the shaper module 3054' provides sufficient clearance for machinery to access and remove the mold assembly from the opposite side of the shaper frame 3052' and linkage 3070''''.

[0386] First molding die 25-28, details of an exemplary mold for use in a station of mold cell 104 will now be described. The embodiment shown is a mold for injection molding (such as injection molding of a preform from which a container may be molded), although many of the features of the described embodiment are expressly not limited to injection molding.

[0387] As shown in FIGS. 12B-12D and 24A-24T, respectively, in mold subassemblies 3040 and 3040′, each platen 196 may have one or more service blocks 5196 secured thereto (see FIGS. 25A and 28A). A cavity plate 194 may be attached to each service block 5196. The cavity plates 194 may take a wide range of configurations. Cavity plates 194 of different configurations may be interchangeable in the service blocks 5196 within mold subassemblies 3040, 3040′. With particular reference to FIGS. 25A-28B, examples of cavity plates 194 are illustrated and described in detail below.

[0388] 25A and 28A, the service block 5196 may be coupled to the platen 196 by threaded bolts 5197 that are received through openings 5198 in the service block 5196 and into threaded openings 5195 in the platen 196.

[0389] The service block 5196 may include channels operable to deliver services such as pressurized air, cooling fluid, electrical / electronic services, etc. to the cavity plate 194. The service block 5196 may remain coupled to the platen 196 during operation of the plastic molding system 100.

[0390] In some embodiments, the cavity plate 194 may be a single, integral body. In other embodiments, the cavity plate 194 may comprise two separate and identifiable portions. The two portions may be integrally formed to create a single, continuous, integral body, or the two portions may be configured as two separate units or portions and may be interconnected during operation of the plastic molding system 100.

[0391] 25A-25K, each cavity plate 194 includes two separate and identifiable portions: a base portion and a mold cavity portion. The base portion (identifiable as base block 5000) may be formed first as a separate body, and then the mold cavity portion (identifiable as mold cavity block 5010 or 5010′) may be formed by a manufacturing process that causes the two portions / blocks to be fused or merged together into a cavity plate 194 that includes a single integral body.

[0392] In the embodiment of FIGS. 26A-26J, each cavity plate 194 includes two separate parts: a base portion (also referred to as a base block 5000) and a mold cavity portion (also referred to as a mold cavity block 5010'' or 5010''). In such an embodiment of FIGS. 26A-26J, the base block 5000 and the mold cavity block (5010'' or 5010'') are formed as separate parts and then coupled together by a coupling mechanism.

[0393] Each mold cavity block 5010, 5010', 5010'', 5010''' of cavity plate 194 may be formed in a particular configuration that is specifically adapted to provide one of the outer mold cavity surfaces of an item to be molded with a desired profile / shape. In plastic molding system 100, a plurality of differently configured cavity plates 194 with differently configured mold cavity blocks 5010, 5010', 5010'', 5010''' and having differently configured mold cavity surfaces may be available for selection and use in mold subassemblies 3040, 3040'.

[0394] In the embodiment of Figures 26A-26J, each base block 5000 may be configured and operable to be coupled to and decoupled from a plurality of different configurations of mold cavity blocks 5010'', 5010''', which when used with the mating mold cavity block pairs 5010'' or 5010''' may provide differently shaped mold cavity surfaces to produce molded items of different shapes / configurations.

[0395] Each base block 5000 of the cavity plates 194 may include one or more “quick connect” mechanisms (described in more detail herein) for coupling each cavity plate 194 to the service block 5196 and further to the platen 196 .

[0396] Referring again to the embodiment of cavity plate 194 shown in Figures 25C and 25D, further details of the base block 5000 and mold cavity blocks 5010, 5010' of cavity plate 194 are illustrated in Figures 25E-25K, 27A and 27B, as described below.

[0397] 27B, the base block 5000 may be used to form any of the mold cavity blocks 5010, 5010', 5010'', 5010''' and the cavity plate 194. The base block 5000 may have a length Y1 and a width X1.

[0398] 25G, mold cavity block 5010' may have a length Y2 and a width X2. X1 may be the same size as X2, and Y1 may be the same size as Y2. Mold cavity block 5000 (as well as mold cavity blocks 5000'' and 5000''') may have the same length and width (Y2 and X2).

[0399] 27A and 27B, each base block 5000 may include a mold cavity block facing surface 5000a (FIG. 27A) that may be generally flat and extend in the vertical direction (direction Y) and the lateral direction (direction X). The mold cavity blocks 5010, 5010' of FIGS. 25A-25K may be formed by an additive manufacturing process whereby material is deposited on top of the mold cavity block facing surface 5000a such that the material bonds with material of the base block 5000 at the mold cavity block facing surface 500b of the base block 5000.

[0400] In other embodiments, the mold cavity block 5010" (FIG. 26B) may include a base block facing surface 5010'a, the surface of which may be generally flat and extend in the vertical direction (direction Y) and the laterally extending direction (direction X). The base block facing surface 5010a" of the mold cavity block 5010 and the mold cavity block facing surface 5000a of the base block 5000 may be configured to be coupled to one another and held in face-to-face, flush mating and contact with one another. Opposite the mold cavity block facing surface 5000a, the base block 5000 may also include a service block facing surface 5000b (FIG. 27B), which may also be generally flat and extend laterally. The service block facing surface 5000b of the base block 5000 of the cavity plate 194 may be operable to couple with a generally flat, laterally extending surface 5196a of the service block 5196 associated with the platen 196 and be held in face-to-face flush mating contact (Figures 25A, 25C, 25D, 26A, 26B, and 28A).

[0401] The coupling mechanism employed between the base block 5000 of the cavity plate 194 and the mold cavity block 5010'' to hold the surfaces 5000a and 5010a'' in mating, face-to-face, flush mating and contact may or may not be one that provides relatively easy quick coupling and decoupling between each other. Each base block 5000 may be decoupled from and coupled with the mold cavity block 5010'' when the cavity plate 194 is removed from the mold subassemblies 3040 and 3040'. In the embodiment of Figures 26A-26J, it is believed that each base block 5000 can be connected to and disconnected from the mold cavity blocks 5010'', 5010''' using threaded bolts 5025 that are received through open holes 5026 extending vertically (direction Z) through the base plate 5000 and into appropriately positioned threaded holes (not shown) in the cavity block 5010'' (see Figures 26D and 26G).

[0402] 27A and 27B, a countersunk opening 5003 may be provided that extends longitudinally through the body of each base block 5000. The opening 5003 is adapted to be received within and secure a threaded base portion of an alignment dowel (5004 (FIG. 25B) that may include an outwardly longitudinally extending portion (embodiment of FIGS. 26A-26J) that passes through an opening in the mold cavity block 5010′ (to which the base block 5000 is attached). The protruding end of the alignment dowel / pin may be received in a corresponding opening in the mold cavity block (e.g., as described further below).

[0403] Additionally, each base block 5000 may include upper clamp connection openings 5002a, 5002b in the upper horizontal surface 5000c, and lower clamp connection openings 5002c, 5002d in the lower horizontal surface 5000d (FIGS. 27A, 27B). Such clamp connection openings may be utilized for connection to fixtures during the manufacture of the base block 5000 itself (e.g., when fixturing of the base block 5000 is required) or when the base block is combined with the mold cavity block 5010, 5010', 5010'', or 5010'''. Such clamp connection openings may also be used for connection to fixtures tied to a handling robot when fixture maintenance activities need to be performed. Additionally, the lower clamp connection openings 5002c, 5002d may also be used to hold the gate cutter assembly 2200 as described above.

[0404] Another coupling mechanism is employed between the base block 5000 and the service block 5196 to releasably hold the surfaces 5000b and 5196a in face-to-face flush contact and engagement. This coupling / retention mechanism may be a quick coupling / uncoupling mechanism (herein referred to as a "quick couple" or "quick couple" mechanism), which facilitates relatively easy and rapid coupling and uncoupling of each base block 5000 of the cavity plate 194. A "quick couple" or "quick couple" mechanism may be considered herein to be a mechanism by which coupling and uncoupling between two components may be accomplished relatively easily, the mechanism having one or more of the following functional characteristics:

[0405] One characteristic that indicates a quick coupling is that a coupling and decoupling mechanism is selectively engageable to hold the base block 5000 relative to the service block 5196.

[0406] Another characteristic that indicates a quick connect is that the mechanism provides the ability to selectively interlock the base block 5000 and the service block 5196 .

[0407] Another characteristic indicative of a quick connect is that the mechanism is operable to provide a clamping action when connecting the base block 5000 and the service block 5196.

[0408] Another characteristic indicative of a quick connection is that the mechanism can be switched between a connected and disconnected state to connect and disconnect the base block 5000 and the service block 5196.

[0409] Another characteristic indicative of a quick connection is that connection and / or disconnection is accomplished via a spring actuated force acting between portions of the base block 5000 and the service block 5196.

[0410] Another characteristic indicative of a quick connection is that the connection and / or disconnection does not require the installation of fasteners (e.g., does not involve twisting or turning forces applied to screws, bolts, nuts, or the like).

[0411] As an example, a quick coupling mechanism such as the retention mechanism 4014 illustrated in FIG. 4H may be employed to releasably couple the base block 5000 to the service block 5196, as described above. Coupling / retention mechanisms such as the Model 306019 Zero Point Pull Stud and Model 305979 Zero Point Clamp Module Socket are available from AMF (Andreas Maier GmbH&Co KG, referred to herein as "AMF", see www.amf.de / en). Thus, the coupling / retention mechanism may include a plurality of vertically spaced studs 4024 and a corresponding plurality of mating sockets 4026 that may be selectively interlocked with the studs. A stud 4024 (FIGS. 25B, 27B) may be attached to the service block facing surface 5000b of the base block 5000 of the cavity plate 194 and extend longitudinally (direction Z) outward from that facing surface and engage with a socket 4026 formed in the base block facing surface 5196a of the service block 5196 (FIG. 25A), the stud extending longitudinally (direction Z) into the body of the service block 5196 (see also FIG. 28A).

[0412] Other features of this retention mechanism shown in FIGURE 4H have been previously described. By providing a quick connect mechanism whereby different mold cavity plates 194 may be quickly swapped on the service block 5196, the mold subassemblies 3040, 3040' may be easily and quickly changed from one particular setup to another without significant changeover downtime.

[0413] Each base block 5000 and service block 5196 may each be made from any suitably strong and rigid material, or combination of materials, such as, for example, 1.2085 grade steel or AISI 422 stainless steel.

[0414] A suitably sized, generally cubic shaped block may first be formed, such as by casting, using known techniques and methods, and then the specific features of the base block 5000 and service block 5916 as described herein may be formed into the cast block using known manufacturing techniques and methods, such as conventional machining equipment and methods.

[0415] Each mold cavity block 5010, 5010', 5010'', 5010''' may also be made from a suitably strong and rigid material(s), such as, for example, 1.2085 or AISI 422 steel.

[0416] In the embodiment of Figures 26A-26J, a suitably sized, generally cubic shaped block may first be formed, such as by casting using known techniques and methods, and then the specific features of the mold cavity block 5010'', 5010''', as described herein, may be formed into the cast block using known manufacturing techniques and methods, such as conventional machining equipment and methods.

[0417] One technique that may be employed to form the mold cavity block 5010, 5010', including techniques for forming the shape of the mold cavity walls 5011, 5011' and the internal core alignment surfaces 5009, 5009' (FIGS. 25D-25K), is a 3D printing process, in particular direct metal laser sintering (DMLS). Such a process may be employed in which material is fed and deposited directly on top of the surface 5000a of the base block 5000, so that the 3D profile of the mold cavity block 5010, 5010' is built on top of the base block. Such a process provides flexibility in terms of the shape of the mold cavity walls 5011, 5011' that may be formed, and in terms of allowing for internal hollow features, such as providing hollow service channels therein (e.g., fluid cooling channels). Such an additive manufacturing process provides a high level of flexibility in providing optimized cooling fluid channels that may surround / cover the entire mold cavity surface. Conventional manufacturing techniques may not be able to achieve the same configuration / arrangement of cooling channels, and even if they could, it may be very difficult and prohibitively costly to achieve.

[0418] 27A, 27B, and 28B, the base block 5000 may be provided with one or more service channels extending therethrough. Such services may include pressurized air (which may be used to actuate a quick connect mechanism operating between the base block 5000 and the service block 5196), electrical / electronic wiring (e.g., for electronically coupling to sensors such as temperature sensors), and fluid cooling (e.g., cooling gas, cooling water) channels.

[0419] As an example, in the embodiment of Figures 26A-26J, in which each base block 5000 is configured and operable to be coupled to and decoupled from a plurality of variously configured mold cavity blocks 5010'', 5010''', the base blocks 5000 may include fluid cooling channels 5020 (Figure 28B) that are part of a cooling fluid circuit 5200 that pumps cooling fluid from a cooling fluid reservoir 5199 to the service block 5196, and then into the base block 5000 and then into the mold cavity block 5010'' (or mold cavity block 5010''') to promote rapid cooling and solidification of molten material after injection into the mold cavity formed by the mating and secured mold cavity block pair 5010 (or mold cavity block 5010', 5010'', 5010'''). The cooling fluid circuit 5200 returns the cooling fluid to the fluid channels 5181 in the service block 5196 and back to the cooling fluid reservoir 5199. Examples of cooling fluids are chilled water, liquid CO2, and other fluids with various heat exchange properties.

[0420] The service block 5196 may include a cooling channel 5080 having an output port 5050a. The cooling channel 5020 in the base block 5000 may include an input port 5020d in a surface 5000b of the base block 5000 that is in fluid communication with an aligned output port 5050a in a surface 5196a of the service block 5196 when the base block 5000 is engaged with the service block 5196, as shown in Figures 26A and 26B. The fluid channel 5020 passes through the base block 5000 to an output port 5020a in the surface 5000a of the base block 5000 that is in fluid communication with an aligned input port 5030a in the surface 5010a of the mold cavity block 5010 (or a corresponding surface of the mold cavity block 5010', 5010'', 5010''') (Figure 25B). The input port 5030a provides an intake for a cooling channel 5030 (FIG. 28B) that passes through the body of the mold cavity block 5010 (or mold cavity block 5010′, 5010″, 5010′″). The cooling channel 5030 may be formed to allow cooling fluid to flow along a serpentine path that passes through the body of the mold cavity block 5010 (or mold cavity block 5010′, 5010″, 5010′″) to the output port 5030b. The serpentine path includes a portion that is configured to at least partially conform to a mold cavity wall surface to enhance the cooling effect of the cooling fluid within the mold cavity block 5010. In some exemplary embodiments, the cooling channel 5030 may be formed at least partially as a recessed groove that may be milled into the base block facing surface 5010a″ of the mold cavity block 5010″. The groove may be completely sealed on top by the opposing mating surface 5000a of base block 5000 when mold cavity block 5010'' engages base block 5000, with surface 5000a in mating contact with surface 5010a''.

[0421] An output port 5030b in surface 5010a of mold cavity block 5010 (or a corresponding surface of mold cavity block 5010', 5010'', 5010''') is in fluid communication with an aligned input port 5020b in surface 5000b of base block 5000 (FIG. 27A). A second fluid channel 5021 passes through base block 5000 from input port 5020b to output port 5020c. Output port 5020c is in fluid communication with input port 5050b in service block surface 5196a of service block 5196.

[0422] The service block 5196 includes a service channel 5081 that provides communication with the input port 5050b and is in fluid communication with the cooling fluid reservoir 5199 so that cooling fluid can be returned to the reservoir.

[0423] 28B , cooling fluid is communicated via various cooling fluid channels from a cooling fluid reservoir 5199, through other components of the mold subassembly 3040, 3040′, into cooling channels 5080 in the service block 5196, then into cooling channels 5020 in the base block 5000, and then into cooling channels 5030 in the mold cavity block 5010″ (or mold cavity block 5010′″). The cooling fluid then flows through cooling channels 5030 and out output port 5030b to input port 5020b which enters cooling channels 5021 in the base block 5000, where it flows through channel 5021 to input port 5050b in the service block surface 5196a of the service block 5196. The cooling fluid may then flow through the cooling fluid channels 5181 and return to the cooling fluid reservoir 5199 via various channels passing through other components of the mold subassembly 3040, 3040'. As part of the cooling fluid circuit 5200, in addition to the cooling fluid reservoir 5199 and flow channels, a device for cooling the fluid is required, and a pump and possibly valves are required to provide cooling fluid flow into and out of the mold cavity block 5010.

[0424] Each of cooling fluid input / output port couplings 5020a / 5030a; 5030b / 5020b; and 5020c / 5050b may be any suitable cooling fluid communication fitting. For example, a suitable water fitting for coupling 5020c / 5050b may be a model AMF 6989N [164988, built-in coupling nipple] and 6989M [164996, built-in coupler] water fitting manufactured by AMF. Couplings 5030a / 5020a; and 5030b / 5020b may be a suitable sealing O-ring between the mating surfaces of base block 5000 and mold cavity block 5010'' (or mold cavity block 5010'') of cavity plate 194, specifically adjacent to where channels 5020 and 5021 are connected to channel 5030.

[0425] In such water fittings, a valve mechanism may be provided to open and close the fluid flow channel. When the male portion of such a cooling fluid fitting is received into the female portion, the valve mechanism is open. When the male portion is removed from the female portion, the valve mechanism is closed. The valve mechanism may be provided on the cooling fluid source side of the fluid circuit supply, for example, at output port 5050a on the service block 5196. Thus, when the base block 5000 is disconnected from the service block 5196, cooling fluid does not flow out of the output port 5050a of the service block 5196.

[0426] Also, note that there is a male and female portion for the male / female type couplings between the base block 5000 and the service block 5196 (both the cooling fluid fittings and the fittings associated with the coupling / retention mechanisms described above). In some embodiments, the female portion of the coupling may be formed in the service block 5196 and the male portion of the coupling may be formed on the base block 5000. This is because such male portions of the couplings are typically inexpensive components in any molding system 100 and there may be a greater number of base blocks 5000 utilized compared to the number of service blocks 5196, so it may be cost effective to provide the male portions of such cooling fluid fittings and retention / coupling mechanisms on the base block 5000. In other embodiments, the male portion of the coupling may be formed in the service block 5196 and the female portion of the coupling may be formed on the base block 5000.

[0427] Similarly, in the embodiment of Figures 25A-25K, each base block 5000 is integrally coupled with a mold cavity block 5010 (or mold cavity block 5010'). Additionally, each base block 5000 may include a fluid cooling channel 5020' (Figure 28C) that is part of a cooling fluid circuit 5200' that delivers cooling fluid from a cooling fluid reservoir 5199 to the service block 5196, into the base block 5000, and then into the mold cavity block 5010 (or mold cavity block 5010') to promote rapid cooling and solidification of molten material after injection into the mold cavity formed by the mating and secured mold cavity block pair 5010 (or mold cavity block 5010'). The cooling fluid 5200 ′ passes through the fluid channels 5181 ′ in the service block 5196 back into the fluid channels in the platen 196 and back to the cooling fluid reservoir 5199 .

[0428] The service block 5196 may include a cooling channel 5080' having an input port 5051a and an output port 5050a. The cooling channel 5020' in the base block 5000 may include an input port 5020d in a surface 5000b of the base block 5000 that is in fluid communication with an aligned output port 5040a in a surface 5196a of the service block 5196 when the base block 5000 is engaged with the service block 5196, as shown in Figures 26A and 26B. The fluid channel 5020' passes through and is integrally coupled for fluid communication with a cooling channel 5030' (Figure 28C) that passes through the body of the mold cavity block 5010 (or mold cavity block 5010'). Similar to cooling channel 5030, cooling channel 5030' may be formed to allow cooling fluid to flow along a serpentine path through the body of mold cavity block 5010 (or mold cavity block 5010') and then be fluidly connected with a second fluid channel 5021' that passes through the base block 5000 to an output port 5020c. Output port 5020c is in fluid communication with an input port 5050b in a service block surface 5196a of service block 5196.

[0429] The service block 5196 includes a service channel 5081' that provides communication between an input port 5050b and an output port 5051b that communicates with an input port 5040b in the platen 196.

[0430] 28C, cooling fluid is communicated via various cooling fluid channels that pass from a cooling fluid reservoir 5199, through other components of the mold subassembly 3040, 3040', into the platen 196, then out an output port 5040a in the platen surface 196a of the platen 196, into and through cooling channels 5080 in the service block 5196, then into cooling channels 5020' in the base block 5000, and then into cooling channels 5030' in the mold cavity block 5010 (or mold cavity block 5010'). The cooling fluid then flows through cooling channels 5030', then through channels 5021' and out into an input port 5050b in the service block surface 5196a of the service block 5196. Cooling fluid can then flow through the cooling fluid channels 5181' to an input port 5040b in the platen surface 196a of the platen 196 to which the service block 5196 is attached. The cooling fluid can then flow through the platen 196 and return to the cooling fluid reservoir 5199 via various channels that pass through other components of the mold subassembly 3040, 3040'. As part of the cooling fluid circuit 5200', in addition to the cooling fluid reservoir 5199 and flow channels, a device for cooling the fluid is required, and pumps and possibly valves are required to provide cooling fluid flow into and out of the mold cavity block 5010.

[0431] Each of cooling fluid input / output port couplings 5051a / 5040a; 5050a / 5020d; 5020c / 5050b; and 5051b / 5040b may be any suitable cooling fluid communication fitting. For example, suitable water fittings for couplings 5051a / 5040a; 5050a / 5020d; 5020c / 5050b; and 5051b / 5040b may also be model AMF 6989N [164988, built-in coupling nipple] and 6989M [164996, built-in coupler] water fittings manufactured by AMF.

[0432] In addition to the base block facing surface 5010a, in the embodiment of Figures 25G and 25H, the mold cavity block 5010 includes an upper horizontal surface 5010c and a lower horizontal surface 5010d that are generally parallel to each other and perpendicular to the surface 5010a. The lateral side of the base block 5000 opposite the base block facing surface 5010a may include a cavity side 5010b having a generally designated surface topography 5012 that may vary in configuration based on one or more of several factors including the item configuration desired to be molded between the pair of fitting alloy mold cavity blocks 5010 and the type of molding material to be injected into the cavity. The cavity side topography 5012 typically includes a surface area that forms at least half of the mold cavity and a contact surface area that is configured to engage an opposing contact surface on a corresponding fitting alloy mold cavity block. In the mould cavity block 5010, a contact surface area 5010g may be provided, which is generally parallel to the base block facing surface 5010a. The cavity wall 5011 extends inwardly of the contact surface area 5010g, which defines the outer surface of the half cavity 5015. The cavity wall 5011 is oriented such that the longitudinal axis of the cavity wall (Y direction) leading to the top open end of the mould cavity is vertical, so that the split line is a vertical line on either side of the moulded item. In other words, the cavity wall 5011 provides the vertical cross-sectional profile of the moulded item, which comprises an opening at the vertical end of the profile.

[0433] The mold cavity block 5010' is similar in configuration to that shown in Figures 25I-25K, in that the contact surface area 5010g' is generally parallel to the base block facing surface 5010a'. The cavity wall 5011' extends inwardly of the contact surface area 5010g', which wall defines the outer surface of the half cavity.

[0434] In each mold cavity block 5010, 5010', the core alignment surface area 5009, 5009' is located on the cavity wall 5011, 5011' and the surface area generally tapers inwardly toward the cavity wall 5011, 5011'' defining a half-cavity suitable for receiving and aligning the upper portions of the outer core 7030 and inner core 7032 of the mold core assembly 190 (see Figures 25D, 25E), which is received in the cavity formed by the cavity walls 5011, 5011'.

[0435] During operation of the system 100 , the inner core 7032 extends vertically into the mold cavity formed by the opposing cavity walls 5011 , 5011 ′ of the opposing fit mold cavity blocks 5010 , 5010 ′ and the walls of the inner core 7032 .

[0436] The gate areas 5016, 5016' may be formed vertically through the bottom of the body of each mold block cavity 5010, 5010' to provide a channel from the exterior of the mold cavity block into the half cavity 5015 and into the mold cavity, which channel is formed when the inner core 7032 and outer core 7030 of the mold core assembly 190 are received into the cavity formed by the inner core receiving surfaces 5009, 5009' and the cavity wall surfaces 5011, 5011' of the fitting alloy cavity block 5010 (or fitting alloy cavity block 5011'). It should be noted that the two opposing facing gate areas 5016, 5016' of the opposing mold cavity block pair 5010, 5010' cooperate to define a gate structure 5017, 5017' (FIG. 25D) when the mold cavity block pair 5010 (or the mold cavity block pair 5010') mates with one another during operation of the mold subassembly 3040, 3040'. Through the formed gate structure 5017' (FIG. 25D), molding material can be injected into the formed mold cavity generally as described herein.

[0437] Also, vent areas 5037, 5037' may be formed through the sides of the body of each mold block cavity 5010, 5010' to provide opposing vent channels between the exterior of the mold cavity block and the interior of the half cavity 5015, 5015'. It will be appreciated that when the two mold cavity blocks 5010 (or mold cavity blocks 5010') contact each other and are oriented in a face-to-face mating relationship with each other by the opposing contact surface areas 5010g, 5010g' facing each other during operation of the system 100, the entire opposed vent structure pair 5038' (FIG. 25C) is formed by the two opposed opposed vent areas 5037' of the opposed mold cavity blocks 5010'. Through the formed vent structure 5038' (FIG. 25C), air may escape from the interior of the mold cavity when molding material is injected into the formed mold cavity.

[0438] It will be appreciated that when two mold cavity blocks 5010 contact each other and are brought into a face-to-face mating relationship with each other by opposing contact surface areas 5010g facing each other during operation of the system 100, the outer surface of the entire mold cavity is formed by the opposing cavity walls 5111. As a result, a vertical split line exists between the two mating mold cavity blocks 5010 at the inner edge defined by the boundary between the cavity walls 5011 and the contact surface areas 5010g. It is important that the mating edges of the two cavity walls contact each other intimately and without breakage, and that the edges are flush with each other to prevent discontinuities at the junction of the adjacent cavity mold faces. To minimize problems associated with visible vertical split lines, it is important that the interface between the mating and engaged mold cavity block pairs 5010 can be controlled to a very high degree of tolerance during operation of the system 100.

[0439] 25G and 25I , in some embodiments, a generally wedge-shaped abutment 5033 extends from opposing angled sides 5010e and 5010f of the mold cavity block 5010. The abutment 5033 on the stationary mold cavity block 5010 may include a longitudinally extending guide pin opening 5035 for receiving a guide pin (not shown in FIG. 25G, see FIG. 26D for similar guide pin 5007″) that may be attached to the opposing wedge-shaped abutment 5033 on the movable mold cavity mold block 5010. For further clarity, it can be understood that for a mating mold cavity block pair 5010, one mold cavity block 5010 can be fixed to a base block 5000 attached to the stationary mold platen 196 and thus can be stationary during operation of the mold subassembly, while the opposing mold cavity block 5010 can move during operation because it is fixed to a base block 5000 attached to the moveable mold platen 196. In other embodiments, both mold cavity blocks 5010 can move during operation of the mold subassembly because each mold cavity block 5010 is fixed to a base block 5000 attached to the moveable mold platen 196.

[0440] The guide pin openings 5035 and guide pins may be formed to very high tolerances to ensure that when the two mold cavity blocks 5010 are brought together into a face-to-face mating relationship with each other by opposing contact surface areas 5010g that contact and face each other, all of the desired outer surface characteristics of the mold cavities are properly formed (e.g., the two mold cavity halves are precisely aligned with each other to help prevent / minimize noticeable vertical split lines on the molded item).

[0441] The upper surface 5033a of the abutment 5033 is recessed below the level of the contact surface area 5010g. Thus, when the two mold cavity blocks 5010 contact each other and move into a face-to-face mating relationship with the opposing contact surface areas 5010g facing each other during operation of the system 100 with a certain known clamping force, the only surfaces that will contact each other will be the contact surface areas 5010g. Thus, the contact pressure at the surfaces 5010g can be calculated as the clamping force divided by the area of ​​the contact surface areas 5010. In addition, the contact pressure desired to ensure proper sealing of the mold cavities by the two mold cavity blocks can be a known range. It is possible that for a certain standard clamping tonnage applied by the clamping mechanism of the mold subassembly 3040', 3040', an acceptable range of contact surface areas can be calculated and provided for a particular cavity mold block 5010. Thus, instead of varying the clamp pressure for items of different sizes / shapes being molded, the surface contact area 5010g for the mold cavity block can be selected and the contact pressure at the surface contact area 5010g can be appropriately maintained within a desired range.

[0442] An alternative configuration of mold cavity block 5010' is shown in Figures 25I-25K. Mold cavity block 5010' may be configured similarly to mold cavity block 5010, including generally the same overall corresponding width X2, but with different length Y3, cooling channels 5030', and wedge-shaped abutment 5033' with recessed top surface 5033a'. Also, abutment 5033' on stationary mold cavity block 5010' may include guide pin openings 5035' for receiving guide pins (not shown) that may be attached to the opposing fitting mold cavity block 5010'. However, the configuration of sides 5010e' and 5010f' and cavity wall 5011' may be such that there is a larger contact surface area 5010g' on mold cavity block 5010' compared to the size of contact surface area 5010g of mold cavity block 5010.

[0443] Mold cavity block 5010' (having a length Y2 the same as or a shorter length Y3 than the length Y2 of mold cavity block 5010) may require a different configuration of contact surface area 5010g' compared to contact surface area 5010g to ensure that the contact pressure is within an acceptable range for standard clamping pressures.

[0444] Table 1 below provides one example of how the configuration and size of the contact surface area may be selected / varied for a variety of different items being molded, where a standard clamp load is applied to clamp two opposing cavity mold blocks together, showing the resulting contact pressures for a variety of somewhat different sizes and shapes of contact surface areas 5010g when a clamp force of 30 tons (294,300N) is applied. [Table 1]

[0445] Therefore, if the size and shape of the mold cavity surfaces differ between the mold cavity blocks, the shape of the contact surface area may vary to some extent between the two mold cavity blocks to ensure that the contact pressure remains within the desired pressure range given the set clamping pressure.

[0446] The ability to vary the shape of the surface contact areas 5010g, 5010g', 5010g'' also allows the pressure distribution applied across the contact surface on the mold cavity block to be adjusted taking into account the location of the force applied via the clamping mechanism. In some situations, the force applied by the clamping mechanism is not evenly distributed. The size of the contact surface in a particular area can be adjusted to accommodate the uneven application of force by the clamping mechanism so that the pressure across the entire contact surface area is fairly even.

[0447] An additional alternative embodiment of mold cavity plate 194'' is shown in Figures 26D-26F, in which the cavity plate may be formed as two separate parts: (a) base block 5000''; and (b) mold cavity block 5010'', which may be connected to one another during use. Base block 5000'' may be formed generally like base block 5000, including base block 5000'' with sides 5000e'' and 5000f'', which are generally longitudinally extending and flat. Mold cavity block 5010'' may be formed generally like mold cavity block 5010, except that sides 5010e'' and 5010f'' are also generally vertically extending and flat. As seen in FIG. 26B and in FIGS. 26D-F, when mold cavity block 5010'' is attached to base block 5000, surface 5010e'' is generally flush with and extends in the same plane as surface 5000e. Similarly, surface 5010f'' is generally flush with and extends in the same plane as surface 5000f. Additionally, surface 5010c'' is generally flush with and extends in the same plane as surface 5000c, and surface 5010d'' is generally flush with and extends in the same plane as surface 5000d. Also, the cavity side topography 5012'' of the mold cavity block 5010'' may be generally divided into the following areas: (i) contact surface area 5010g''; (ii) slightly lower recessed non-contact surface area 5010h''; and (iii) cavity wall area 5011''. It may be appreciated that if the size and shape of the mold cavity surfaces differ between the two mold cavity blocks 5010'', the shapes of the contact surface area 5010g'' and non-contact surface area 5010h'' may be varied to some extent between the two mold cavity blocks to ensure that the contact pressure remains within a desired pressure range when a set clamping pressure is applied, even if the two mold cavity blocks 5010'' are used to produce items of different sizes / shapes.

[0448] With particular reference to Figures 26A-26C, the mold cavity for the item to be molded is formed between the outer surface of the inner core 7032 and the matingly engaging cavity walls 5011'' of the cavity mold block 5010''. The upper portion of the mold cavity is sealed by a horizontal circular ring-shaped edge 7030a of the bottom of the outer core 7030. Alignment of the outer core 7030 and the top of the inner core 7032 with the cavity walls 5011' ensures that the lower portion of the inner core 7032 is properly positioned within the cavity walls 5011' to form the precise mold cavity configuration desired. Each mold cavity block 5010' may also include opposing outer surfaces 5010e'' and 5010f''.

[0449] Referring again primarily to Figures 26E and 26F, a vertically extending guide pin opening 5035'' may be provided in a non-contact surface area 5010h'' of a stationary mold cavity block 5010'' (Figure 26E) interconnected to the stationary platen 196 for receiving a guide pin 5007'' which may be attached to an opening 5008'' on a movable mold cavity mold block 5010'' (Figure 26F) interconnected to the stationary platen 196. The guide pin openings 5035'', 5008'' and guide pins 5007'' can be formed to very high tolerances to ensure that when the two mold cavity blocks 5010'' are brought together into a face-to-face mating relationship with each other with opposing contact surface areas 5010g'' in contact with each other and facing each other, all of the desired outer surface characteristics of the mold cavities are formed properly (e.g., the two mold cavity halves are precisely aligned with each other to help prevent / minimize noticeable vertical split lines on the molded item).

[0450] Additionally, as shown in Figures 26D-26F, the mounting block 5060 may be secured by bolts 5063 received in apertures 5064 and passing through the mounting block 5060 into aligned threaded apertures in surface 5000b''. The mounting block 5060 may also be secured to the service plates 5196, 5196' using bolts 5062 received through apertures 5061 into aligned threaded apertures in 5196, 5196'. The mounting block 5060 helps stabilize the base block 5000 (and the mold cavity block attached thereto) before and when it is loaded by the clamping mechanism.

[0451] An advantage of the base block 5000 and mold cavity block 5010'' cavity plate combination is that the exterior surface area is generally consistent, i.e., of a standard shape, but the cavity side topography 5012'' can be modified to accommodate any shape and size (within certain limits) of the item to be molded. This allows the relative sizes of the contact surface area 5010g''; the recessed non-contact surface area 5010h'' to be adjusted to take into account the configuration and size of the cavity wall area 5011''.

[0452] 26A-26F, a gate area 5016'' may be formed vertically through the bottom of the body of each mold block cavity 5010'' to provide a channel from the exterior of the mold cavity block into the half cavity 5015'' and into the mold cavity when the inner core 7032 and outer core 7030 of the mold core assembly 190 are received into the cavity formed by the inner core receiving surface 5009'' and the cavity wall surface 5011'' of the fitting mold cavity block 5010'' (FIG. 26A). The two opposing facing gate areas 5016'' of the opposing pair of mold cavity blocks 5010'' cooperate to define a gate structure 5017'' (FIG. 26D) when the pair of mold cavity blocks 5010'' are mated with one another during operation of the mold subassemblies 3040, 3040'. Through a gate structure 5017'' formed generally as described herein, molding material can be injected into a mold cavity formed.

[0453] Also, opposing vent area pairs 5037'' may be formed through each opposing side of the body of each mold block cavity 5010'' (FIG. 26E) to provide opposing vent channel pairs between the exterior of the mold cavity block and the interior of the half cavity 5015''. It will be appreciated that when the two mold cavity blocks 5010'' contact each other and are brought into a face-to-face mating relationship with each other by opposing contact surface areas 5010g'' facing each other during operation of the system 100, the entire opposing vent structure pair is formed by the two opposing facing vent areas 5037' of the opposing mold cavity blocks 5010'. Through the formed vent structures, air may escape from the interior of the mold cavity when molding material is injected into the formed mold cavity.

[0454] It will be appreciated that when two mold cavity blocks 5010'' contact each other and are brought into a face-to-face mating relationship with each other by opposing contact surface areas 5010g'' facing each other during operation of the system 100, the outer surface of the entire mold cavity is formed by the opposing cavity wall surfaces 5111''. As a result, a vertical split line exists between the two mating mold cavity blocks 5010'' at the inner edge defined by the boundary between the cavity wall surfaces 5011'' and the contact surface areas 5010g. Again, it is important that the mating edges of the two cavity walls contact each other intimately and without breakage, and that the edges are flush with each other to prevent discontinuities at the junction of adjacent cavity mold faces. To minimize problems associated with visible vertical split lines, it is important that the interface between the mating and engaged mold cavity block pairs 5010'' can be controlled to a very high degree of tolerance during operation of the system 100.

[0455] 26J, an additional mold cavity block 5010''' is illustrated in which a cavity side topography 5012''' may be formed generally in the same manner as the cavity side topography of mold cavity block 5010'', as described above. A base block facing surface 5010a''' of mold cavity block 5010''' and its surface topography and characteristics may be generally similar to that of mold cavity block 5010'', with the following exceptions: A generally cuboid shaped open-bottom trough area 5013''' may be formed in surface 5010a'''. Trough area 5010a''' may be formed by milling material from surface 5010a''' using conventional milling equipment and methods. Trough area 5010''' may be configured to receive cooling channel module 5019''' therein.

[0456] The cooling channel module 5019''' may include one or more cooling channels 5030''' (FIG. 26J), each having an input port and an output port for connecting to a corresponding port of the channel 5020 / 5021 in the base block 5000, so that cooling fluid may flow through the cooling channels 5030''', as described above. The configuration of the cooling channels in the cooling channel module 5019''' may vary and be designed to provide the desired cooling in a particular configuration of the cavity wall 5011. The cooling channel module 5019''' may include a generally outer rectangular framework having side frame members and a base that support the cooling channels therein. The outer framework may provide a friction fit of the cooling channel module 5019'' with the vertical walls of the trough area 5010'''.

[0457] In embodiments in which the mold cavity block is manufactured as a separate piece from the base block (such as mold cavity block 5010'' and base block 5000'', or cavity block 5010''' and base block 5000''', sealing rings may be provided on opposing mating surfaces of the cavity block and base block near the water fittings to provide a water seal. For example, as shown in FIG. 26J, a sealing O-ring 5022 made from a suitable material, such as a suitable rubber, may be provided between the mold cavity block 5010''' and base block 5000''' to provide a fluid seal between them. Internal sealing within the mold cavity block 5010'''' and cooling channel module 5019'''' is not typically required.

[0458] As a result, a standard configuration of surface topography 5012''' defining trough area 5013''' can be milled onto the cavity side of cavity mold block 5010'' and then specially configured cooling channel modules 5019'' can be inserted therein to provide the particular cooling channel configuration desired for the particular cavity wall configuration for the particular item being molded. This improves the efficiency of the manufacturing process.

[0459] The components of the cooling channel module 5019'' may be formed from any one or more suitable material(s), such as copper, stainless steel, or a suitable plastic, such as PP (polypropylene) or PE (polyethylene).

[0460] 28A, there is shown a sequence of steps (a)-(f) by which the service block 5196 and cavity plate 194 may be coupled to the platen 196. In a first step (a)-(c), the service block 5196 is attached to the platen 196. The service block 5196 may be coupled to the platen 196 by threaded bolts 5197 that are received through openings 5198 in the service block 5196 and into threaded openings 5195 in the platen 196.

[0461] The cavity plate 194 previously prepared in step (d) is then made connectable to a service block 5196, which may include a base block 5000 and a mold cavity block 5010, 5010', 5010'', or 5010'''. A quick connect of the type described above may be utilized to connect the base block 5000, and thus the cavity plate 194, to the service block 5196 to provide a platen and cavity plate assembly as shown in FIG. 28A(f).

[0462] During operation of the mold subassembly 3040, 3040' as described elsewhere in this disclosure, the platen pair 196 will have at least one service block 5196 mounted thereon. One or more mold cavity plates 194 will be mounted to the service block 5196. The cavity plate 194 may include a base block 5000 and a mold cavity block 5010, 5010', 5010'', or 5010''', and may produce molded items in mold cavities formed between the opposing mold cavity block pairs 5010, 5010', 5010'', or 5010'''. Cooling fluid and / or other services may be provided from the platen 196 to the service block 5196 and over the base block 5000 and corresponding mold cavity block 5010.

[0463] If it is desired to change the type of molded item produced by a particular mold cavity plate 194 of a mold subassembly 3040, 3040', the quick connect mechanism associated with the appropriate cavity plate pair 194, along with the currently used mold cavity block 5010 (attached to the base block 5000), can be operated to disconnect the base block 5000 from the service block 5196 using the quick connect mechanism. A replacement cavity plate 194 can be installed by connecting the base block 5000 to that service block 5196 using the quick connect mechanism, thereby connecting the replacement mold cavity block 5010 attached to the replacement base block 5000. The replacement pair of base block 5000 and respective mold cavity block 5010, 5010', 5010'', or 5010''' may be configured to produce a different type / shape of molded item than the removed base block and mold cavity block pair 5010, 5010', 5010'', or 5010'''.

[0464] Transfer of material to shaper Referring primarily to Figures 29-37, details of exemplary features for transporting molding material into a shaper will now be described.

[0465] 29 shows a partial cross-sectional view of the container 124 and a portion of the cavity plate 194 of the mold 200. As shown, the orifice 136 of the container 124 is aligned with the gate passage 2002 and feedstock is injected through that passage into the mold 200. To cause such injection, the sealing member 140 is withdrawn into the opening orifice 136. Injection is then achieved by driving the piston 182 towards the orifice 136 to reduce the volume of the cavity 134 and force the molding material through the orifice 136.

[0466] During injection of the feedstock into the mold 200, the tip of the container 124 fits into a corresponding recess defined in the cavity plate 194 adjacent the gate passage 2002. The container 124 is heated to a temperature corresponding to the molten feedstock. After injection into the mold 200, the mold 200 is maintained at a relatively low temperature, such as ambient temperature, to promote rapid cooling and solidification of the feedstock.

[0467] Typically, it is desirable to maintain the molten feedstock at a high target temperature until just prior to injection, and then subject the feedstock to a significant thermal gradient to rapidly cool and solidify the material in the mold. Such thermal control may maintain the flowability of the feedstock during injection to achieve uniform filling of the mold. Additionally, such processing may ensure desired product characteristics. For example, rapid cooling tends to limit or prevent crystallization of the feedstock, which provides desired strength and cosmetic properties in the finished part. Such rapid cooling may be achieved by maintaining the mold 200 at a low temperature relative to the molten feedstock.

[0468] The insulator 1332 and cap 1334 help maintain a desired thermal gradient at the interface of the vessel 124 and the mold 200. Specifically, as discussed above, the insulator 1332 has low thermal conductivity and thus provides a barrier to prevent heat transfer between the tip 1322 of the vessel 124 and the mold 200.

[0469] On the other hand, the cap 1334 has a relatively high thermal conductivity and tends to promote cooling of the sealing member 140 through heat transfer with the mold 200 .

[0470] 12A-12D, molding station 104-1 also includes an actuator assembly 204 aligned with the injection assembly and aligned with axis MM. Actuator assembly 204 includes a container positioning actuator (not shown) and an injector 210. The container positioning actuator may be extended to bias container 124 into abutment with mold 200. In this position, gate orifice 136 of container 124 is aligned with mold entry gate 202 of mold 200.

[0471] The molding station 104-1 may also include a valve lock assembly that may serve as a trigger to release the sealing member 140 from its sealing position. Figure 30 is a series of corresponding isometric and overhead views illustrating the operation of an example valve lock assembly 2080.

[0472] The valve lock assembly 2080 includes a cam guide 2082 with a slot 2084 that receives a bearing 1276 that is rigidly attached to the movable arm 1272 of the carrier 125. The bearing 1276 is received in the slot 2084 as the carrier 125 moves the container 124 toward the molding axis MM of the molding station. The direction of movement of the carrier 125 and container 124 is indicated by arrow D in FIG.

[0473] The slot 2084 includes a profile that acts as a cam for the bearing 1276 and arm 1272. That is, as the carrier 125 and container 124 advance along the molding axis MM, the slot 2084 causes the bearing 1276 and arm 1272 to pivot from an initial position in which the arm 1272 engages the sealing member 140 and holds the sealing member in its sealing position to a final position in which the arm 1272 disengages from the sealing member 140 so that the sealing member may be displaced from the sealing position.

[0474] As the arm 1272 moves away from the sealing member 140, the sealing member 140 may be pushed downward into the container 124, unblocking the orifice 136 and transferring the molten molding material into the container 124. The sealing member 140 may be retracted, for example, via an actuator located above or below the container 124, or by the pressure of the molten molding material acting on the sealing member 140 through the orifice 136.

[0475] 7 and 30, a closure assembly 1270 including a movable arm 1272 and a bearing 1276 is located at the bottom of the carrier 125. However, in other embodiments, the closure assembly may be located at the top of the container.

[0476] For example, FIG. 31 shows a carrier 125' with a top mounted closure assembly 1270', a movable arm 1272', and a bearing 1276'. In the embodiment shown, a cam guide 2082 with a slot 2084 is also positioned on top of the carrier 125 and above the container 124. The movable arm 1272' shields the orifice 136 from the outside. Thus, the arm 1272' functions as a sliding gate that seals the orifice 136. That is, as the arm 1272' moves toward the closed position, it slides over the top of the container 124. In this embodiment, the sealing member 140 may be omitted from the container 124 or may alternatively provide a redundant sealing process with the movable arm 1272'.

[0477] 12A-12D, the injector 210 of the actuator assembly 204 can be extended to act on the piston 182 of the container 124, urging the piston 182 towards the gate orifice 136 and forcing the molten feedstock out of the cavity 134 through the gate orifice 136. The feedstock is injected into the mold 200 and then cooled to form the molded workpiece 101′.

[0478] A second track 144 of the transport subsystem 110 passes through a discharge location beneath molding station 104-1 and is aligned with the discharge axis EE.

[0479] Carriage 129 is received in track 144 and is slidable along the track, for example by electromagnetic, pneumatic, or mechanical actuation. Transport subsystem 110 is capable of indexing individual carriages to specific locations on track 144. For example, the transport subsystem may include a sensor or encoder (not shown) to repeat the precise position of carriage 129.

[0480] The carriage 129 includes a workpiece grip 131 for physically holding the workpiece on the carriage. As shown, the grip 131 includes a nest, which may be shaped to receive the molded workpiece 101'. In some embodiments, the nest may have a shape that complements the workpiece 101'. In other embodiments, the nest may not exactly complement any particular workpiece 101; instead, it may have a shape (e.g., a concave curve, etc.) designed to reliably receive workpieces of a range of shapes and sizes. Suction may be applied to the nest to withdraw the workpiece 101' from the carriage 129. The actuator assembly 201 is in a discharge position and is operable to extend and push the carriage 129 toward the mold 200 so that the nest 133 is positioned immediately adjacent to the mold 200.

[0481] The tracks 144 of the transport subsystem 110 are offset from one another to provide clearance for the carriages 125, 129 and the work pieces 101', and the containers 124. The offset between the tracks can be in either or both the horizontal and vertical directions.

[0482] 32 shows actuation assembly 204 of molding station 104-1 in detail. In some embodiments, an injection station of dispensing cell 102 may include an actuation assembly substantially similar to actuation assembly 204. Actuation assembly 204 includes a carriage 2040 for supporting container 124 in proximity to mold 200. Carriage 2040 is movable relative to mold 200 by a linear drive (e.g., servo or hydraulic piston) 2042.

[0483] The carriage 2040 has a nest 2044 mounted thereon for receiving the container 124. The nest 2044 is disposed adjacent the track 144 so that the container 124 can be transported above the nest 2044 by the carriage 125 moving along the track 144, as indicated by arrow T in FIG.

[0484] 33A, 33B, and 33C are isometric, isometric, and cross-sectional views, respectively, showing details of nest 2044 and container 124.

[0485] As shown, the nest 2044 includes an opening 2045 that receives the base of the container 124. The nest 2044 includes sidewalls that project upwardly but are sized to provide clearance for the tongs 1254 (FIGS. 7A, 7B) so that the container 124 can be inserted into the nest 2044 while being grasped by the tongs 1254.

[0486] The nest 2044 includes a locking protrusion 2046 sized and positioned to interface with a detent 1256 of the container 124. The protrusion 2046 may be semi-annular in shape. When the container 124 is inserted into the nest 2044, the protrusion 2046 is received in the detent 1256, retaining the container in the nest 2044.

[0487] Although the closure assembly 1270 and the valve locking assembly 2080 are not shown in Figures 32, 33A, and 33B, it should be understood that the valve locking assembly 2080 is positioned adjacent to the nest 2044 such that the arm 1272 pivots away from the nest 2044 prior to or simultaneously with the insertion of the container 124 into the nest 2044 (see Figure 30).

[0488] The nest 2044 includes a channel 2048 that receives the base of the sealing member 140 , which includes the detent 180 .

[0489] The bottom of the nest 2044 is open, allowing the actuation assembly 204 to interact with the body of the container 124, the sealing member 140, and the piston 182. In the specifically illustrated embodiment, the actuation assembly 204 includes an actuator, such as, for example, a pneumatic or servo-driven piston, cylinder, or the like, that can extend through the bottom of the nest 2044 to act on the body of the container 124, the sealing member 140, or the piston 182.

[0490] 33C, the actuators acting on the vessel 124, sealing member 140, and piston 182 may be in a nested (e.g., concentric) arrangement. Specifically, a hollow vessel locking actuator 2062 is positioned against the base of the vessel 124. A flow actuator, i.e., injection actuator 2102, is nested within the vessel positioning actuator 2062. A gate operating actuator 2104 is in turn nested within the injection actuator 2102.

[0491] The container locking actuator 2062 and the injection actuator 2102 can be tubular, i.e., annular surfaces from top to bottom. The top surfaces of the actuators 2062 and 2102 (i.e., the surfaces closest to the orifice 136 along the longitudinal axis) abut the container 124 and the piston 180, respectively. The gate operating actuator 2104 can include a gripping mechanism 2106 having a notch shaped to receive and interface with the detent 180 of the sealing member 140.

[0492] In the embodiment shown, the vessel locking actuator 2062 and the gate operating actuator 2104 are pneumatically driven and the injection actuator 2102 is servo driven, although each actuator may be driven by any suitable drive type.

[0493] As will be described in further detail, the container locking actuator 2062 is operable to bias the container 124 toward the mold 200 so that the leading edge of the container 124 is in tight contact with the mold. In such a condition, the container 124 is loaded against the protrusions 2046 of the nest 2044.

[0494] In the embodiment shown, the gate actuator 2104 includes a first section 2105 and a second section 2107 that are coupled by a coupling pin 2109 that extends through a slot defined by the injection actuator 2102. Specifically, the pin 2109 may extend through holes in the first and second sections 2105, 2107 to couple the sections together such that the sections extend together. In the embodiment shown, the first section 2105 is a generally hollow tubular element while the second section is a generally cylindrical member. The first section 2105 has an inner diameter sufficient to accommodate the independent sliding movement of the injection actuator 2102 nested therein. Similarly, the injection actuator 2102 is a tubular member with an inner diameter that accommodates the second section 2107 of the gate actuator 2104 nested therein.

[0495] The gate operating actuator 2104 is operable to extend the sealing member 140 to a sealing state and to retract the sealing member 140 to open the orifice 136, in which the sealing member 140 substantially prevents the flow of material through the orifice 136.

[0496] As mentioned above, in the illustrated embodiment, the injection actuator 2102 is servo driven. Servo drive of the injection actuator 2102 may allow for application of large forces to apply suitable injection pressures to the molding material with relatively high positional accuracy of the injection actuator 2102, and thus of the piston 182. In other embodiments, other suitable drives may be used. For example, in some embodiments, the injection actuator 2102 may be hydraulically driven.

[0497] The injection actuator 2102 is operable to act against the piston 182 to force the molding material out of the container 124 .

[0498] Figures 34A-34K show molding station 104-1 at various stages of the molding operation. For simplicity, the core placement actuator 1046 and the load actuator 1050 are omitted from Figures 34A, 34B, 34C, 34E, 34I, and 34J.

[0499] As shown in Figure 34A, the carriage 125 carrying the container 124 is transported on the track 144 to an injection position opposite the injection station 104-1 and aligned with the mold axis MM. The orifice 136 of the container 124 opens as the carriage 125 and container 124 move into position with the mold axis MM, for example as described above with reference to Figure 30. Once in that position, the container lock actuator 2062 extends to lock the container 124 in the injection station 104-1.

[0500] As shown in Figures 34B and 34C, core assembly 190 moves into alignment with mold axis MM and cavity plate 194-2. Platen 196-1 moves towards platen 196-2 to lock mold 200 in the closed position.

[0501] As shown in FIG. 34D, the camshaft 3154 of the load actuator 3050 rotates to urge the moving mold plate 3142, the loading frame 3104, and the core 190 downward. The moving mold plate 3142, the loading frame 3104, and the core 190 move in a short stroke. In the example shown, the stroke length is about 2 mm. A downward force is applied to the loading frame 3104 and the core 190 to resist the pressure with which the molding material is injected into the mold 200. The downward force may be referred to as a preload. In the example shown, the preload is about 60 kN.

[0502] The linear drive 2042 retracts to move the carriage 2040 towards the mold 200 so that the container's mating assembly sealingly abuts the mold plate of the mold 200 and the orifice 136 of the container 124 is aligned with the gate 202 of the mold 200. The linear drive also controls the contact force (effectively the sealing force) between the mold and the container. The gate operating actuator 2104 then retracts the sealing member 140 away from the mold 200, thereby fluidly connecting the container 124 with the mold cavity.

[0503] The injector 210 extends, pushing the piston 182 towards the orifice 136, reducing the volume of the cavity 134 and forcing the molten feedstock through the gate 202 and into the mold 200. The feedstock cools and solidifies to form a solid molded article (FIG. 34E). The gate actuator 2104 then extends the sealing member 140 to close the mold 200, thereby separating the container 124 from the mold cavity.

[0504] Once molding is complete, as shown in FIG. 34F, the load actuator 3050 moves the moving mold plate 3142, the loading frame 3104, and the core 190 upward in a short stroke. In the embodiment shown, the stroke can typically be 3 mm or less in length. The camshaft 3154 rotates and strikes the rocker 3152, pushing the moving mold plate 3142 upward. The protrusion 3174 of the moving mold plate 3142 strikes the load frame 3104, moving it upward. The inner core 3112 moves upward with the load frame 3104. The force applied to the inner core 3112 during the upward stroke can be relatively large. In some embodiments, the magnitude of the force can be similar to the preload created by the load actuator 3050 prior to molding. The upward movement removes the molded article from the inner core 3112. That is, the movement forms a small initial crack between the molded article and the inner core 3112.

[0505] As shown in FIG. 34G, the mold 200 is opened by the clamp subassembly 3042 retracting the platen 196-1 and cavity plate 194-1 from the platen 196-2 and cavity plate 194-2.

[0506] As shown in FIG. 34H, the secondary mold opening actuator 3180 extends to move the core assembly 190 away from the platen 194 so that the core assembly 190 is aligned with the discharge axis EE (FIG. 39G).

[0507] Carriage 129 is extended upwardly so that its nest is positioned directly beneath molded workpiece 101' and suction is applied through the nest to help pull molded workpiece 101' from core assembly 190. Carriage 129 carrying molded workpiece 101' then moves along track 144 for further processing.

[0508] The workpiece 101' is removed from the core assembly 190 by retracting the inner core 3112 from the carriage 129 along the discharge axis EE. Specifically, the cylinder 3108 of the core placement actuator 3046 extends, moving the load frame 3104 and inner core 3112 away from the outer core 3114 and carriage 129. As the inner core 3112 retracts, the outer core 3114 abuts the workpiece, pushing it away from the core assembly 190 as the core retracts.

[0509] Figures 35A-35F show the operation of the actuation assembly 204 in detail. Figures 35A-35F are isometric cross-sectional views taken at a 90 degree angle relative to the views of Figures 33B and 33C. As shown in Figure 35A, when the container 124 is moved into position on the nest 2044, the container locking actuator 2062 extends, which urges the container towards the mold 200 and against the projections 2046 of the nest 2044. As previously described, the linear drive then retracts, moving the carriage towards the mold so that the container sealingly abuts the mold plate of the mold and the orifice of the container is aligned with the gate of the mold.

[0510] As shown in Figure 35B, the injection actuator 2102 extends and contacts the piston 182. As shown in Figure 35C, the gating actuator 2104 retracts and the sealing member 140 retracts from the sealed position to the open position, where molding material is free to flow through the orifice 136.

[0511] Once sealing member 140 retracts to unseal orifice 136, injection actuator 2102 extends one stroke, as shown in FIG. 35C, to force molding material out of container 124 and into mold 200. The stroke may be a specific length defined by the drive mechanism of injection actuator 2102, or the stroke may continue until piston 182 abuts tip 1322 of the container. Thus, the amount of material pushed out of container 124 may be determined by injection actuator 2102 or its drive mechanism, or may be determined by the internal volume of container 124.

[0512] The orifice 136 is resealed by the extension of the sealing member 140, as shown in Figure 35E, i.e., the gating actuator 2104 extends, moving the sealing member 140 to the sealing position.

[0513] After the injection is completed, the injection actuator 2102 may be withdrawn, as shown in FIG. 35F. As shown, the piston 182 may remain in its extended position following retraction of the injection actuator 2102. For example, the piston 182 may maintain its position by friction. In other embodiments, the piston 182 may retract with the injection actuator 2102.

[0514] In an alternative embodiment, as shown in FIG. 36, the molding station 106-1 may further include a gate assembly 2200 disposed between the container 124 and the mold 200 for selectively cutting the marks of the injected material between the container 124 and the mold 200 after the injection of the molding material is completed. The gate assembly 2200 is particularly useful when used in combination with a container without a sealing member 140 as described above. When used in combination with a container 124 with a sealing member 140, the gate assembly 2200 may nonetheless assist in trimming the marks formed on the base of the preform prior to demolding. The gate assembly 2200 may include a plate 2202 and a blade 2204, which may be mounted below the mold 200. The blade 2204 may be received in a pocket 2206 defined in the plate 2202. As shown, the blade 2204 includes an arched cross-sectional shape. The arched portion of the blade 2204 is compressed into a pocket 2206 between the plate 2202 and the mold 200. The compression of the blade 2204 urges the blade against the underside of the mold 200 such that the blade fits tightly against the mold 200. However, in other embodiments, the blade 2204 may have a different cross-sectional shape. For example, the blade 2204 may be substantially planar. The gate assembly 2200 may also include a scraper 2208 positioned to scrape the underside of the blade 2204 when extended, thereby removing residual molding material from the underside of the blade. In the embodiment shown, the scraper 2208 is serrated. In other embodiments, the scraper 2208 may comprise a straight edge.

[0515] 37A and 37B are cross-sectional views illustrating the process of cutting the stream of molding material between the container 124 and the mold 200. This process can occur immediately after completing the injection of the molding material into the mold 200. As shown in FIG. 37A, the blade 2104 advances in the direction of the stream of molding material, which may be partially or completely solidified.

[0516] 37B, the blade 2104 cuts through the stream of molding material, thereby separating the article within the mold 200 from any remaining molding material outside the mold 200 or within the container 124. After such separation, the container 124 may be pulled from the mold 200. The blade 2104 then extends over the scraper 2108 to remove any remaining molding material from under the blade.

[0517] 38 shows in detail the conditioning cell 108 and the molding cell 106. As shown, the stations of the conditioning cell 108 and the stations of the molding cell 106 are located in close proximity to one another, that is, the conditioning station 108-1 and the molding station 106-1 are located near one another.

[0518] heat adjustment 39-40, details of an exemplary reconciliation cell 108 will now be described.

[0519] In the illustrated embodiment, the conditioning cell 108 is for heating the molded workpiece to generate a desired thermal profile to prepare the workpiece for a subsequent molding operation in the mold cell 106. For example, the stations in the conditioning cell 108 may be configured to heat or cool the workpiece to change its overall temperature, or may be configured to preferentially heat or cool certain areas of the workpiece to change the temperature distribution within the workpiece; or a combination thereof.

[0520] 39 shows a cross-sectional view of conditioning station 108-1. Conditioning station 108-1 includes a frame 400 and a heat generating assembly 402, a heating chamber 404, a thermal monitoring system 406, and a mandrel 408, all of which are supported by frame 400.

[0521] The heating assembly 402 includes devices that apply heat to a received workpiece. In some embodiments, heating may be achieved by exposing the workpiece to microwave radiation. In other embodiments, heating may be achieved by directing infrared light onto the workpiece. In other embodiments, other suitable techniques may be used. For example, the workpiece may be immersed in a heated fluid, such as air.

[0522] The heat generation assembly 402 may include one or more thermal metering devices 410. The thermal metering devices 410 are operable to control the rate at which heat is applied to the workpiece. For example, the thermal metering devices 410 may include a wavelength tuner that affects the characteristics of the microwave radiation by altering the standing wave pattern of the radiation within the chamber 404, e.g., to control the location of high emissivity regions relative to the workpiece within the chamber. Alternatively or additionally, the thermal metering devices 410 may include a shield that partially or completely blocks incident radiation, or a valve that regulates the flow of a heated fluid.

[0523] The heating chamber 404 is configured to receive the workpiece, and heat from the heat generating assembly 402 is directed into the heating chamber 404 such that the temperature of the workpiece increases while in the heating chamber 404. In some embodiments, heat may be focused on specific areas of the workpiece to generate a particular desired temperature profile. The (e.g., average) temperature of the entire workpiece may increase, remain static, or decrease. For example, in some embodiments, portions of the workpiece may be heated or allowed to cool while heat is applied to other portions. The thermal metering device 410 may provide control of the heat distribution and resulting temperature profile.

[0524] A mandrel 408 is mounted on the frame 400 and is rotatable about its axis and movable in three dimensions.

[0525] The mandrel 408 includes a gripping assembly 412 configured to releasably engage a workpiece. As shown, the gripping assembly 412 includes a fixed block 414 and a movable block 416. The fixed block 414 is rigidly supported on the mandrel 408. The movable block 416 is attached to a linear actuator 418, which is in turn attached to the mandrel 408.

[0526] The compressible member 415 is disposed between the fixed block 414 and the movable block 416. A linear actuator 418, which thereby compresses the compressible member 415 in an axial direction, may retract the movable block 416. The axial compression of the compressible member 415 causes the member to expand radially and contact the interior wall of the workpiece 101. The compressible member 415 frictionally engages the workpiece, thereby retaining it to the mandrel 408.

[0527] The movable block 416 has a tapered leading surface that is sized to slightly interfere with the cavity of the workpiece 101' at its widest point. The movable block 416 may stretch into the workpiece 101'. Such stretching may relieve strain on the compressible members 415, causing them to regain their original shape and release the workpiece 101'. The stretchable block 416 may then push the workpiece 101' away from the mandrel 408.

[0528] The heating chamber 404 includes a top opening 422 through which a mandrel 408 may lower a workpiece into the chamber. The thermal monitoring system 406 includes temperature probes 407 located proximate the top opening 422 to measure and record the temperature profile of the workpiece entering the heating chamber 404. In the embodiment shown, there are four temperature probes 407, evenly spaced around the perimeter of the top opening 422. The temperature probes 407 shown are infrared cameras. In other embodiments, other types of temperature measurement devices may be used. For example, the temperature probes may include thermocouples. As will be apparent to one of ordinary skill in the art, other suitable temperature measurement devices may be used.

[0529] Figures 40A-C show conditioning station 108-1 at various stages of the conditioning operation, with Figure 40C showing a cross section of conditioning station 108-1, showing the internal components.

[0530] As shown in Figure 40A, the workpiece 101' is delivered to the conditioning station 108-1 by a carriage 129 that moves along a track 144. The carriage 129 moves to a carriage load position.

[0531] As shown in Figure 40B, the mandrel 408 is positioned over the workpiece 101' with the gripping assembly 412 received inside the workpiece. The movable block 416 of the gripping assembly 412 retracts toward the fixed block 414, forcing the compressible member 415 against the workpiece. Friction between the compressible member 415 and the workpiece 101' holds the workpiece to the mandrel 408.

[0532] The mandrel 408 moves the workpiece 101' into a position adjacent the top opening 422 of the heat chamber 404, and then moves the workpiece 101' into the heat chamber 404, as shown in FIG. 40C. The workpiece 101' is subjected to a process. Specifically, heat is generated by the heat generating assembly 402 and applied to the workpiece within the heat chamber 404.

[0533] Once processing of the workpiece 101 ′ is complete, the mandrel 408 withdraws the workpiece 101 ′ from the heating chamber 404 .

[0534] Secondary molding 41-51, exemplary station features and operation will now be described in detail for exemplary mold cell 106 and mold cell dies. In the embodiment shown, the exemplary station is for blow molding plastic articles, although many features of the described embodiment are expressly not limited to blow molding.

[0535] 41A and 41B show molding station 106-1 of molding cell 106 in greater detail.

[0536] As shown, molding station 106-1 is a stretch blow molding station for forming hollow containers from molded workpieces. In an alternative embodiment (not shown), the molding station is a liquid molding station, and the operations of forming and filling the containers are combined. Station 106-1 includes a mold 500 defined by a plurality of mold sections 502-1, 502-2, ..., 502-n (individually and collectively mold sections 502). In the embodiment shown, mold 500 includes two sections 502-1, 502-2, and a bottom plug 503; however, more or fewer sections may be present.

[0537] Mold sections 502 are mounted to respective platens 504 of a press 506. Some or all of the mold sections 502 are mounted to movable platens so that the mold 500 can be opened to allow insertion of a workpiece or removal of a finished part, or so that the mold 500 can be fixed and closed during molding.

[0538] The press 506 is mounted to a support frame 510, which is in turn removably mounted to a base 512. A clamp assembly 514 is mounted to the support frame 510, and the platen 504 is secured to the clamp assembly 514 for opening and closing the platen.

[0539] The clamp assembly 514 is shown in detail in Figure 47. In the embodiment shown, the clamp assembly 514 includes two linkages 516, each coupled to a respective platen 504.

[0540] Each linkage 516 is substantially identical to linkage 3070 shown in Figure 12D and includes a drive link 518 and rockers 520, 522. Drive link 518 is coupled to a crosshead 524, which is driven in reciprocating motion by a linear actuator, such as a ball screw driven by an electric motor 526.

[0541] In other embodiments, both platens may be driven by a single linkage, for example the linkage may be substantially identical to any of linkages 3070', 3070'', 3070'''', 3070''''.

[0542] The press 506, mold section 502, and bottom plug 503 may be loaded onto and removed from the support base as a single assembly substantially as described above with respect to the shaper module 3054 of molding station 104-1.

[0543] The molding cell 106 is located close to the conditioning cell 108 and is within an area reachable by the mandrel 408, so that the mandrel 408 can reach a station in the conditioning cell 108 and a station in the molding cell 106. In other words, the mandrel 408 can remove a workpiece from the heating chamber 404 of the conditioning station 108-1 and place the workpiece in the mold 500 of the molding station 106-1 for forming into a container.

[0544] The forming head 504 is attached to a second mandrel 506 and is operable to inject pressurized fluid into a workpiece in the mold 500 to expand the workpiece to conform to the mold. The forming head 504 includes a gripping assembly similar to the gripping assembly 412 of the mandrel 408. The gripping assembly includes a fixed block 510 and a movable mold block 512, and includes a compressible member 514 for frictionally gripping the workpiece 101' when the workpiece is forced between the blocks 510, 512. The forming head 504 further includes a fluid injection passage extending along the axis of the mandrel 506 through which pressurized fluid (e.g., air or liquid) may be injected into the workpiece 101'.

[0545] 42 and 43 show the components of shaper station 106-1 in greater detail. As described above, mold 500 includes mold sections 502-1, 502-2, and bottom puck 503. Mold sections 502-1, 502-2 are attached to platen 196, which is supported by shaper frame 8052.

[0546] The platen 196 is movable between an open position and a closed position by clamp 8070. In the closed position, the mold parts 502-1, 502-2 and the bottom puck 503 mate and cooperate to define the mold cavity 8000. In the open position, the platens 196 are spaced apart. In a first mode, the mold parts 502-1, 502-2 are coupled to the platen so that the molded parts can be removed. In a second mode, the mold parts 502-1, 502-2 are decoupled from the platen 196 so that they can be removed as an assembly.

[0547] The shaper frame 8052 and clamps 8070 are substantially identical to the shaper frame 3052 and clamps 8070 .

[0548] There may be multiple interchangeable molds 500, each including a set of mold portions 502-1, 502-1, and a bottom puck 503. Each mold defines a particular mold cavity 8000 in operation to form parts of a particular configuration. For example, at any one time, a single mold 500 may be mounted on the platen 196 of the shaper station 106-1. The mold 500 may be exchanged for other molds, for example, to produce parts of different configurations or for maintenance or repair.

[0549] Each mold section 502 is removably mounted to a service block 8004. Each service block 8004 is then mounted directly to the platen 196. The mold sections 502 may be formed from a relatively lightweight material, such as an aluminum alloy. The service blocks 8004 may be formed from a suitable tool steel or a high strength aluminum alloy.

[0550] During molding (as shown in Figures 42 and 43), clamps 8070 apply a closing force to mold 500. The closing force urges mold sections 502 together, providing mold conditions suitable for high quality molded articles. However, mold sections 502 tend to be formed from relatively weak materials. Therefore, service block 8004 includes a load limiting mechanism, namely load limiting block 8005, formed on opposing faces of service block 8004.

[0551] At nominal molding conditions, the load limit blocks 8005 are spaced apart by a small margin. However, if the load applied by the clamps 8070 is too great, the mold sections 502 may deform or compress incrementally, causing the load limit blocks 8005 to abut against each other. In this condition, the load limit blocks 8005 bear at least a portion of the clamp load, thus protecting the mold sections 502 from further deformation.

[0552] Figure 44 shows an isometric view of mold 500 and service block 8004, with service block 8004 exploded from mold segments 502. Figure 45 shows an isometric view of mold 500, with mold segments 502 and puck 503 exploded from one another. As shown, each mold segment 502 includes semi-cylindrical outer and inner surfaces 8012 shaped according to the desired configuration of mold cavity 8000 (and thus the manufactured part).

[0553] Each mold section 502 includes a support ledge 8014 on its top surface. Each support ledge 8014 is generally annular. In the closed position, with the mold sections 502 abutting each other, the support ledges 8014 cooperate to define a mold open position. A preform in the shaper cell 104 may be supported on the support ledge 8014 such that a neck ring of the preform abuts the support ledge 8014 and the preform extends into the mold cavity 8000.

[0554] Mold section 502 includes handling studs 8020 that extend outwardly from an outer surface. Handling studs 8020 include connectors 8022 for engagement by a material handling device, such as a robot. Additionally, mold section 502 includes connectors 8024 on outer surface 8010 that face service block 8004 during operation. As will be described in further detail, connectors 8024 can selectively engage with corresponding connectors on service block 8004 to couple mold section 502 to service block 8004.

[0555] As shown in Figure 45, mould section 502 includes a recess 8019 at its lower end. Recess 8019 is semi-cylindrical and sized to cooperate to receive bottom puck 503 when mould 500 is closed (Figure 46). A semi-annular retention flange 8021 projects inwardly from the wall of recess 8019. When mould 500 is closed, flange 8021 is received by and interlocks with puck 503 such that puck 503 is retained as part of mould 500 when the mould is closed.

[0556] Each service block 8004 includes a mold-facing surface 8030 and a back surface 8032. The back surface 8032 is shaped to mate with the platen 196 and the mold-facing surface 8030 is shaped to mate with the outer surface 8010 of the mold section 502. In the embodiment shown, the back surface 8030 is generally flat and the cavity block facing surface 8030 is generally semi-cylindrical.

[0557] The back surface 8032 includes a number of connectors 8034 that, in operation, align with corresponding connectors on the platen 196. In the embodiment shown, the connectors between the service block 8004 and the platen 196 are fasteners, such as bolts. Dowels (not shown) may be attached to position the service block 8004 relative to the platen 196.

[0558] The cavity block opposing surface 8032 includes a connector 8036 that, in operation, faces the corresponding mold section 502 and is aligned with connector 8024. As described above, connector 8036 and connector 8024 can selectively engage with one another to lock the mold section 502 and service block 8004 together.

[0559] Also, in the embodiment shown, the service block 8004 may include service connections. For example, electrical circuits connect sensors, such as thermocouples, and electrical heating elements. Pneumatic circuits are used to drive actuators, such as to control a quick connect mechanism. Water circuits provide cooling. The cooling and pneumatic services do not necessarily have to go through the mold section 502 as shown. Rather, pneumatic operation of connectors 8024 / 8036 is provided within the service block 8004. Cooling fluid flows through circuits that go through the service block 8004, which cools the mold section 502 by conduction. In some embodiments, the service connections are through the sides of the service block 8004. Alternatively or additionally, the service connections may go through the platens 196 or through discrete distribution plates mounted between each platen 196 and the service block 8004.

[0560] In other embodiments, in addition to the physical coupling via the connectors 8024, 8036, the mold section 502 and the base plate 8004 may be coupled by one or more services, such as electrical circuits, pneumatic circuits, and water circuits. For example, a liquid cooling circuit may be defined in the mold section 502 and pneumatic lines may be defined in the mold section 502 for operation of the connectors.

[0561] The service block 8004 includes auxiliary pneumatic ports 8037, 8039. The auxiliary pneumatic ports 8037, 8039 are for providing pressurized air to operate the connector 8036. The port 8037 is for receiving a pressurized stream to center the connectors 8036, 8024 relative to one another. That is, with the connectors 8024 and 8036 mated to one another, a stream of pressurized air can be provided to the port 8037 to quickly unload the connectors. Releasing the pressurized air returns the connectors to their nominal locked position. The port 8039 is for receiving a pressurized stream of air to disengage the connector 8036, i.e., bias the connector to a released state, in which the connector 8024 may be freely removed.

[0562] 46, the bottom puck 503 includes a puck cavity block 8050, a puck base block 8053, and a coupling block 8054. The coupling block 8054 is then coupled to an actuator block 8056. The puck 503 as an assembly is movable along an axis perpendicular to the closing axis of the clamp 8070. Such movement may be performed, for example, by one or more linear actuators mounted below the actuator block 8056 and supported by the shaper frame 8052. The linear actuators may be, for example, servos or hydraulic or pneumatic pistons.

[0563] The pack cavity block 8050 defines the bottom of the mold cavity 8000 when the mold 500 is closed. It will be appreciated that molding occurs at a relatively high temperature. Once the part has assumed its final shape, it is desirable to quickly cool the part to prevent deformation or other defects and to allow for removal of the part. A thermal regulating circuit 8058 is defined between the pack cavity block 8050 and the pack base block 8053. A fluid, such as water, may be circulated through the circuit to facilitate or remove heat from or add heat to the molded part.

[0564] The pack base block 8053 is attached (e.g., bolted) to the underside of the pack cavity block 8050. The base block 8053 includes an annular locking ring 8060 inlaid about its periphery. The locking ring 8060 defines a pocket into which the locking flange 8021 of the cavity block is received when the mold 500 is closed, thereby locking the base block 8053, connecting block 8054, and pack cavity block 8050 to the mold section 502.

[0565] The connection block 8054 is attached (e.g., bolted) to the base block 8053. The connection block 8054 includes a connector 8062 on its underside, which in operation faces the actuator block 8056. The connection block 8054 further includes one or more ports for services such as pneumatic, cooling, and electrical circuits. A flow path for cooling fluid extends from the ports through the base block 8053 and the connection block 8054 to the cooling circuit 8058. The connection block 8054 and the actuator block 8056 may be connected in fluid communication via quick connection ports, which connect to each other when brought together. This connection may be automatic, e.g., electronically triggered and operated, or spring-loaded and triggered by insertion.

[0566] The connector 8062 is received in a corresponding socket 8064 in the actuator block 8056 (FIG. 43). The actuator block 8056 is configured to mate with a linear actuator for movement of the puck 503.

[0567] Any of the connectors 8024, 8036, 8062, 8064 may be a quick connector, i.e., any of the connectors 8022, 8024, 8034, 8036 may form a quick connect mechanism with a mating connector. Such a quick connect mechanism may have the characteristics described above.

[0568] In the embodiment shown, the quick connection mechanism includes a stud protruding from the mold part 502 toward a mating socket defined in the service block 8004 and a connector 8062, which is a stud protruding from the connection block 8054 toward a mating connector 8064, which is a socket defined in the actuator block 8056.

[0569] As described above, the socket is operable into engaged and disengaged states. In the disengaged state, the stud may freely move in and out of the socket. In the engaged state, the gripper in the socket is biased into interlocking engagement with the stud. The stud may be shaped such that interlocking with the socket biases the stud to hold a precise position relative to the socket. In other words, the quick connect mechanism may position the mold section 502 and the service block 8004 relative to one another and hold them in position relative to one another.

[0570] The socket of the quick connect mechanism may, for example, be spring biased into one operational configuration (e.g., an engaged state) and may be shifted to another state (e.g., a disengaged state) by application of air pressure. Thus, an air pressure supply may be routed through the service block 8004 for operation of the quick connect mechanism.

[0571] In the embodiment shown, the quick connect mechanism is substantially similar to that shown in the previous FIG. 4H. For example, the quick connect mechanism can be model 305979 and 306050 connectors manufactured and sold by Andreas Maier GMBH & CO. KG (AMF) of Germany. The quick connect mechanism for a service port, such as a fluid port, can be model 6989N and 6989M connectors manufactured and sold by AMF.

[0572] Advantageously, the coupling and decoupling of the mold halves 502 and the service block 8004 via quick connect type connections allows the mold 500 to be quickly and easily removed and replaced with another mold 500.

[0573] 47 to 49 show stages in which the mold 500 is changed.

[0574] As shown in Figures 47A and 47B, the platen 196 is held in the closed position by the abutting mold sections 502-1, 502-1. With the mold in the closed position, a grip plate 8080 attached to a material handling device, i.e., a robotic arm (not shown), approaches the side of the mold 500. The grip plate 8080 includes a connector that corresponds to the handling connector 8022 of the mold section 502. Specifically, the connector of the grip plate 8080 is positioned and sized to mate with the connector 8022 of the mold section 502. In the embodiment shown, the connector is a socket configured to matingly receive the connector 8022 to define a quick connect mechanism.

[0575] In some embodiments, the grip plate 8080 may approximate a vertical orientation. In other embodiments, the grip plate may approximate a horizontal orientation.

[0576] Upon engagement with connector 8022, as shown in Figures 48A and 48B, grip plate 8080 and its associated robotic arm can support and lift mold 500 as a single assembly. Specifically, mold sections 502-1, 502-2, and puck 503 may be removed as an assembly.

[0577] After the grip plate 8080 engages the connector 8022, pressurized air is provided to the auxiliary port 8039 of the service block 8004. The supply of pressurized air via the auxiliary port 8039 causes the connector 8036 to release the connector 8024, thereby decoupling the mold section 502 from the service block 8004. In the embodiment shown, the pressurized air is provided from a line tied to the shaper station 106-1. Alternatively, the supply line may be tied to the grip plate 8080.

[0578] The platen 196 and service block 8004 are pulled away from the mold halves 502. Meanwhile, the gripper plate 8080 holds the mold halves 502 together.

[0579] When mold sections 502 are assembled together with service block 8004, it similarly holds bottom pack 503 in assembly. Specifically, semi-circular annular retention flange 8021 of mold sections 502 aligns with locking ring 8060 of bottom pack 503.

[0580] The connector 8062 of the puck connection block 8054 is released from the actuator block 8058. The release may be accomplished, for example, by pneumatic actuation. Once the connector 8062 is released, the bottom puck 503 may be freely pulled from the actuator block 8058.

[0581] The grip plate 8080 and associated robotic arm can then remove the mold 500 as a single assembly, as shown in Figures 49A and 49B. Specifically, in the embodiment shown, the robotic arm lifts the grip plate 8080 and mold 500 away from the service block 8004, the actuator block 8056, and the platen 196.

[0582] The installation of a new mold 500 may follow.

[0583] The grip plate 8080 and associated robotic arm interfaces with and locks into the connector 8022 of another mold 500 .

[0584] Once the new mold 500 is engaged with the grip plate 8080, the robotic arm places the new mold 500 into the shaper cell 106-1 for attaching the new mold 500 to the platen 196. The clamps 8070 then move the platen 196 and the service block 8004 inwardly. The connector 8024 of the mold section 502 is aligned in register with the connector 8036 of the service block 8004. The connectors 8024, 8036 engage and lock together. A pneumatic supply may be provided to the auxiliary port 8037 of the service block 8004 to seat the connectors 8024, 8036 together.

[0585] The actuator block 8056 extends upwardly toward the connecting block 8054 of the bottom pack 503. The connector 8064 of the actuator block 8056 and the connector 8062 of the connecting block 8054 align with one another. The connector 8064 receives and locks with the connector 8062 of the connecting block 8054.

[0586] When connector 8062 is received in connector 8064, connector 8064 is actuated, for example by application of air pressure, to a closed configuration, thereby locking bottom puck 503 to actuator plate 503.

[0587] Once the base plate 8004 is coupled to the service plate 8006 and the bottom puck 503 is coupled to the actuator plate 8056 , the mold 500 can be manipulated by the clamping unit 8070 to produce a part according to the configuration of the cavity 8000 .

[0588] Thus, in the embodiment shown, replacement of mold 500 can be accomplished relatively quickly and easily with little or no manual setup. In fact, the connections between base plate 8004 and mold sections 502, and between actuator plate 8056, connection block 8054, puck base block 8053, and puck cavity block 8050, can be fully automated. For example, all connectors can be operated by actuators so that they can be easily switched between locked and unlocked states.

[0589] Thus, shaper station 106-1 can be easily configured to shape a variety of parts in a variety of different shapes and sizes.

[0590] In the embodiment shown, molding station 106-1 is a stretch blow molding apparatus. Rod 520 extends within mandrel 506 and may extend into workpiece 101' within mold 500 to mechanically stretch the workpiece. In other embodiments, the stations of molding cell 106 may be for other types of molding operations. For example, the stations of molding cell 106 may be any suitable type of blow molding apparatus.

[0591] 51A-51D show the mold components of mold cell 106-1 at various stages of the molding operation.

[0592] Mandrel 408 (FIGS. 39-40) carries workpiece 101' from conditioning cell 108-1 to a mold position within mold 500 of molding cell 106-1. Grip assembly 412 releases the workpiece and mandrel 408 is withdrawn. Mandrel 506 moves into position adjacent mold 500.

[0593] As shown in FIG. 51B, the mandrel 506 moves towards the workpiece 101' and the gripping assembly 508 extends into the workpiece 101'. The compressible members 514 press into the workpiece and grip it. The rods 520 extend into the workpiece 101' and the workpiece stretches due to the rods 520 and the injection of pressurized air to conform to the shape of the mold 500 (FIG. 37C). The stretched workpiece cools and hardens to form the final shaped workpiece 101'', e.g. a hollow container such as a bottle. The mold 500 is opened and the mandrel 508 removes the workpiece 101''.

[0594] Transportation Subsystem Referring primarily to Figures 52-66, details of an exemplary transport system will now be described.

[0595] As discussed above and shown in Figures 39-40 and 50-51, molding cell 106 and conditioning cell 108 include associated mandrels 408, 506, which form part of the transport subsystem 110. Each mandrel can reach conditioning stations 108-1, 108-2, ... 108-n and molding cells 106-1, 106-2, ... 106-n. In other embodiments, mandrels 408, 506 can be longer, such that a single mandrel can reach multiple conditioning stations and multiple molding stations.

[0596] In other embodiments, one or both of the mandrels 408, 506 may be replaced by one or more tracks 144. The track may include one or more loops and one or more branches connecting individual conditioning or molding stations to one or more loops.

[0597] As thus shown, molding material is processed in four stages to produce a workpiece 101'', such as a bottle. Specifically, molding material is dispensed at dispensing station 102-1 and molded into a preform in a primary molding operation, i.e., injection molding at molding station 104-1. The preform is heated at conditioning station 108-1 to produce a suitable temperature profile for blow molding, and the heated preform is molded into its final shape in a secondary molding operation, i.e., stretch blow molding at molding station 106-1.

[0598] The workpiece 101'' so produced has certain properties depending on the processing stage. Properties such as material type, color, and mass depend on the configuration of the dispensing station 102-1. The shape of the bottle depends on the configuration of the molding station 104-1, the conditioning station 108-1, and the molding station 106-1.

[0599] Dispense stations 102-2, 102-3, 102-4 may be configured differently from dispense station 102-1. For example, dispense stations 102-2, 102-3, 102-4 may include different ingredients and / or different colors.

[0600] Similarly, molding station 104-1 may be configured differently from the other stations of molding cell 104, and molding station 106-1 may be configured differently from the other stations of molding cell 106. For example, each station of molding cell 104 may be fitted with a mold defining a unique preform size and shape. Each station of molding cell 106 may be fitted with a mold defining a unique bottle size and shape. A pre-molded workpiece 101' having a given size, shape, and weight may be transformed into any of a number of possible types of finished workpiece 101'' (e.g., bottles of different sizes and shapes) depending on the molding station 106 at which the pre-molded workpiece is processed. Similarly, the stations of molding cell 106 may be used to form any of a number of possible types of finished workpiece 101'', depending on the pre-molded workpiece 101' used. For example, a large pre-molded workpiece 101'.

[0601] The stations of the conditioning cell 108 may also be configured differently to produce articles with different properties. For example, the final shape produced in the stations of the molding cell 106 may be influenced by the temperature profile of the workpiece 101' at the beginning of molding. That is, hotter parts of the workpiece 101' may be more easily reshaped. Thus, the stations of the conditioning cell 108 may be configured to produce a non-uniform temperature distribution in the workpiece 101' to produce a non-uniform stretching, such as an elliptical shape.

[0602] The transport subsystem 110 flexibly interconnects with the stations of the process cells 102, 104, 106, 108 such that the molding system 100 can be rapidly configured to produce parts with altered characteristics. In some embodiments, multiple types of parts, differing in color, shape, size, or the like, can be produced simultaneously.

[0603] FIG. 52 is an overhead plan view of the system 100 showing an exemplary configuration of the transport subsystem 110.

[0604] As mentioned above, in the illustrated example, the transport subsystem 110 includes a series of tracks 144. The tracks 144 are organized into individual segments 144-1, 144-2, 144-3, ... 144-n. The segments 144-1, 144-2 are shared loops that access any of the stations in the dispense cell 102, the mold cell 104, and the conditioning cell 108, respectively. The other segments are branches that connect the shared loops to individual stations or to each other. In the illustrated embodiment, there are 16 track segments that include two shared loops. However, depending on the configuration of the system 100, there may be more or fewer tracks that include more or fewer shared loops. For example, the number of stations in each of the process cells 102, 104, 106, 108, and the physical layout of the stations will affect the total number of tracks 144 and the number of shared loops of the tracks 144. In some embodiments, the transport subsystem 110 may not include any of the shared loops of the tracks 144.

[0605] Each track 144 is configured to releasably engage and retain a carriage 125, 129. The carriages may be coupled to the track 144, for example, by rollers that interface with the track 144. Alternate carriages 125, 129 may be magnetically coupled to the track 144. In some embodiments, the carriages 125, 129 may be attached to a shuttle that is itself coupled to the track 144 and movable along the track. In some embodiments, such coupling may be electromagnetic or may be achieved using suitable mechanical fasteners.

[0606] The carriages 125, 129 may be moved along the track 144 by any suitable drive mechanism. In some embodiments, the carriages 125, 129 may be coupled to a belt or chain drive mounted on the track 144. In other embodiments, the carriages 125, 129 may be moved by electromagnetic drive. For example, the magnetic drive may include an array of drive electromagnetic induction coils that may be sequentially activated to lift and move the magnetized vessels 125, 129 along the track 144. An array of electromagnetic detection coils may be positioned proximate to the array of drive induction coils and used to detect and track the position of the vessels 125, 129.

[0607] 52, a path through system 100 may include one or more of shared track loops 144-1, 144-2 and one or more individual track segments. For example, a path through dispensing station 102-1, molding station 104-1, conditioning station 108-1, and molding station 106-1 may require carriages 125, 129 to carry work pieces along each of track loops 144-1, 144-2, and track segments 144-3, 144-7, and 144-15.

[0608] The transport subsystem 110 may include a control system 1000 to direct and track the positions of the carriages 125, 129. In some embodiments, the positions of the individual carriages 125, 129 may be tracked using drive mechanisms with position encoders. In other embodiments, the positions of the carriages 125, 129 may be tracked using machine vision systems, radio frequency tracking, or other suitable techniques.

[0609] In some embodiments, multiple carriages 125, 129 may be transported simultaneously on the track 144. Accordingly, the control system 1000 may maintain a data structure that includes position data for each carriage 125, 129.

[0610] At several locations in the transport subsystem 110, the carriages 125, 129 may be transferred from one segment of the track 144 to another segment of the track 144. Such transfer may be performed by a diverter unit (not shown). For example, a diverter unit may be provided at each junction between the shared track loops 144-1, 144-2 with another track segment. The diverter unit, under the control of the control system 1000, is operable to selectively engage and disengage the carriages 125, 129 from a first segment of the track 144, move the carriages 125, 129 to a second segment of the track 144, and disengage the carriages when they are coupled with the second segment of the track 144. The diverter unit may be actuated based on a measured position of the carriages 125, 129 on the track 144.

[0611] Thus, through operation of the diverter unit under the control of the control system 1000 , each part produced by the molding system 100 can follow a particular selectable path through the system 100 .

[0612] Thus, molding system 100 may be configured to simultaneously produce one or more parts of a common type or types in virtually any ratio. For example, parts may be produced in lot sizes as small as one unit, i.e., as a single part having a particular set of characteristics.

[0613] For example, in a particular configuration, the stations of the molding cells 104, 106 each include a uniquely shaped mold, while the dispensing cell 102 may include multiple stations that use the same material. Through the coordinated operation of the diverter units, any given dose of raw material may be routed through a sequence of process stations to produce a particular type of article, while different orchestrations of the operation of the diverter units may route a dose of raw material through different sequences of process stations to produce different types of parts.

[0614] The transfer subsystem 110 and the stations of the process cells 102, 104, 106, 108 collectively define multiple paths through the molding system 100. For example, a unique path corresponds to and is defined by each unique combination of the dispensing station; the cell molding station 104; the cell conditioning station 108; and the cell molding station 106. Additionally, in some embodiments, one or more of the cells 104, 106, 108 may be bypassed. For example, in some cases, it may be possible to transport a workpiece directly from the molding cell 104 to the shaper cell 106 without an intermediate conditioning step. For example, this may be possible if the workpiece temperature following the first molding operation is relatively high and the workpiece can be transported relatively quickly to the stations of the molding cell 106 so as to not lose significant heat, or if the molding process and molds are designed such that the temperature profile of the workpiece leaving the stations of the molding cell 104 is ideal for the process being performed in the molding cell 106.

[0615] Alternatively or additionally, in some embodiments, additional process cells may be present and may be included in some paths through molding system 100. For example, one or more of a bottle or preform coating cell, a labeling cell, a filling cell, a capping cell, or an inspection cell may be present.

[0616] An inspection cell (not shown) may include a detection device located proximate the transport subsystem 110 for viewing workpieces, such as molded preforms or finished molded articles, as they are conveyed past the detection device. The detection device generally includes a camera and an evaluation unit. An image of the workpiece is generated by the camera and the image is compared to a set value for a defect-free workpiece using image processing methods to determine if defects are present. The inspection cell may further include means for classifying molded articles that are deemed defective.

[0617] 53 and 54 are plan and side views of an injection molding system 6000 constructed in accordance with another embodiment of the subject system. Parts of system 6000 that are the same as parts of system 100 are given reference numbers.

[0618] In overview, the molten molding material is transferred to individual containers 124, which are then transported along the track 6110 to the subsequent process cells. The containers are carried by independently controllable carriages and proceed sequentially along the delivery line of the track. The containers may stop at the molten molding material dispensing cell 102, where a dose of the molten molding material is dispensed from the molten molding material dispensers (also called molten molding material stations) 102-1, 102-2 (extruder 112 in the illustrated embodiment) into the containers. The containers then proceed further along the track to the preform molding cell 6104, where the molten molding material is dispensed from the containers to the preform molding machines (preform molding stations) 6104-1, 6104-2, 6104-3, 6104-4, 6104-5, 6104-6. The containers are then transferred to the return line. Preforms 101' molded in the preform molding cell are transferred to a carriage on a return line. The return line passes through a conditioning cell 108 and a blow molding cell 106 where the preforms on the return line are transferred to conditioners 108-1, 108-2 and blow molders 106-1, 106-2 and blow molders 106-1, 106-2 for blow molding into articles. At the end of the return line, the containers are transferred to an outgoing line, optionally after an initial stop at a buffering and washing cell 6530.

[0619] A controller monitors the location and controls the movement of each carriage, container, and preform so that the correct containers are filled with the correct molten molding material, the molten molding material is dispensed into the correct preform molding machine, and the preforms formed by this machine are transferred to the correct blow molding machine.

[0620] This system allows a variety of different blow molded articles to be produced by placing different preform and blow molders in cells along the track and filling containers with different dosages and compositions of molten molding material that are optimal for some of the preform and blow molders.

[0621] The track 6110 of the injection molding system 6000 is made up of repeating segments. With reference to Figures 55A and 55C, each track segment 6540 includes an array of electromagnets 6542 extending along its length. Each track segment also includes a scale 6543 and an encoder output sensor 6544 extending along its length. A controller provides control voltages to the electromagnets of the track segments and is coupled to the encoder output sensor.

[0622] The carriages ride on a track. Referring to Figs. 55B and 55C, each carriage 6125, 6129 is supported on the track by rollers 6546 that ride on upper and lower track surfaces that prevent the carriage from lifting off the track. Each carriage includes a series of permanent magnets 6548 and a position encoder flag 6550 that responds to a scale carried by the track to output a position pulse sensed by the track's encoder output sensor. This arrangement allows the controller to keep track of each carriage's current location, ID, and speed, and to apply suitable control voltages to the track's electromagnets to move each carriage independently in either direction on the track.

[0623] The track 6110 and carriages 6125, 6129 may be manufactured by Beckhoff Automation GmbH & Co. KG under the registered trademark XTS.

[0624] Returning to FIG. 54, the track of the injection molding system 6000 includes an outgoing line 6110o, a parallel return line 6110r positioned directly above the outgoing line, a spool line 6110sp positioned away from the left end of the return line, a left transfer line 6110ls that can be shifted from a low position, and a right transfer line 6110rs that can be shifted from a low position, where at the low position of the left transfer line the outgoing line is extended to a raised position at which the return line is extended and the return line merges with the spool line, and at the low position of the right transfer line the outgoing line is extended to a raised position at which the return line is extended.

[0625] 56 in conjunction with FIGS. 55A and 55B, an upwardly extending arm 6564 is attached to each carriage 6125 and an upwardly extending arm 6569 is attached to each carriage 6129. The arm 6564 of carriage 6125 includes a pair of horizontally projecting flanges 6566, each of which terminates in a concave arcuate tip 6568. The upwardly extending arm 6569 of carriage 6129 includes a horizontally projecting flange 6576, which terminates in a concave arcuate tip (not shown). The arms 6564, 6569 switch direction from one carriage to the next, such that carriage 6125a on outgoing line 6110o with a flange 6564a projecting to the right follows carriage 6125b on outgoing line 6110o with an arm with a flange 6564b projecting to the left. (On the return line 6110r, this is reversed: the carriage 6125a on the return line 6110r with the flange 6564a protruding to the right leads the carriage 6125b with the arm with the flange 6564b protruding to the left.) This arrangement allows the carriages to be grouped with adjacent carriage pairs with complementary features, i.e., flanges facing each other. The carriages 6125, 6129 with arms of different lengths are arranged on the outgoing line 6110o such that the carriage pair 6129a, 6129b with the longer length arms 6569a, 6569b leads the carriage pair 6125a, 6125b with the shorter length arms 6564a, 6564b. (On the return line 6110r, this is reversed: the carriage pair 6125a, 6125b with the short length arms leads the carriage pair 6129a, 6129b with the long length arms.) The flanges 6566 of the short arms are configured such that when an opposing pair of such flanges approach one another, they fit snugly into the annular notches 1255, 1256 (FIG. 7A) of the container 124, trapping the container between the flange pair. Furthermore, due to the length of the short arms, trapping the container between the flange pair lifts the container away from the base of the carriage 6125 below the container. The flanges with long arms are configured such that when an opposing pair of such flanges approach one another, they stretch around the preform workpiece 101′ (FIGS. 29J and 68) below the edge 6570 of the preform (FIG. 60), such that the edge 6570 of the preform is supported by the opposing flanges.

[0626] 53 and 54, the injection molding system 6000 is divided into a number of cells. The cells used along the delivery line 6110o are, from left to right, a left transfer cell 6620, a sorting cell 6630, a molten molding material dispensing cell 102, a preform molding cell 6104, and a right transfer cell 6640. The cells used along the return line are, from right to left, a right transfer cell 6640, a preform molding cell 6104, a conditioning and blow molding cell 106 / 108, a left transfer cell 6620, and a buffering and washing cell 6530.

[0627] Each transfer cell 6620, 6640 includes a transfer line and an elevator to which the transfer line is attached. Returning to FIG. 56, the right transfer line 6110rs is mounted for slidable movement on a vertical pillar 6660, which is essentially a track segment with a series of electromagnets, like the track segment 6540. Magnets (not shown) are attached to the transfer line 6110rs, so that the transfer line is a carriage that rides on the pillar. A controller is coupled to the control input of the pillar. With this arrangement, the pillar acts as an elevator 6662 for the transfer line 6110rs, moving the transfer line between the lower outgoing line 6110o and the upper return line 6110r. It will be apparent that if the right transfer line is aligned perpendicular to the outgoing line, the transfer line abuts the right end of the outgoing line 6110o, effectively extending the outgoing line. Similarly, when the transfer line is aligned perpendicular to the return line 6110r, the transfer line abuts the right end of the return line and extends the return line. The left transfer line is configured similarly, but in addition, when the left transfer line is aligned with the return line, the left transfer line also abuts the end of the spool line 6110sp (FIG. 54) to merge the return line 6110r with the spool line.

[0628] The sorting cell 6630 comprises one or more sorting devices 6632. Referring to FIG. 57 (showing one sorting device 6632), the device comprises a rail 6670 (configured as a primary part of a linear actuator) extending transversely to the outgoing line 6110o, and a carriage 6672 (which is a secondary part of the linear actuator) slidably mounted on the rail. A rotary servo motor is attached to the carriage, and a turntable 6676 (which is a gear box) is attached to the rotor (not shown) of the servo motor. Four outwardly facing grippers 6680-1, 6680-2, 6680-3, 6680-4 are attached to the turntable and are equally spaced apart on the turntable. The grippers may be servo driven or spring biased closed to open the air circuit. A controller provides control inputs to the linear actuators, to the rotary servo motors, and to the grippers.

[0629] As shown in FIG. 53, two molten molding material dispensers 102-1, 102-2 are arranged one on each side of the delivery line, staggered along the line. A hand-off device 6730 is associated with each molten molding material dispenser. Turning to FIG. 58, the hand-off device 6730 comprises a rail 6770 (which is a primary part of a linear actuator) extending transversely to the delivery line 6110o, and a carriage 6772 (which is a secondary part of the linear actuator) slidably mounted on the rail. A stator (not shown) of a rotary servo motor is attached to the carriage, and a turntable 6776 is attached to a rotor (not shown) of the servo motor. Two pairs of outwardly facing grippers 6780-1, 6780-2 (spring biased closed, air circuit open or servo controlled) are attached to the turntable opposite each other. The controller provides control inputs to the linear actuators, to the servo motors, and to the gripper.

[0630] The preform molding cell 6104 includes preform molders 6104-1, 6104-2, 6104-3, 6104-4, 6104-5, and 6104-6 staggered along both sides of the delivery line. The preform molders are similar to preform molders 104-1, 104-2, 104-3, 104-4, 104-5, 104-6, 104-7, 104-8, except for the differences described below. Referring to FIG. 59, similar to the preform molders of cell 104, the actuator assembly includes a vertically movable nest 2044 with a semi-annular slot (shown in FIG. 32) into which the base of the container 124 can slide such that the container can be held by the nest. A hand-off device 6830 having two pairs of outwardly facing grippers 6840-1, 6840-2 is associated with each molten molding material dispenser, similar to the hand-off device 6730, and is mounted between each preform molding machine and the delivery line 6110o for transferring containers to and from the nest 2044 of the preform molding machine.

[0631] The preform molding machine 104 positions the carriage 129 (FIG. 34I) on the second track 144 extending below the preform molding machine 104 below the preform mold 200 before the inner mold core 3112 (FIG. 18B) which moves upwards a short distance to release the seal between the preform and the mold core 190. The carriage 129 is provided with a nest shaped to receive the preform, and suction can be applied to draw the preform into the nest. Meanwhile, in the injection molding system 6000 as shown in FIG. 59, the transfer device is a robot arm 6850, which is mounted beside the mold 200 of each preform molding machine 6104. The injection molding system 6000 operates the robot arm so that the end effector grips the preform before releasing the seal between the preform and the mold core.

[0632] Referring to FIG. 60 in conjunction with FIG. 59, a robotic arm 6850 comprises a fixed trunk 6852 supporting a stator of a first servo motor 6854. An upper robotic arm 6856 is attached at a first end to a rotor 6858 of the first servo motor. A second end of the upper robotic arm supports a stator of a second servo motor 6860, and one end of a lower robotic arm 6862 is attached to the rotor 6864 of the second servo motor 6860. A second end of the lower robotic arm 6862 comprises a rotatable distal pulley 6870, and an end effector 6872 is attached to the shaft of the distal pulley so as to project laterally from the shaft. The end effector comprises a servo controlled gripper pair 6874a, 6874b. A base pulley 6876 is fixed to the trunk 6852 so as not to rotate. A double-wide intermediate pulley 6878 is rotatably mounted to the robot arm coincident with the axis of rotation of the rotor 6864 of the second servo motor 6860. All three pulleys 6870, 6876, 6878 have the same radius. A coupling belt 6880 extends around the base pulley 6876 and the intermediate pulley 6878. A second coupling belt 6882 extends around the intermediate pulley and the distal pulley 6870. A controller controls the servo motors of the robot arm to position the end effector. In this regard, one skilled in the art will recognize that with the end effector initially projecting horizontally, as the lower and upper arms are rotated by the servo motors 6850, 6860 by the action of the coupling belts 6880 and 6882, the end effector will maintain its horizontal orientation. The controller also controls the gripper of the end effector.

[0633] 59 in conjunction with FIG. 60, this arrangement causes the robot arm to move into position with grippers 6874a, 6874b g...

Claims

1. A container (124) for holding molten molding material, comprising: a barrel (1320) defining an internal cavity (134) for holding the molten molding material, and a tip (1322) fitted to the barrel; a cap (1334) disposed on said tip to close said cavity and having an orifice (136) through which said molten molding material passes; a discharge mechanism including a piston (182) housed within the cavity, the piston being movable between an extended position adjacent the orifice and a retracted position displaced away from the orifice; A container, wherein the cap and tip are configured to engage corresponding positioning features of a station in a plastic molding system (100) as a coupling means to receive and expel the molten molding material into and from the cavity through the orifice.

2. 2. The container of claim 1, wherein the tip is configured to fit and seal with an end of the barrel, the tip and the barrel cooperating to define the cavity, and the tip defines the orifice for receiving the molten molding material.

3. 2. The container of claim 1, wherein the orifice is a fill orifice and a discharge orifice.

4. The container of any one of claims 1 to 3, comprising a thermal regulation assembly disposed in at least a portion of the barrel and tip for controlling a thermal profile of the molten molding material.

5. The container of claim 4 , wherein the thermal regulating assembly comprises an insulator.

6. The container of claim 4 , wherein the thermal regulating assembly includes a heat sink.

7. The container of any one of claims 4 to 6, wherein the thermal regulating assembly includes a sleeve around the barrel and the tip.

8. The container of any one of claims 4 to 7, wherein the thermal regulation assembly includes a heating element.

9. The container of any one of claims 1 to 8, further comprising a seal assembly sealing the orifice.

10. The container of claim 9 , wherein the seal assembly includes a valve stem.

11. 11. The container of claim 10, wherein the valve stem extends within the interior cavity along an axis of the barrel.

12. The container of any one of claims 9 to 11, wherein the seal assembly includes a slide gate.

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