Molding systems and related methods

Abstract

Improved devices, systems, and processes for manufacturing articles using molding techniques are provided. In one embodiment, a system (42) for conditioning a preform (34) for molding includes a heating cavity (46) for receiving the preform (34), a heater (48) configured to heat a gas, and a blower (58) configured to direct the gas heated by the heater (48) into the heating cavity (46) and toward an outer surface of the preform (34). In another embodiment, a method for conditioning a preform (34) for molding includes positioning the preform in the heating cavity (46) and directing heated gas into the heating cavity (46) and toward an outer surface of the preform (34). In another embodiment, a system (70) for molding an object is provided. In yet another embodiment, an actuator system for use in a molding system (70) is provided.

Description

[Technical field]

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 62 / 442,984, filed January 6, 2017, the disclosure of which is incorporated herein by reference in its entirety.

[0002] The present invention relates to devices, systems, and processes for manufacturing articles such as plastic bottles or containers using molding techniques such as blow molding. More specifically, the present invention relates to devices, systems, and processes for manufacturing containers that are scalable, modular, and lockable with other similar containers in both lateral and vertical directions. [Background technology]

[0003] Blow molding is a well-known technique used to manufacture plastic products such as bottles, containers, automotive parts, or cases. In a one-stage or "single-stage" blow molding machine, the process begins with the production of a hot injection-molded preform or "parison" of hollow plastic material in a first station, which is further conditioned in a second station, and then moved and positioned in a third station having a mold cavity with inner walls in the shape of the final article to be molded. In a "two-stage" machine, the preform is produced externally, but is transported to a conditioning station where it is reheated before being moved to the blow cavity.

[0004] Injection stretch blow molding (ISBM) is a technical term that refers mostly, if not entirely, to biaxial PET blow molding from a preform. ISBM technology has been around for only about 35 years. Some blown plastic bottles are blown from an extrusion tube where a closed mold pinches off at its bottom end. ISBM is used to provide machined plastic containers or other useful articles from preforms that are first stretched axially and then blown into a mold with high pressure air in the circumferential direction. Hot preforms may be produced through an injection molding station on a "single-stage" or "single-step" stretch blow molding machine, after which the preforms are temperature conditioned and then stretch blow molded into the final article and cooled in the same machine before finally being removed.

[0005] Materials used in blow molding to make plastic products include polyethylene (PE) and polyethylene terephthalate (PET) due to their high level of thermoplasticity.

[0006] A typical sequence of steps in a single-stage ISBM machine is as follows: PET is delivered to the machine site in small flake form, usually contained in a fairly large box ("Gaylord"). When the Gaylord box is opened, the PET particles immediately begin to absorb excessive levels of moisture from the surrounding air. Therefore, virtually all single-stage ISBM machines run the PET material through a dryer. The material then enters a "manifold" designed to keep the PET hot and dry during transport to the preform molding station, where a parison is formed by injecting the liquefied PET material into a mold cavity according to the shape of a preform insert rod that is lathed to specification, along with the thickness of the parison and its internal profile. Once cool enough for transport, the molded preform moves to a conditioning station where the optimal (e.g., article-specific) pre-blow temperature is achieved for the parison, both internally and on its exterior surface. The conditioned parison then moves to a blow station where compressed air works in conjunction with stretch rods to expand the PET resin until it comes into contact with the walls of the mold cavity, at which point it rapidly cools and hardens, after which the mold is opened to allow removal of the article. Summary of the Invention [Problem to be solved by the invention]

[0007] Manufacturers and other practitioners of molding technologies are continually striving to improve such technologies, and it would therefore be desirable to provide improved devices, systems, and processes for producing articles using molding technologies. [Means for solving the problem]

[0008] In one embodiment, a system for conditioning a preform for molding includes a heating cavity for containing the preform, a heater configured to heat a gas, and a blower configured to blow the gas heated by the heater into the heating cavity toward an exterior surface of the preform. The system may further include a nozzle, the nozzle including at least one sidewall and positioned within the heating cavity to at least partially surround the preform. The at least one sidewall may include at least one opening for directing the gas through the opening, such as for directing the gas to a predetermined portion of the exterior surface of the preform. In one embodiment, the at least one opening includes at least one of a hole, a slot, a curved portion, or a ventilator. Additionally or alternatively, the at least one opening may include an adjustable cross-sectional dimension. In one embodiment, the at least one sidewall includes at least one cylindrical sidewall and includes at least one opening, a plurality of openings arranged in a uniform pattern on the at least one cylindrical sidewall.

[0009] In another embodiment, a method of preparing a preform for molding includes positioning the preform in a heated cavity and directing heated gas into the heated cavity toward an exterior surface of the preform. The method may further include positioning a nozzle having at least one sidewall within the heated cavity to at least partially surround the preform. The at least one sidewall may include at least one opening, and directing heated gas into the heated cavity may include directing heated gas through the at least one opening, such as toward a predetermined portion of the exterior surface of the preform. In one embodiment, directing heated gas into the heated cavity includes directing heated air into the heated cavity.

[0010] In another embodiment, a system for molding an object may include an articulated mold having an axis, the articulated mold including a plurality of mold parts configured to collectively define a mold cavity for shaping the object when disposed at respective molding positions. The system also includes a plurality of actuators, each of the plurality of actuators operatively coupled to a respective mold part of the plurality of mold parts and configured to move the respective mold part along the axis from the respective molding position to a respective removal position to release the object. The system further includes a controller in communication with each of the plurality of actuators, the controller configured to independently actuate each of the plurality of actuators to move one of the plurality of mold parts along the axis from its molding position to its removal position while simultaneously keeping at least one other mold part of the plurality of mold parts stationary relative to the object to at least partially support the object. The mold cavity may include at least one of a tongue and a groove extending in a direction parallel to the axis. Additionally or alternatively, the multiple actuators may be configured to move the respective mold parts along an axis in the same direction from the respective molding positions to the respective ejection positions.

[0011] In one embodiment, the controller is configured to sequentially actuate each of the plurality of actuators. For example, the plurality of mold parts may include a bottom part and at least one side part distributed along an axis, and the at least one side part may be configured to move along an axis from its molding position to its removal position before the bottom part moves along an axis from its molding position to its removal position such that the bottom part supports the object during the movement of the at least one side part. In another embodiment, the plurality of mold parts may include an upper side part and a lower side part distributed along an axis, and the lower side part may be configured to move along an axis from its molding position to its removal position before the upper side part moves along an axis from its molding position to its removal position such that the upper side part supports the object during the movement of the lower side part. In yet another embodiment, the plurality of mold parts may include first and second adjacent parts distributed about an axis, and the first adjacent part may be configured to move along the axis from its molding position to its removal position before the second adjacent part moves along the axis from its molding position to its removal position such that the second adjacent part supports the object during movement of the first adjacent part.

[0012] In another embodiment, a method of releasing a molded object from a mold cavity defined by a plurality of mold parts of an articulated mold having an axis is provided. The method includes moving a first mold part of the plurality of mold parts along the axis from its molding position to its removal position, the object being supported by a second mold part of the plurality of mold parts during the movement of the first mold part. The method further includes subsequently moving the second mold part along the axis from its molding position to its removal position. In one embodiment, moving the first mold part includes actuating a first actuator operably coupled to the first mold part. Moving the second mold part may include actuating a second actuator operably coupled to the second mold part.

[0013] In one embodiment, when the first and second mold parts are in their respective molding positions, the first mold part is disposed below the second mold part along the axis. In another embodiment, when the first and second mold parts are in their respective molding positions, the first mold part is disposed above the second mold part along the axis. In yet another embodiment, when the first and second mold parts are in their respective molding positions, the first and second mold parts are disposed adjacently about the axis.

[0014] In another embodiment, an actuator system for use in a molding system includes a first actuator operably coupled to a first mold part and configured to move the first mold part along an axis in a first direction from a first molding position to a first removal position. The system also includes a second actuator operably coupled to a second mold part and configured to move the second mold part along an axis in a first direction from a second molding position to a second removal position. The system further includes a controller in communication with the first and second actuators and configured to independently operate the first and second actuators. In one embodiment, the controller is configured to sequentially operate the first and second actuators to move the respective mold parts in the first direction. For example, the controller may be configured to operate the first actuator before operating the second actuator. At least one of the first and second actuators may include a hydraulic actuator.

[0015] In one embodiment, the first and second actuators are configured to move the first and second mold parts, respectively, from the removal position toward the respective molding positions in a second direction opposite the first direction. For example, the controller may be configured to simultaneously actuate the first and second actuators to move the respective mold parts in the second direction.

[0016] In another embodiment, a method of manufacturing an object with an articulating mold having an axis is provided. The method includes positioning a plurality of mold parts of the articulating mold at respective molding positions to define a molding cavity, and molding the object in the molding cavity. The method also includes moving a first mold part of the plurality of mold parts along the axis from its molding position to its removal position, the object being supported by a second mold part of the plurality of mold parts during the movement of the first mold part. The method further includes subsequently moving the second mold part along the axis from its molding position to its removal position. In one embodiment, moving the first mold part includes actuating a first actuator operably coupled to the first mold part. Moving the second mold part may include actuating a second actuator operably coupled to the second mold part.

[0017] In one embodiment, when the first and second mold parts are in their respective molding positions, the first mold part is disposed below the second mold part along the axis. In another embodiment, when the first and second mold parts are in their respective molding positions, the first mold part is disposed above the second mold part along the axis. In another embodiment, when the first and second mold parts are in their respective molding positions, the first and second mold parts are disposed adjacently about the axis.

[0018] Molding the object may include blow molding the object from the preform. For example, blow molding the object may include stretch blow molding the object from the preform. The method may further include conditioning the preform prior to blow molding, where conditioning the preform includes positioning the preform within the heated cavity and directing heated gas into the heated cavity toward an outer surface of the preform. Conditioning the preform may further include positioning a nozzle having at least one sidewall within the heated cavity to at least partially surround the preform. The at least one sidewall may include at least one opening, and directing heated gas into the heated cavity may include directing heated gas through the at least one opening. For example, directing heated gas through the at least one opening may include directing heated gas toward a predetermined portion of the outer surface of the preform.

[0019] Various additional features and advantages of the present invention will become more apparent to those skilled in the art upon review of the following detailed description of one or more exemplary embodiments taken in conjunction with the accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate one or more embodiments of the present invention and, together with the general description above and the detailed description below, serve to explain one or more embodiments of the invention. [Brief description of the drawings]

[0020] [Figure 1] FIG. 1 is a perspective view of a modular interlocking container constructed in accordance with one embodiment of the present invention. [Diagram 2] FIG. 2 is a cross-sectional view of a heating station illustrating heated air being directed into the heating station during a conditioning operation, in accordance with one embodiment of the present invention. [Diagram 3]1A-1C are cross-sectional views of a molding station showing mold parts of an articulated mold in respective molding positions, in accordance with one embodiment of the present invention; [Figure 4] 4 is a partial cross-sectional view of the molding station of FIG. 3 illustrating pressurized gas directed into the molding station during a blow molding operation. [Diagram 5] 4 is a partial cross-sectional view of the molding station of FIG. 3 showing the side mold parts retracted during a demolding operation. FIG. [Figure 6] FIG. 6 is a view similar to FIG. 5 showing the bottom and side mold pieces retracted during a demolding operation. [Figure 7] 7 is a view similar to FIG. 6 showing the bottom and side mold pieces in their respective ejection positions and the top mold piece retracted during the demolding operation. FIG. [Figure 8] FIG. 8 is a view similar to FIG. 7 showing the bottom, side and top mold parts in their respective ejection positions and a conveying device releasing the blown container during the demolding operation. [Figure 9] FIG. 9 is a view similar to FIG. 8 showing containers dropping onto a collection ramp during a demolding operation. [Figure 10] FIG. 2 is a partial cross-sectional view of an alternative molding station in accordance with one embodiment of the present invention showing the lowermost horizontal section of a side mold part retracted during a demolding operation. [Figure 11] FIG. 11 is a view similar to FIG. 10, showing the middle and uppermost horizontal sections of the side mold parts retracted during the demolding operation. [Figure 12] FIG. 12 is a view similar to FIG. 11 showing the bottom mold piece and horizontal section retracted during the demolding operation. [Figure 13] FIG. 2 is a partial cross-sectional view of an alternative molding station according to one embodiment of the present invention showing a first vertical section of a lateral mold part retracted during a demolding operation. [Figure 14] FIG. 14 is a view similar to FIG. 13 but showing the second and third sections of the side mold parts retracted during the demolding operation. [Figure 15] FIG. 15 is a view similar to FIG. 14 showing the bottom mold piece and vertical section retracting during the demolding operation. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] Although exemplary embodiments are described below for use in stretch blow molding procedures, those skilled in the art will understand that the embodiments described herein can be used in other molding or die casting applications, including, but not limited to, extrusion blow molding, injection molding, or tumble molding.

[0022] As used herein, relative terms, e.g., first and second, top and bottom, etc., are used merely to distinguish one entity from another, or actions by one entity from actions by another, and do not necessarily require or imply an actual relationship or order between such entities or actions. The terms "comprises," "comprising," or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements may include not only those elements, but also other elements not expressly listed or alternatively inherent to such process, method, article, or apparatus. An element preceded by "comprises..." does not exclude the presence of additional identical elements in the process, method, article, or apparatus that includes the element, unless there is further constraint.

[0023] Embodiments of the present invention include systems, devices, and processes for manufacturing scalable, modular, interconnected, and connectable containers with a variety of uses and applications as described in U.S. Patent Application No. 14 / 777,210, filed September 15, 2015 ("the '210 Application"), which is incorporated by reference in its entirety. An exemplary first use of such containers is to transport and / or store flowable materials such as liquids or pourable solids. An exemplary second use of such containers is for creative modeling elements or for sturdy, low-cost, easily assembled block materials of a standardized nature. These embodiments can be used to build homes, warehouses, or other practical structures, including applications employed for disaster relief and humanitarian development projects, for military or defense purposes, and for other practical and modeling purposes. These embodiments include systems, devices, and processes for manufacturing a single container that is connected to other modular containers of the same or different sizes. Each modular container can slide-lock with the others to form robust walls and building structures that can be filled with fluids such as water, natural soil, sand, or other natural or engineered materials, thereby forming sturdy structures without the need for mortar and able to accommodate the uneven ground typically found in natural terrains.

[0024] Referring now to FIG. 1, an exemplary scalable, modular, interconnected container 10 is a hollow or partially hollow element that may be constructed from plastic, metal, resin, or composite materials. For example, in certain embodiments, the container is made from PE, PET, and / or other thermoplastic materials. Alternatively, the container 10 may be constructed from any rigid material that has suitably high strength and can provide sufficient rigidity to be stackable and connectable. The container 10 includes a plurality of upright walls 12. In the embodiment shown in FIG. 1, the container 10 is shown with eight longitudinal walls 12 of equal or varying heights, the eight longitudinal walls 12 forming a generally octagonal cross section. In other embodiments, the container 10 may be formed with variously shaped cross sections, such as, for example, circular, oval, polygonal, triangular, square, rectangular, or hexagonal. In any event, the container 10 may be configured to hold liquids, solids, and / or gases, and may be configured for use as a modeling or architectural element, with or without contents therein.

[0025] As shown, the container 10 includes a top section 14 including a neck 16 terminating in an opening 18 for filling the container 10 with any gas, fluid, granular material, flakes, or other material. In one embodiment, the container 10 may be manufactured with an airtight or pressure resistant seal or cap (not shown). The neck 16 is configured to mate with such a cap via threads 20 provided on the neck 16 to seal the contents within the container 10. Alternatively, the neck 16 may be configured to mate with a cap via a snap-fit ​​mechanism or any other suitable type of connection to form a suitable seal to prevent the contents of the container 10 from leaking out of the container 10 and / or to prevent foreign objects from entering the container 10. With a suitable seal formed between the neck 16 and the cap, the container 10 may be made liquid-tight for holding and transporting liquids (e.g., water, juice, edible oil) or may form a suitable seal for granular or powdered goods (e.g., grains, seeds, flour, flakes), household materials (e.g., soap, detergent), or building materials (e.g., cement, grout, sand). As shown, a ring 22 is formed near the base of the neck 16 and may provide a seat for a tamper-evident ring (not shown) which may be positioned between the base of the neck 16 and the threads 20, if desired.

[0026] The depicted container 10 includes a bottom end section 24 including a vertical interconnection receptor 25 (FIG. 4) formed as a recess therein, the vertical interconnection receptor 25 having a cross-sectional dimension dimensioned to receive a closure cap and ring 22 from a similar second container 10. The receptor 25 may have a limiting edge with a cross-sectional dimension dimensioned to engage the ring 22 and provide a stopper therewith during vertical interconnection with a similar second container 10.

[0027] In the illustrated embodiment, the container 10 provides a mechanism for laterally connecting with other containers 10 in a slidable interlocking manner. For example, lateral connection of multiple containers 10 may be enabled by tongues 26 and grooves 28 distributed at multiple locations laterally or on the interior side of the wall 12 of the container 10. In this regard, each tongue 26 is configured as a raised flat protrusion and / or a raised slightly rounded protrusion formed on or on the interior side of the respective wall 12. Each groove 28 is provided by recessing the respective wall 12 and is configured to receive a corresponding tongue 26 from a second container 10 having similar interlocking characteristics. In one embodiment, the tongues 26 and grooves 28 are formed along the wall 12 in a direction generally perpendicular to the top section 14 and the bottom section 24. As shown, the tongues 26 and grooves 28 may be positioned at every other location around the container 10, where a tongue 26 is positioned on every other wall 12 and a groove 28 is positioned on every other wall 12 between the tongues 26. Alternatively, one or more tongues 26 may be formed in one or more walls 12 and one or more grooves 28 may be formed in the remaining walls 12. In other embodiments, a container 10 may only have a groove 28 in its respective sidewall 12 while other containers 10 may only have a tongue 26 formed in its respective sidewall 12. Regardless of the distribution pattern, separate containers 10 may be connected to one another via the tongues 26 and grooves 28.

[0028] For this reason, a connection mechanism is provided using an undercut 30 in each tongue 26 that can be received in a corresponding extension cut 32 in each groove 28 of a similar second container 10. The undercut 30 and / or extension cut 32, together with the respective tongues 26 and / or grooves 28 of the containers, may be referred to as a "dovetail". The undercut 30 is formed such that each tongue 26 is joined to the respective wall 12 by a base that is narrower than the width of the tongue 26 at its outermost portion. Similarly, the width of each groove 28 including the respective extension cut 32 is greater than the width of each groove 28 excluding the respective extension cut 32, such that when the two containers 10 are connected to the corresponding grooves 28 via longitudinal sliding of the tongues 26, a width portion of the outer edge of the tongues 26 is fixed laterally behind the respective extension cut 32. It should be understood that each container 10 may include any number of tongues 26 and / or grooves 28 for interconnection as required. In one embodiment, the configuration of the container, including any of the tongues 26, grooves 28, undercuts 30, and / or extension cuts 32, may be similar to the containers described in the '210 application.

[0029] Referring now to FIG. 2, a preform 34 may be used to form the container 10. The preform 34 may be similar to the preforms described in the '210 application. For example, the preform 34 may be formed by injection blow molding in a preform mold cavity (not shown) as a closed-ended cylindrical article shaped approximately like a test tube. As shown, the preform 34 is initially formed with a generally cylindrical body 36 that includes the neck 16, opening 18, threads 20, and ring 22 of the final container 10. As described in more detail below, during the stretch blow molding process, the cylindrical body 36 may expand to conform to the inner wall of the mold, while the neck 16 may remain substantially the same in shape, size, and configuration. In the illustrated embodiment, the cylindrical body 36 terminates in a closed end 38 that includes a protruding tip 40 that is a product of the injection process. The thickness of the cylindrical body 36 and / or the closed end 38 may vary by design or product. For example, as described in more detail below, the closed end 38 may have a thickness greater than that of the cylindrical body 36 to facilitate plastic flow into the lower portion of the mold.

[0030] In any case, the preform 34 may undergo an ISBM technique, such as a hot parison technique, and after formation, the preform 34 is immediately transported to a conditioning station where the latent heat in the preform 34 obtained during the injection molding process can be utilized and fine-tuned for the ISBM operation to produce the container 10. In this regard, the distribution of heat in the hot end closed preform 34 can significantly affect the wall thickness and plastic flow of the final blown container 10. As such, temperature variations in the preform 34 can cause defects in the final blown container 10. For example, such variations can lead to undesirably thin walls in parts of the container 10 and / or the material being unable to flow properly in the mold due to cooling and hardening of the material. This can be particularly problematic for molds having complex geometries, such as deep and / or narrow crevices into which it is desired for the material to flow to form features such as the dovetail of the container 10.

[0031] 2, in one embodiment, an exemplary conditioning or heating station 42 for heating the exterior surface of the preform 34 is provided that overcomes certain problems or shortcomings of conventional preform heating stations, particularly when used to manufacture articles having complex geometries, such as the dovetail of the interconnect container 10. For example, it should be appreciated that conventional preform heating stations are typically unable to heat the exterior surface of the preform 34 to a sufficiently high temperature required to blow the preform 34 into a mold having complex geometries to form features such as the dovetail of the container 10. Conventional preform heating stations also are unable to accurately measure heat and precisely regulate the heat transferred from the heating station to the exterior surface of the preform 34. Additionally, conventional preform heating stations are unable to uniformly heat the exterior surface of the preform 34 and are unable to direct heat toward specific areas of the exterior surface of the preform 34 where it is desired that more material flow in the next stage of the blow molding process.

[0032] The exemplary heating station 42 can address challenges that exist when making a container 10 with a dovetail, but that do not typically exist when manufacturing conventional articles, such as conventional containers. In this regard, the container 10 may be particularly sensitive to heating temperatures, and the container 10 may desire to apply very high heat to the exterior surface of the preform 34 during the preform heating stage to allow material to flow into the dovetail and / or vertical interconnect receptor 25. The difference in wall thickness from one side of the container 10 to the other side can affect the strength of the dovetail connection, which in turn can significantly affect its function. The difference in wall thickness from the top of the container 10 to the bottom of the container 10 can affect the strength of the container 10, which in turn can affect the stability of the container 10. For example, insufficient wall thickness can lead to bursting during blow molding. The characteristics and properties of the container 10 vary significantly from top to bottom and side to side, due to the dovetail and vertical receptor, etc.

[0033] The exemplary heating station 42 is configured to heat an exterior surface of the preform 34 in preparation for blow molding. More specifically, the heating station 42 includes a manifold 44 defining a heating cavity 46 for receiving the preform 34, and a heater 48 in thermal communication with the heating cavity 46 and configured to heat a suitable gas, such as air. In one embodiment, the heating station 42 may further include a conveyor 49 configured to firmly grip the neck 16 of the preform 34 outside the heating cavity 46 with the cylindrical body 36 of the preform 34 positioned within the heating cavity 46. In this regard, the conveyor 49 includes first and second arms 50, 52 each having a groove or thread 53 for engaging the thread 20 of the neck 16 when the neck 16 is clamped between the first and second arms 50, 52. As shown, the first and second arms 50, 52 are carried by first and second supports 54, 56, respectively. As described in more detail below, the arms 50, 52 and / or supports 54, 56 may be movable to grip, release, and / or transport the preform 34 between the heating station 42 and other stations for performing the blow molding procedure. A core rod 57 may extend downwardly from the carrier 49 into the interior of the preform 34 to support the preform 34. In one embodiment, the core rod 57 may assist in heating and / or maintaining the temperature of the preform 34. For example, the core rod 57 may be heated to about 60° C. In one embodiment, the core rod 57 may be inserted into the preform 34 only during a portion of the time that the preform 34 is conditioned at the preform heating station 42. For example, the core rod 57 may be inserted into the preform 34 for about 3 seconds, while the cylindrical body 36 of the preform 34 may be positioned within the heated cavity 46 for about 10 seconds.

[0034] The heating station 42 further includes a blower 58 configured to blow gas heated by the heater 48 into the heating cavity 46 and toward the exterior surface of the preform 34, as indicated by arrow A1. Thus, unlike conventional heating or conditioning stations that typically utilize radiant heat, the heating station 42 uses the blown hot air to heat the exterior surface of the preform 34 in the heating cavity 46. By blowing the hot air onto the exterior surface of the preform 34, the exemplary heating station 42 allows the exterior surface of the preform 34 to be heated more quickly and more completely than conventional radiant heating methods. The heating station 42 may also provide the ability to heat the exterior surface of the preform 34 to a higher temperature in a shorter period of time compared to conventional radiant heating methods. In one embodiment, the temperature of the hot air in the heating cavity 46 at or near the exterior surface of the preform 34 may be about 200° C. to about 600° C. For example, the temperature of the hot air may be about 285° C. to about 315° C. In one embodiment, the temperature of the hot air may be about 300° C. Additionally or alternatively, the heating station 42 may be configured to expose the preform 34 to the injected hot air for approximately 10 seconds. Such 10 second period may be substantially the entire period during which the cylindrical body 36 of the preform 34 is within the heating chamber 46. In one embodiment, the pressure of the hot air blown onto the exterior surface of the preform 34 may be approximately 20 PSI. A portion of the hot air may escape between the neck 16 of the preform 34 and the arms 50, 52.

[0035] In one embodiment, the exemplary heating station 42 may be configured to direct the hot air injected toward specific points on the exterior surface of the preform 34, unlike conventional heating stations that cannot direct radiant heat toward specific areas that may require additional heating to enable effective blow molding. In this regard, mold wall temperature differentials, while undesirable, may cool certain portions of the blown preform before others, so long as they are not prevented by increasing heating of the preform 34 at corresponding locations. Similarly, the dovetail formed as the preform 34 is blown may cool faster as a result of protruding beyond the inner wall of the mold and interacting with the relatively thin outer wall of the mold. In certain embodiments, the closed end 38 of the preform 34 may be required to flow further than the cylindrical body 36 of the preform 34 to flow into the dovetail at the bottom of the mold, but may cool before filling the dovetail due to contact with the bottom wall of the mold. It is therefore desirable to direct heat to specific areas of the exterior surface of the preform 34 to prevent premature cooling of those areas within the mold and to maintain the preform 34 in a properly temperature-regulated, plasticized state prior to stretch blow molding.

[0036] To this end, the illustrated heating station 42 includes a nozzle 60 that includes a cylindrical sidewall or shell 62 and is disposed within the heating cavity 46 to at least partially surround the preform 34. The nozzle 60 is provided for targeted heating of specific regions of the exterior surface of the preform 34. In this regard, the sidewall 62 of the nozzle 60 includes a number of openings, such as holes 64 for directing gas therethrough. For example, hot air may be blown through the holes 64 in the sidewall 62 by the blower 58 and directed toward the predetermined regions of the exterior surface of the preform 34 where further heating is desired. In one embodiment, the holes 64 may have a cross-sectional dimension, such as a diameter, of about 0.200 inches to about 0.205 inches. Although generally circular holes 64 are shown, the openings in other embodiments may include slots, bends, vents, or any suitable type and / or shape of openings capable of directing the hot air directed toward specific or targeted areas of the exterior surface of the preform 34 inside the heating cavity 46. The nozzle 60 may partially or completely surround the preform 34 within the heating cavity 46 and may direct hot air toward a portion of the preform 34 at any desired location on the exterior surface of the preform 34. Additionally or alternatively, the holes 64 may be adjustable in terms of their position, cross-sectional size, and / or shape, etc. For example, the holes 64 may be opened, closed, moved, or redirected to direct the hot air toward areas of the exterior surface of the preform 34 where more heat is desired and / or away from areas of the exterior surface of the preform 34 where less heat is desired to create the desired flow in the next blowing stage.

[0037] In one embodiment, the holes 64 are arranged in a uniform pattern on the sidewall 62 of the nozzle 60 to provide an even heat distribution around the circumference of the nozzle 60. The holes 64 may be arranged in a pattern to minimize the overall temperature difference and maximize uniformity. In this regard, the pattern of holes 64 may be varied from the illustrated holes to encourage the blown air stream to move in a manner that smooths out any temperature gradients. In another embodiment, the holes 64 may be arranged to differentially apply heat around the circumference of the nozzle. The locations of particular holes 64 may correspond to the locations of various geometric features on the container 10 being blown, such as the dovetail.

[0038] The nozzle 60 may be configured to provide a gap between the preform 34 and a sidewall 62 of the nozzle 60 when the preform 34 is inserted into the heated cavity 46 and at least partially surrounded by the nozzle 60. For example, the outer diameter of the cylindrical body 36 of the preform 34 may be about 24 mm and the inner diameter of the cylindrical sidewall 62 of the nozzle 60 may be about 34.5 mm, thereby providing a gap of about 5.25 mm between the preform 34 and the sidewall 62.

[0039] Thus, heating station 42 may precisely direct more heat toward areas of the exterior surface of preform 34 where additional flow is desired in the next blow stage of the blow molding procedure, and precisely avoid heating areas of the exterior surface of preform 34 where additional flow is not desired in the next blow stage of the blow molding procedure.

[0040] It should be understood that the container 10 and / or the preform 34 may need to be heated to temperatures significantly higher than conventional containers. In some embodiments, the temperature desired in the blow molding process may reach the limit of the temperature to which the preform 34 can be heated without starting to melt or deform in the heating station 42. For example, the temperature of the hot air directed at the exterior surface of the preform 34 may approach the melting temperature of the material of the preform 34. Such deformation may prevent the container 10 from being properly blown. Therefore, it may be desired to increase the temperature of the air blown against the exterior surface of the preform 34 by increasing it very slightly, precisely to the point where the desired flow of material in the blow molding process is achieved without deformation of the preform 34.

[0041] To this end, the heating station 42 may be configured to precisely regulate and measure the temperature of the hot air delivered to the exterior surface of the preform 34. In this regard, the heating station 42 includes a temperature controller 66 in communication with the heater 48 and a thermometer 68 in communication with the temperature controller 66. The temperature controller 66 is configured to regulate the power of the heater 48 and thus the temperature of the air delivered to the exterior surface of the preform 34, and the thermometer 68 is configured to measure the temperature of the hot air delivered to the exterior surface of the preform 34. For example, the thermometer 68 may be positioned within the heating cavity 46 adjacent the exterior surface of the preform 34 to precisely measure the temperature of the air delivered to the exterior surface of the preform 34. In one embodiment, the thermometer 68 may be positioned within the nozzle 60. In any case, the thermometer 68 may be configured to transmit a signal indicative of the temperature measurement to the temperature controller 66, which may be used by the temperature controller 66 to determine the appropriate power of the heater 48 and adjust the power of the heater 48 accordingly. In this manner, the temperature controller 66 and thermometer 68 may provide for precise measurement of the temperature of the air blown onto the exterior surface of the preform 34 and precise adjustment of the temperature of the air blown onto targeted or specific areas of the exterior surface of the preform 34.

[0042] 3-9, in one embodiment, an exemplary blow molding station 70 is provided for forming a finished article, such as a container 10, from a preform 34, which overcomes various problems and / or shortcomings of conventional blow molding stations. As described in more detail below, the blow molding station 70 is configured to form the preform 34 into the finished shape of the container 10, including the dovetail. The blow molding station 70 addresses various challenges that are present when making the container 10, but that may not typically be present when manufacturing conventional articles, such as conventional containers. In this regard, conventional articles, such as conventional containers, are typically removed from a mold in an injection stretch blow molding machine via a clamshell opening process. The container 10 may not be suitable for removal from the mold via a clamshell opening process, for example, due to the undercut 30 and extension cut 32 of the dovetail. In one embodiment, the exemplary blow molding station 70 may enable the removal of a variety of interlocking articles that include deeper undercuts 30 and extension cuts 32 in the tongues 26 and grooves 28 than those described in the '210 application.

[0043] In one embodiment, the exemplary blow molding station 70 may be used in combination with the exemplary heating station 42, so that material flows to a better extent into the deeper crevices of the dovetail during the blow molding process. For example, the heating station 42 may be configured as a separate device that can be attached to the blow molding station 70 and modified to be operatively integrated therewith. In other words, the heating station 42 may be operatively synchronized with the process of the blow molding station 70 to heat the preforms 34 before they are automatically moved to the blow molding station 70 to be blown. Such a modular approach may enable, for example, retrofitting of an existing blow molding station 70.

[0044] It should be appreciated that various challenges and difficulties may exist during demolding, such as when manufacturing the container 10 after exposing the associated preform 34 to the exemplary preform heating station 42. For example, due to the heating process at the preform heating station 42, which favorably aids in the flow of material into and / or around the dovetail portion during the blow step, the container 10 may be "grabbed" more tightly by at least a portion of the mold as the mold is lowered to remove the container 10 following the blow stage due to static friction between the container 10 and the mold. As a result, the container 10 may undesirably deform or break during removal from the mold. Such deformed portions may include areas on or around the neck 16 of the container 10 that may be stretched, such that the neck 16 is held firmly in place while the wall 12 of the container 10 may be pulled down by the retracted mold or mold part due to static friction between the container and the mold. The resulting tension could stretch the neck 16, rendering the container 10 unusable and / or tearing the container 10 into separate pieces. As described below, the exemplary blow molding station 70 may be configured to address one or more of these problems.

[0045] In the illustrated embodiment, the blow molding station 70 includes an articulated mold 72 having a plurality of mold parts configured to collectively define a molding cavity 74 for molding the preforms 34 into a finished article, such as the container 10, when disposed within the respective mold parts. More specifically, the illustrated articulated mold 72 includes a bottom mold part 76, a generally cup-shaped side mold part 78, and first and second top mold parts 80, 82. The articulated mold 72 has a longitudinal axis L along which the bottom mold part 76, the side mold part 78, and the top mold parts 80, 82 are distributed. In the illustrated embodiment, the side mold part 78 includes at least one dovetail 84 including a tongue or groove extending in a direction parallel to the axis L to form a corresponding dovetail in the container 10.

[0046] As shown, the bottom mold part 76 is attached at its bottom end to a bottom mold platform 86 having a pair of openings 88 extending therethrough, the purpose of which will be explained below. The side mold part 78 is attached at its bottom end to a side mold platform 90 having a generally central opening 92 through which the bottom mold part 76 extends. In the illustrated embodiment, the side mold platform 90 itself may provide the molding surface for the container 10. The first and second top mold parts 80, 82 are attached at their outer sides to first and second top mold platforms 94, 96, respectively. In certain embodiments, any of the mold parts 76, 78, 80, 82 may be integrally formed with the respective platform 86, 90, 94, 96 as a one-piece part.

[0047] In the illustrated blow molding station 70, the conveying device 49, described above in connection with the heating station 42, is configured to firmly grip the neck 16 of the preform 34 outside the mold cavity 74 with the cylindrical body 36 of the preform 34 positioned therein. In this regard, the conveying device 49 may be configured to move (e.g., rotate and / or translate) from the heating station 42 to the blow molding station 70 to automatically transport the preform 34 from the heating cavity 46 to the mold cavity 74. In this manner, the heating station 42 may be integrated with the blow molding station 70. In another embodiment, the blow molding station 70 may include a dedicated conveying device (not shown).

[0048] In any event, the blow molding station 70 also includes a compressed gas conduit 98 and a nozzle 100 configured to extend at least partially into the neck 16 of the preform 34 to direct compressed gas, such as air, into the preform 34 for blowing the preform 34 into its final shape as the container 10, as indicated by arrow A2 (FIG. 4). A stretch rod 102 terminating in a stretch rod tip 104 extends through the conduit 98 and the nozzle 100 and is configured to lower the stretch rod tip 104 into the preform 34 to stretch the preform 34 into the mold cavity 74. In one embodiment, the preform 34 may be stretched by the stretch rod 102 and / or stretch rod tip 104 into the mold cavity 74 up to the bottom mold piece 76 (wherein the protruding tip 40 may interact with the bottom mold piece 76 to aid in centering the preform 34 within the mold cavity 74) and exposed to pressurized gas directed toward the interior of the preform 34 via the compressed gas conduit 98 and nozzle 100. For example, the pressure of the gas directed toward the interior of the preform 34 may be about 585 PSI. In one embodiment, the stretching of the preform 34 by the stretch rod 102 and / or stretch rod tip 104 and the blowing of the preform 34 with the compressed gas may be performed substantially simultaneously.

[0049] After blowing the container 10, the exemplary blow molding station 70 is configured to provide effective and efficient demolding of the final container 10 so as to minimize the risk of damage to the container 10 including the neck 16 and the dovetail including the tongue 26 and groove 28. In the illustrated embodiment, each of the mold parts 76, 78, 80, 82 and the arms 50, 52 are independently movable. More specifically, the bottom mold part 76 and the side mold part 78 are independently movable along the axis L, and the top mold parts 80, 82 and the arms 50, 52 are independently movable radially relative to the axis L. In this regard, the blow molding station 70 includes a plurality of actuators, such as a hydraulic actuator 110, each actuator operably coupled to a respective mold part 76, 78, 80, 82 or arm 50, 52. Each illustrated actuator 110 includes a cylinder 112 and a piston 114 extendable from and / or retractable into the respective cylinder 112, the piston 114 being coupled at its distal end to one of the platforms 86, 90, 94, 96 or arms 50, 52. In the illustrated embodiment, the piston 114 coupled to the lateral mold platform 90 extends through an opening 88 in the bottom mold platform 86 to reach the lateral mold platform 90. Although a hydraulic actuator 110 is illustrated, it should be understood that any suitable actuator may be used, such as a pneumatic actuator or a translation screw actuator.

[0050] The blow molding station 70 includes a controller 120 in communication with each of the actuators 110, the controller 120 being configured to independently actuate each of the actuators 110 to retract the respective mold parts 76, 78, 80, 82 and arms 50, 52 during the demolding process, and more specifically to independently "pull down" the bottom mold part 76 and the side mold parts 78 during the demolding process. In this regard, the controller 120 may be configured to sequentially actuate the actuators 110 of each of the platforms 86, 90, 94, 96 and / or supports 54, 56. For example, the controller 120 may be configured to first actuate the actuators 110 of the side mold parts 78 to retract their respective pistons 114 to move the side mold parts 78 downwardly along the axis L from their molding position to their ejection position, as indicated by arrow A3 (FIG. 5). As the lateral mold parts 78 move toward their ejection positions, the inner surfaces of the openings 92 of the lateral mold platforms 90 may move laterally along the outer surface of the bottom mold part 76. The controller 120 may sequentially actuate the actuators 110 of the bottom mold parts 76 to retract the pistons 114, respectively, to move the bottom mold part 76 downwardly along the axis L (FIG. 6) from its molding position toward its ejection position. In the illustrated embodiment, the controller 120 is configured to actuate the actuators 110 of the bottom mold parts 76 when the lateral mold platforms 90 contact or nearly contact the bottom mold platform 86. In this manner, the bottom and lateral mold parts 76, 78 may be moved together toward their respective ejection positions when the lateral mold platforms 90 reach the bottom mold platform 86, as indicated by arrow A4. Alternatively, bottom mold part 76 may begin moving toward its removal position almost immediately following the side mold parts 78 beginning to move and overcoming static friction with container 10 .

[0051] Thus, bottom mold piece 76 may provide support for container 10 being blown for at least a predetermined period of time until static friction is overcome between container 10 and side mold pieces 78. Once static friction is overcome and side mold pieces 78 move downward, any friction between container 10 and side mold pieces 78 becomes kinetic friction. Such kinetic friction may be lower than the static friction previously present between container 10 and side mold pieces 78. More specifically, this kinetic friction may be low enough to allow bottom mold piece 76 to move downward without stretching container 10 beyond the normal limits associated with breakage or rupture.

[0052] In other words, after the static friction between container 10 and side mold pieces 78 is overcome, the kinetic friction between container 10 and the moving side mold pieces 78 may be insufficient to deform or damage container 10. The support by bottom mold piece 76 may help prevent container 10 from being stretched beyond its limits and / or falling apart during the demolding process. In this manner, side mold pieces 78 may begin the demolding process before bottom mold piece 76 is lowered.

[0053] Once the bottom and side mold pieces 76, 78 have been moved towards or to their respective removal positions, the top mold piece 80, 82 may be moved laterally away from axis L in the opposite direction via the controller 120 and respective actuators 110, as shown by arrow A5 (FIG. 7). Similarly, the first and second arms 50, 52 may be moved laterally away from axis L in the opposite direction via the controller 120 and respective actuators 110, as shown by arrow A6, to release the container 10 and allow it to drop, as shown by arrow A7 (FIG. 8). In the illustrated embodiment, the container 10 is dropped onto a collection ramp 122, as shown by arrow A8 (FIG. 9), which may direct the container 10 towards a collection bin (not shown). When the container 10 exits the blow molding station 70, the controller 120 may be configured to actuate the actuators 110 to extend the respective pistons 114 to move the respective mold parts 76, 78, 80, 82 in a direction opposite to that described above, thereby returning each of the mold parts 76, 78, 80, 82 to their respective molding positions. For example, the controller 120 may simultaneously actuate the actuators 110 of the mold parts 76, 78, 80, 82 to return each of the mold parts 76, 78, 80, 82 to their respective molding positions to perform the next molding operation.

[0054] In one embodiment, the actuator 110 and / or controller 120 enable multiple, sequential, coordinated and / or timed movements of the bottom and side mold pieces 76, 78 along axis L such that the bottom and side mold pieces 76, 78 can be lowered sequentially, in parallel and / or carefully. Such coordination may enable removal of the container 10 without deformation or damage to the container 10, even when configured with deeply blown undercuts 30 and / or extension cuts 32, that would otherwise be caused by such deeply blown undercuts 30 and / or extension cuts 32 due to excessive friction or other strong side-by-side connections.

[0055] The controller 120 may be configured with timing software and / or hardware to coordinate the operation of the various actuators 110. For example, the controller 120 may include software that executes instructions and instructions for a microprocessor (not shown) to operate and / or synchronize the actuators 110. In one embodiment, the controller 120 may be configured to synchronize the actuators 110 with other components of the blow molding station 70 and / or other processes of the blow molding procedure for fast and efficient production.

[0056] For example, there is a limited amount of time between different blow molding process steps. Thus, the sequential "pulling" of the various mold parts 76, 78, 80, 82 must be accomplished within the time frame allotted to the pulling phase of the blow molding machine process. By coordinating and timing the actuation of the actuators 110 to move each mold part 76, 78, 80, 82 toward the removal position efficiently within that time frame, the minimum time required to sequentially overcome stiction may be available, which in turn minimizes the overall cycle time, thereby reducing the cost of manufacturing each container 10 and increasing productivity.

[0057] In one embodiment, the preform heating station 42 and the blow molding station 70 are integrated with a preform forming (e.g., injection molding) station for initially forming the preform 34 (not shown), and the transporter 49 may transport the formed preform 42 from the preform forming station to the preform heating station 42 and position the cylindrical body 36 of the preform 34 in the heating cavity 46. The core rod 57 may be lowered into the preform 34 substantially simultaneously. The cylindrical body 36 of the preform 34 may be maintained in the heating cavity 46 for about 10 seconds. Hot air may be directed toward the exterior surface of the preform 34 for substantially the entirety of this approximately 10 seconds, with the temperature of the hot air being about 285° C. to about 310° C. and the hot air pressurization being about 20 PSI. The transporter 49 may then transport the conditioned preform 34 to the blow molding station 70 and position the cylindrical body 36 of the preform 34 in the molding cavity 74. To blow the preform 34 into the final container 10, a stretch rod 102 may be lowered to the bottom mold part 76 to stretch the preform 34, and pressurized air may be directed into the interior of the preform 34 via compressed gas nozzle 100 at approximately 585 PSI. The container 10 may then be demolded and placed on a collection ramp 122.

[0058] In one embodiment, the preform forming station, the preform heating station 42, and the blow molding station 70 may be angularly displaced from one another by approximately 120 degrees. Thus, the transporter 49 may be configured to rotate between the stations at 120 degree intervals. In one embodiment, the preform 34 and / or container 10 may reside at each station for approximately 16.8 seconds. Thus, the overall cycle time for the preform 34 to be formed, conditioned, blown into the final container 10, and laid down may be approximately 50.4 seconds.

[0059] 10-12, an alternative exemplary blow molding station 70' is provided. The blow molding station 70' of this embodiment is substantially similar to that of the above-described embodiment, with the primary difference being that the lateral mold parts are divided into three horizontal sections 78a, 78b, 78c that are independently movable along axis L via actuators and controllers (not shown) similar to those described above. In this regard, the lowermost horizontal section 78a may be mounted to a lateral mold platform 90, while the remaining horizontal sections 78b, 78c may be mounted to separate platforms (not shown) or directly coupled to their respective actuators. In any event, the horizontal sections 78a, 78b, 78c may collectively define at least one dovetail that includes a tongue or groove (not shown) extending in a direction parallel to axis L to form a corresponding dovetail in the container 10.

[0060] Thus, in the illustrated embodiment, the lateral mold parts are divided into horizontal sections 78a, 78b, 78c arranged in a stack along axis L. In one embodiment, the horizontal sections 78a, 78b, 78c may be connected together using a connecting mechanism or mechanical fasteners (not shown), such as when in their respective molding positions. Although three such sections 78a, 78b, 78c are illustrated, any suitable number of sections may be used. For example, the number of separate horizontal sections 78a, 78b, 78c may be selected based on the amount of static friction that must be overcome and the number of sections necessary to overcome the static friction in a manner sufficient to avoid deformation or damage of the container 10 during the demolding process.

[0061] In one embodiment, the controller may be configured to involve a timed stroke sequence during the demolding process in which the horizontal sections 78a, 78b, 78c of the side mold parts are sequentially lowered, starting with the lowest horizontal section 78a first and ending with the highest horizontal section 78c. For example, each horizontal section 78a, 78b, 78c may remain stationary until the next lower horizontal section is lowered. In this manner, the stationary upper horizontal section 78b, 78c may support the container 10 for a short period of time, at least until static friction between the lower horizontal section 78a and the container 10 is overcome. Once static friction between the container 10 and the lower horizontal section 78a is overcome, thereby causing the lower horizontal section 78a to move downward as indicated by arrow A9 (FIG. 10), the reduced kinetic friction between the moving horizontal section 78a and the container 10 is low enough to allow the next higher horizontal section 78b to move downward without stretching the container 10. The upper horizontal section 78c may help support the container 10 as the lower horizontal sections 78a, 78b move downward, thus reducing the overall friction in the container 10 by a factor corresponding to the number of horizontal sections 78a, 78b, 78c. In the illustrated embodiment having three horizontal sections 78a, 78b, 78c, the initial friction that exists between the first to move (e.g., the lowest) horizontal section 78a and the container 10 is only about ⅓ of the friction that might otherwise exist between the container 10 and the entire side mold piece 78.

[0062] Once the static friction is overcome in the lower horizontal sections 78a, 78b, the remaining kinetic friction caused by the moving lower horizontal sections 78a, 78b is reduced, so that the container 10 is not deformed or damaged in the demolding process. The horizontal sections 78a, 78b, 78c can move downward one by one after the static friction is overcome in each section, as shown by arrow A10 (FIG. 11), and the remaining kinetic friction in the horizontal sections 78a, 78b, 78c moving downward to release the container 10 may be insufficient to deform or damage the container 10. Thus, the exemplary blow molding station 70′ can prevent the container 10 from being stretched and / or pulled apart into separate pieces during the demolding process.

[0063] In the illustrated embodiment, the bottom mold piece 76 is independently movable in a manner similar to the above-described embodiments. Thus, the controller may be configured to lower the bottom mold piece 76 after the side mold pieces (e.g., each of the horizontal sections 78a, 78b, 78c) have been at least partially lowered in a manner similar to that of the above-described embodiments, as shown by arrow A11 (FIG. 12) to support the container 10 during the demolding process. In another embodiment, the controller may be configured to lower the bottom mold piece 76 simultaneously with one or more of the horizontal sections 78a, 78b, 78c of the side mold pieces. For example, the controller may be configured to lower the bottom mold piece 76 simultaneously with the lowermost horizontal section 78a of the side mold pieces. In one embodiment, the bottom mold piece 76 may be integrally formed with the lowermost horizontal section 78a of the side mold pieces as a one-piece part.

[0064] The remaining features and advantages of blow molding station 70' are substantially similar to those of blow molding station 70 and are readily understood, and therefore will not be repeated for the sake of brevity.

[0065] 13-15, an alternative exemplary blow molding station 70″ is provided. The blow molding station 70″ of this embodiment is substantially similar to that of the embodiment described above with the primary difference being that the lateral mold parts are divided into four vertical sections 78e, 78f, 78g (three sections are shown), which are independently movable in a direction parallel to the axis L via actuators and controllers (not shown) similar to those described above. In this regard, each of the vertical sections 78e, 78f, 78g may be mounted to a respective dedicated platform 90a, 90b, 90c. At least one of the vertical sections 78e, 78f, 78g may define at least one dovetail including a tongue or groove (not shown) extending in a direction parallel to the axis L to form a corresponding dovetail in the container 10.

[0066] Thus, in the illustrated embodiment, the lateral mold parts are divided into vertical sections 78e, 78f, 78g disposed side-by-side about axis L. In one embodiment, sections 78e, 78f, 78g may be connected together using a connecting mechanism or mechanical fasteners (not shown), such as when in their respective molding positions. Although there are four such sections 78e, 78f, 78g in the illustrated embodiment, any suitable number of sections may be used. For example, the number of separate vertical sections 78e, 78f, 78g may be selected based on the amount of static friction that must be overcome and the number of sections necessary to overcome the static friction in a manner sufficient to avoid deformation or damage of container 10 during the demolding process.

[0067] In one embodiment, the controller may be configured to involve a timed stroke sequence during the demolding process, in which the vertical sections 78e, 78f, 78g of the lateral mold parts are sequentially lowered, starting with one or more vertical sections 78e, 78f, 78g, followed by the remaining vertical sections 78e, 78f, 78g in sequence. In this manner, the stationary vertical sections 78e, 78f, 78g may support the container 10 for a short period of time, at least until static friction is overcome by the moving vertical sections 78e, 78f, 78g. Once static friction is overcome in at least one vertical section 78e, thereby causing at least one vertical section 78e, 78f, 78g to move downward as indicated by arrow A12 (FIG. 13), the reduced kinetic friction between the moving vertical section 78e and the container 10 is low enough to allow one or more of the other vertical sections 78f, 78g to move downward without stretching the container 10. The stationary vertical sections 78e, 78f, 78g help support the container 10 as the other vertical sections 78e, 78f, 78g move downward, and therefore may reduce the overall friction in the container 10 by a factor corresponding to the number of vertical sections 78e, 78f, 78g. In the illustrated embodiment having four vertical sections 78e, 78f, 78g, the initial friction that exists between the first moving vertical section 78e and the container 10 may be about 1 / 4 of the friction that may otherwise exist between the container 10 and the entire side mold piece 78.

[0068] Once the static friction is overcome in the first vertical section 78e, the remaining kinetic friction caused by the moving vertical section 78e is reduced, so that the container 10 is not deformed or damaged by the demolding process. The vertical sections 78e, 78f, 78g can move downward one by one as shown by arrow A13 (FIG. 14) after the static friction is overcome in each section, and the remaining kinetic friction in the vertical sections 78e, 78f, 78g moving downward to release the container 10 may be insufficient to deform or damage the container 10. Thus, the exemplary blow molding station 70″ can prevent the container 10 from being stretched and / or pulled apart into separate pieces during the demolding process.

[0069] In the illustrated embodiment, the bottom mold piece 76 is independently movable in a manner similar to the embodiments described above. Thus, the controller may be configured to lower the bottom mold piece 76 after the side mold pieces (e.g., each of the vertical sections 78e, 78f, 78g) have been at least partially lowered in a manner similar to that of the embodiments described above, as shown by arrow A14 (FIG. 15) to support the container 10 during the demolding process. In another embodiment, the controller may be configured to lower the bottom mold piece 76 simultaneously with one or more of the vertical sections 78e, 78f, 78g of the side mold pieces. In one embodiment, the bottom mold piece 76 may be integrally formed with any of the vertical sections 78e, 78f, 78g of the side mold pieces as a one-piece part.

[0070] The remaining features and advantages of blow molding station 70" are substantially similar to those of blow molding station 70 and are readily understood, and therefore will not be repeated for the sake of brevity.

[0071] Although the present invention has been illustrated by the description of its various embodiments, these embodiments have been described in considerable detail, but it is not intended that these embodiments be limited or in any way restrict the scope of the appended claims to such details. Thus, the various features described herein may be used alone or in any combination. Additional advantages and modifications will be readily apparent to those skilled in the art. Thus, the invention in its broader aspects is not limited to the specific details and illustrative examples shown and described. It is therefore possible to depart from such details without departing from the scope of the general inventive concept. [Explanation of symbols]

[0072] 10 containers 12 Side wall 14 Upper Section 16 Neck 18 Aperture 20 threads 22 Ring 24 Bottom Section 25 Connection Receptor 26 tongue 28 Groove 30 Undercut 32 Extended Cut 34 Preform 36 Cylindrical body 38 Closed End 40 Protruding tip 42 Heating Station 44 Manifold 46 Heating Cavity 48 Heater 49 Transport Equipment 50 First Arm 52 Second Noarm 53 Thread 54 First Support 56 Second Support 57 Core Rod 58 Blower 60 Nozzles 62 Cylindrical side wall 64 holes 66 Temperature Controller 68 Thermometer 70, 70', 70” Blow Molding Station 72 Articulated Mold 74 Molding Cavity 76, 78, 80, 82 Molded parts 78a, 78b, 78c Horizontal Sections 78e, 78f, 78g Vertical Sections 84 Dovetail 86 Bottom mold platform 90 Lateral mold platform 94, 96 Upper mold platform 98 Compressed Gas Pipe 100 nozzles 102 Extension rod 104 Extension rod tip 110 Actuator 112 cylinders 114 Piston 120 Controller 122 Collection Ramp

Claims

1. 1. A system for molding an object, comprising: an articulated mold including a plurality of mold parts having a longitudinal axis and configured to collectively define a mold cavity for shaping the object when disposed in respective molding positions; a plurality of actuators, each of the plurality of actuators operatively coupled to a respective one of the plurality of mold parts and configured to move the respective one of the mold parts from the respective molding positions towards a respective removal position for releasing the object; a controller in communication with each of the plurality of actuators and configured to independently actuate each of the plurality of actuators to move one mold part of the plurality of mold parts from the molding position toward the removal position while at least one other mold part of the plurality of mold parts remains stationary relative to the object to at least partially support the object; Equipped with the plurality of mold parts include a bottom part, an upper side part, and a lower side part distributed along the longitudinal axis; the lower side part includes at least one of a tongue and a groove extending in a direction parallel to the longitudinal axis, In the forming position, the lower side part is positioned within the upper side part such that a portion of the lower side part is located closer to the object than the upper side part; The system is characterized in that the lower side part is configured to move along the longitudinal axis from the molding position to the removal position before the upper side part moves radially relative to the longitudinal axis from the molding position to the removal position such that the upper side part supports the object during the movement of the lower side part.

2. The system of claim 1 , wherein the controller is configured to sequentially actuate each of the plurality of actuators.

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