Multiple mold single press manufacturing system and method

Abstract

A multiple mold rotary system includes a frame and a mold support chassis rotatably supported by the frame and adapted to rotate relative to the frame about an axis of rotation. First and second injection molds are connected to the mold support chassis. The mold support chassis is selectively rotated relative to the frame to: (i) a first position where the first injection mold is operatively positioned for injection molding operations in an associated injection molding press and the second injection mold is located in a staging position where the second injection mold can be opened; (ii) a second position where the second injection mold is operatively positioned for injection molding operations in the associated injection molding press and the first injection mold is located in the staging position where the first injection mold can be opened. A multiple mold rotary injection molding process is also provided.

Description

Attorney Docket: CSAZ 200557W001MULTIPLE MOLD SINGLE PRESS MANUFACTURING SYSTEM AND METHODCross-Reference to Related Application

[0001] This application claims priority from and benefit of the filing date of U.S. provisional application Ser. No. 63 / 680,579 filed August 7, 2024, and the entire disclosure of said provisional application is hereby expressly incorporated by reference into the present application.Field

[0002] This disclosure relates to injection molding of parts for the automotive industry and others. More particularly, the present disclosure relates to a new and improved system and method for alternative use of multiple injection molds in a single injection molding press to reduce cycle times and increase productivity.Background

[0003] Certain known injection molding systems utilize a single injection mold in a single press, where the mold is opened and closed after each press cycle. In other known systems, two identical mold bottoms are used with a single mold top that is alternatively associated with the two mold bottoms to reduce cycle times. These known methods have been found to be suboptimal in certain instances where shorter cycle times are required to further increase press productivity.Summary

[0004] In accordance with one aspect of the present development, a multiple mold rotary system includes a frame; a mold support chassis rotatably supported by the frame and adapted to rotate relative to the frame about an axis of rotation; first and second injection molds connected to the mold support chassis, wherein the mold support chassis is selectively rotated about said axis of rotation relative to said frame to: (i) a first position where the first injection mold is operatively positioned for injection molding operations in an associated injection molding press and the second injection mold is located in a staging position where the second injection mold can be opened; (ii) a second positionAty Docket: CSAZ 200557W001 where the second injection mold is operatively positioned for injection molding operations in the associated injection molding press and the first injection mold is located in the staging position where the first injection mold can be opened.

[0005] In accordance with one aspect of the present development, the first and second positions of said mold support chassis are 180 degrees angularly offset with respect to each other.

[0006] In accordance with another aspect of the present development, the first and second injection molds are located respectively at first and second opposite ends of the mold support chassis and the axis of rotation is vertically oriented and passes through the mold support chassis between the opposite first and second ends.

[0007] In accordance with a further aspect of the present development, the system further includes a rotary actuator for selectively rotating the mold support chassis to and between the first and second positions.

[0008] In accordance with another aspect of the present development, the system further includes a stop system including first and second stops connected to the frame and a stop arm that rotates about the axis of rotation with the mold support chassis, wherein contact between the stop arm and the first stop defines the first position of the mold support chassis and contact between the stop arm and the second stop defines the second position of the mold support chassis.

[0009] In accordance with a further aspect of the present development, the system further includes a mold opening system for opening either one of: (i) the first injection mold when the first injection mold is located in the staging position; (ii) the second injection mold when the second injection mold is located in the staging position. The mold opening system can include: a lift beam connected to the frame; a lift beam actuator for selectively moving the lift beam between a raised position and a lowered position; left and right lift arms each movably connected to the lift beam and each adapted to move between a retracted position and an extended position, wherein the left and right lift arms, when moved to their respective extended positions when the lift beam is in its lowered position and located adjacent one of the first and second injection molds located in the staging position, are adapted to capture a mold top of the one of the first and second injection molds to the lift beam for movement of the mold top with the lift beam when the lift beamAty Docket: CSAZ 200557W001 moves from its lowered position toward its raised position. The mold support chassis can include left and right lock bars and the mold top includes left and right lock blocks that each move between a locked position and an unlocked position, wherein the left and right lock blocks are engaged with the left and right lock bars to capture the mold top adjacent a corresponding mold bottom of the one of the first and second injection molds located in the staging position when the left and right lock blocks are respectively located in the locked position. The left and right lift arms can respectively move the left and right lock blocks from the locked position to the unlocked position when the lift beam is in its lowered position and located adjacent the one of the first and second injection molds located in the staging position and the left and right lift arms are moved to their respective extended positions. The left and right lock bars can include respective a lock recesses into which the left and right lock bars respectively extend when the first and second lock bars are in their respective locked positions. The system can further include a left spring operatively positioned between the mold top MT and the left lock block for continuously biasing the left lock block toward its locked position; and, a right spring operatively positioned between the mold top MT and the right lock block for continuously biasing the right lock block toward its locked position. The lift beam actuator can be connected to a gantry beam that extends over the staging position. The system can further include a safety hook connected to the gantry beam and adapted to selectively engage a catch portion of the lift beam to prevent movement of the lift beam from its raised position to its lowered position. A safety hook actuator can be operatively connected between the gantry beam and the safety hook for selectively moving the safety hook between an engaged position and a disengaged position, wherein said safety hook is positioned to engage the catch portion of the lift beam when the safety hook is in its engaged position and wherein the safety hook is disengaged from the catch portion of the lift beam when the safety hook is in its disengaged position.

[0010] In accordance with another aspect of the present development, the system further includes a left lift arm actuator operatively connected between the lift beam and the left lift arm for selectively moving the left lift arm between the extended and retracted positions of the left lift arm; and, a right lift arm actuator operatively connected betweenAty Docket: CSAZ 200557W001 the lift beam and the right lift arm for selectively moving the right lift arm between the extended and retracted positions of the right lift arm.

[0011] In accordance with another aspect of the present development, the system further includes at least one first extrusion support connected to and movable with the mold support chassis adjacent the first injection mold for supporting a first associated extrusion placed in the first injection mold; and at least one second extrusion support connected to and movable with the mold support chassis adjacent the second injection mold for supporting a second associated extrusion placed in the second injection mold.

[0012] In accordance with a further aspect of the present development, each of the first and second injection molds includes a retractable core handle to prevent contact between the core handle and the frame.

[0013] In accordance with another aspect of the present development, the system can further include a platform located adjacent and beneath the mold support chassis, and a heating platen can be connected to the platform and located at the staging position to heat the second injection mold when the mold support chassis is located in the first position and to heat the first injection mold when said mold support chassis in located in the second position.

[0014] In accordance with a further aspect of the present development, a method for using first and second injection molds in an associated press includes: supporting a first injection mold and a second injection mold on a rotatable chassis; selectively rotating the rotatable chassis about a vertical axis of rotation between: (i) a first position where the first injection mold is operatively positioned for injection molding operations in an associated injection molding press and the second injection mold is located in a staging position where the second injection mold can be opened; (ii) a second position where the second injection mold is operatively positioned for injection molding operations in the associated injection molding press and the first injection mold is located in the staging position where the first injection mold can be opened.

[0015] In accordance with a further aspect of the present development, the method can further include: unlocking and opening the second injection mold when the mold support chassis is located in the first position; and, unlocking and opening the first injection mold when the mold support chassis is located in the second position.Atty Docket: CSAZ 200557W001

[0016] In accordance with another aspect of the present development, the method further includes heating the second injection mold when the mold support chassis is located in the first position and heating the first injection mold when the mold support chassis in located in the second position.Brief Description of the Drawings

[0017] FIG. 1 is a front view of a known injection molding system for natural or synthetic rubber material like EPDM (dense or sponge) including a press and a single mold or die that includes a single top mold portion and a single bottom mold portion.

[0018] FIG. 2 is a top view of the known injection molding system of FIG. 1 .

[0019] FIG. 3 is an isometric view of an embodiment of a multiple mold (each mold has its own top and bottom) single press injection molding system for natural or synthetic rubber material like EPDM (dense or sponge) provided in accordance with an embodiment of the present development;

[0020] FIG. 4A is a front view of the system of FIG. 3, with the first and second molds in first (active) and second (inactive) positions, respectively .

[0021] FIG. 4B is a top view of the system of FIG. 3, but with the position of the molds switched with respect to each other such that the first and second molds are located in second (inactive - mold opening position to load and upload the part) and first (active - mold on injection process) positions, respectively.

[0022] FIG. 5 is a front view similar to FIG. 3 but omits the injection mold press to simplify the drawing.

[0023] FIG. 6 is a partial isometric view of a rotary table portion of the multiple mold single press injection molding system of FIG. 5, with first and second molds located in a first intermediate position.

[0024] FIG. 7 is another partial isometric view of the rotary table portion of the multiple mold single press injection molding system of FIG. 5 that is similar to FIG. 6 but omits certain frame structures for clarity and shows the first and second molds in a second intermediate position that is different than the first position.Atty Docket: CSAZ 200557W001

[0025] FIG. 8 is a partial view of the multiple mold single press injection molding system of FIG. 5, showing a stop system for the rotary table and rotary cylinder.

[0026] FIG. 9 is a top view of the stop system of FIG. 8 with portions removed for clarity.

[0027] FIG. 10 is a side view of a mold alignment system of the present development.

[0028] FIG. 11 is a partial section front view of the mold alignment system of FIG. 10 in its operative state with the press in a closed position or configuration.

[0029] FIG. 12 is a section view that shows a sprue configuration for the multiple mold single press injection molding system of FIG. 5.

[0030] FIG. 13 is a partial isometric view of a mold locking system provided in accordance with an embodiment of the present development.

[0031] FIG. 14 is a front section view of the mold locking system of FIG. 13 and shows a mold opener portion of the system operatively engaged with the mold for opening the mold (the mold is shown with the right side lock engaged and the left side lock disengaged).

[0032] FIGS. 15A provides an enlarged view of the right side lock and right side portion of the mold opener (with the lock in the engaged or extended position).

[0033] FIG. 15B provides an enlarged view of the left side lock and left side portion of the mold opener (with the lock in the disengaged or retracted position).

[0034] FIG. 16 is a partial front view of the multiple mold single press injection molding system of FIG. 5 showing the mold opening system operative engaged with a mold top portion and supporting the mold top portion in an opened or lifted position to provide access to the mold bottom portion.

[0035] FIG. 17 is a top view of the rotary table showing optional extrusion supports respectively associated with each mold that rotate with the respective molds for supporting portions of an extrusion being molded in the mold.

[0036] FIG. 18 shows that the molds can include a retracting core handle to eliminate contact between the core handle and the frame of the system.Aty Docket: CSAZ 200557W001Detailed Description

[0037] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of one or more embodiments of the present disclosure as defined by the claims and their equivalents. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the various embodiments described herein can be made without departing from the scope and spirit of the present disclosure. Various exemplary embodiments of the present disclosure are not limited to the specific details of different embodiments and should be construed as including all changes and / or equivalents or substitutes included in the ideas and technological scope of the appended claims. In describing the drawings, where possible similar reference numerals are used for similar elements.

[0038] FIG. 1 is a front view of a known injection molding system for natural or synthetic rubber material like EPDM (dense or sponge) including a press P' and a single mold or die M' that includes a single mold top MT' and a single mold bottom MB'. FIG. 2 is a top view of the known injection molding system of FIG. 1. As is generally known in the art, the mold top MT' is separated from the mold bottom MB' between cycles of the injection molding press P to insert any part to be insert-molded or overmolded and / or to remove finished parts from the mold M'. Because the mold M' includes a single mold bottom MB' and a single mold top MT, the cycle times of the press P are relatively slow to allow for insertion of any part to be insert-molded or overmolded, and for the molded part to be formed, cooled, and removed from the mold M' so that the cycle can then be repeated.

[0039] FIG. 3 is an isometric view of an embodiment of a multiple mold single press injection molding system S for natural or synthetic rubber material like EPDM (dense or sponge) provided in accordance with an embodiment of the present development. FIG. 4A is a front view of the system of FIG. 3, and FIG. 4B is a top view of the system of FIG. 3. FIG. 5 is a front view similar to FIG. 3 but omits the injection mold press P to simplify the drawing. The multiple mold single press injection molding system S can include a conventional injection molding press P as described in relation to FIGS. 1 and 2 (the pressAty Docket: CSAZ 200557W001P is shown in a simplified manner with parts removed for clarity). Unlike know systems, however, the system S comprises a multiple mold rotary system RS located adjacent to the press P that selectively positions one of two or more different injection molds M in an active position where the mold is operatively positioned relative to the press P for formation of an injection molded part within the active mold, while simultaneously positioning at least another one of the molds M in an inactive staging position where the inactive mold is spaced from the press P and operatively associated with a mold opening system for opening the inactive mold to allow for part insertion and / or removal relative to the inactive mold. In the illustrated embodiment discussed herein the mold rotary system S cycles two different injection molds, a first mold M1 and a second mold M2, each of which molds M1,M2 is a complete injection mold M including a bottom portion MB and a mating top portion MT.

[0040] The mold rotary system RS comprises a frame F that supports a rotary table RT that rotates the first and second molds M (M1 ,M2) alternatively between the active position within the press P and the staging position outside the press P and accessible for opening the mold. In the illustrated example, the rotary table RT comprises a rotatable mold support chassis CH that rotates about a vertical axis of rotation X relative to a fixed, horizontally extending platform PT that is located adjacent and beneath the rotating mold support chassis CH. The platform PT can be defined by a generally circular periphery as shown and must be dimensioned and conformed so as not to interfere with the press P. Likewise, the rotatable mold support chassis CH must be dimensioned and shaped so as to be rotatable as described without contacting the press P. The rotatable mold support chassis CH comprises opposite first and second ends CH1 ,CH2 that respectively support the first and second molds M1 ,M2, and the axis of rotation X for the mold support chassis CH is located between the opposite first and second ends CH1.CH2, such as at a midpoint between the first and second ends CH1 ,CH2 in which case the axis of rotation X bisects the mold support chassis CH. More particularly, as shown in FIG. 6, each mold M1 ,M2 comprises: (i) a mold bottom MB support on the rotatable mold support chassis CH; and (ii) a mold top MT that is selectively connected to or lifted away from the respective mold bottom MB as described in more detail below.Aty Docket: CSAZ 200557 O01

[0041] The rotatable mold support chassis CH is rotatably supported relative to the platform PT and rotates about the vertical axis of rotation X in a reciprocal manner through at least a 180 degree arc such that either the first mold M1 or the second mold M2 can be located in the active position operatively positioned within the press P so as to be the active mold (shown as mold M1 in FIGS. 3 & 4B) while the other mold M (the mold M2 in FIGS. 3 & 4B) is the inactive mold located in the staging position 180 degrees offset from the active position and 180 degrees offset from the press P where the inactive mold can be opened for molded part removal and optional insert of a part to be insert-molded or overmolded. As noted, the positions of the active and inactive molds M1 ,M2 can be swapped by rotation of the rotatable mold support chassis CH through a 180 degree arc relative to the platform PT and frame F such that either mold M (or any mold if more than two molds are provided) can be the active mold while the other mold is the inactive mold.

[0042] FIGS. 6 and 7 respectively show the rotatable mold support chassis CH rotated to first and second intermediate angular positions where the first and second molds M1 ,M2 are located at respective angular positions between the active position and the staging position.

[0043] The frame F comprises an overhead gantry beam G that extends over the staging position for the inactive mold. The gantry beam G of the frame supports a mold opening system O that selectively engages the mold top MT of the inactive mold that is located in the staging position and lifts the mold top MT vertically upward and away from the mold bottom MB as shown in FIGS. 4A, 5, and 16. The opening system O comprises a lift beam LB that is operatively connected to a lift actuator LA that can comprise a hydraulic cylinder, a pneumatic cylinder, an electric linear actuator or other lift mechanism that selectively vertically raises and lowers the lift beam LB relative to the gantry beam G of the frame F between an elevated or raised position as shown in FIGS. 3, 4A, 5 and a lowered position as shown in FIG. 14. As described in more detail below and as shown in FIG. 14, when the lift beam LB is located in its lowered position, the mold opening system O is configured to selectively engage the mold top MT of the inactive mold M (M1 or M2) located in the staging position so that the mold top MT can be lifted away from its corresponding mating mold bottom MB by activation of the lift actuator LA to vertically raise the lift beam LB to its raised position. Correspondingly, a mold top MT engaged andAty Docket: CSAZ 200557W001 being carried by the lift beam LB in the raised position can be selectively lowered into operative engagement with its corresponding mold bottom MB by operating the lift actuator LA to vertically lower the lift beam LB from its raised position to its lowered position where the mold top MT carried by the lift beam LB is once again operatively mated with its corresponding mold bottom MB. When the mold top MT is separated from the mold bottom, a finished part can be removed from the inactive mold bottom MB and a new workpiece part to be insert-molded or overmolded (if any) can optionally be inserted into the mold bottom MB before the mold top MT is reconnected to the mold bottom MB.

[0044] As shown in FIGS. 4A, 5, and 16, the opening system O can comprise a safety hook H pivotally or otherwise movably connected to the frame gantry beam G and selectively movable to an engaged position (as shown) where the safety hook is engaged with a catch portion C that is connected to and / or formed as a part of the lift beam LB (the catch portion C is shown as a pin) such that the safety hook H engages and retains the pin or other catch portion C when the safety hook H is in its engaged position. In the event of a failure or malfunction of the lift actuator LA, the lift beam LB is restrained in its elevated position as shown in FIG. 16 by the engagement of the safety hook H with the catch portion C. The safety hook H is operatively connected to a hydraulic or pneumatic cylinder or other safety hook actuator SA that selectively moves the safety hook H between its engaged and disengaged positions. In one example, the safety hook H is spring-biased into its engaged position as shown in FIG. 16 and is automatically engaged with the pin or other catch portion C when the lift beam LB is moved upwardly to its elevated position and the catch portion C contacts and deflects the safety hook to move over the safety hook H such that the safety hook H is thereafter spring-biased into engagement with the catch portion C. The safety hook H can be selectively pivoted or otherwise moved by the safety hook actuator SA to its disengaged position where it is moved away from and disengaged from the pin or other catch portion C to allow the lift beam LB to be lowered by the lift actuator LA toward its lowered position.

[0045] FIGS. 13 - 15B illustrate a mold locking system LS provided in accordance with an embodiment of the present development. Each mold M1 ,M2 is provided with a locking system LS to keep the mold closed with the mold top MT and mold bottom MB operatively engaged at all times during the injection molding operation in the press P and alsoAty Docket: CSAZ 200557W001 thereafter when the mold M1 ,M2 is being rotated from the active position in the press P to the staging position, and still further until the mold M is opened by the opening system O. As shown in FIGS. 13 and 14, each mold M comprises left and first (first and second) vertically extending lock bars KB1.KB2 that are fixedly secured to and that extend upwardly from the rotating chassis CH of the rotary table RT. Each lock bar KB1.KB2 comprises a lock recess KR that can be provided by a through-hole that extends laterally partially or completely through the lock bar LB. The mold top MT correspondingly comprises left and right (first and second) lock blocks K1 ,K2 that are movable relative to the mold top MT between an extended or locked position (FIG. 13, 15A) and a retracted or unlocked position (FIG. 15B). The lock system LS further comprises first (left) and second (right) springs N1,N2 respectively operatively positioned between the mold top MT and the first (left) and second (right) lock blocks K1 ,K2 for continuously biasing the respective lock blocks K1 ,K2 toward their respective extended / locked positions. When the mold top MT is operatively mated with its corresponding mold bottom MB, the first and second lock blocks K1 ,K2 extend into the respective lock recesses KR of the first and second lock bars KB1.KB2 such that the mold top MT is fixedly secured to the mold bottom MB in an operative position for molding operations. In contrast, when the first and second lock blocks K1 ,K2 are retracted and not engaged with the respective lock recesses KR of the first and second lock bars KB1 ,KB2, the mold top MT is released from and can be lifted away from the mold bottom MB.

[0046] The mold locking system LS can be selectively unlocked by the mold opening system O as shown in FIGS. 14 - 15B. FIG. 14 shows the lift bar LB in its lowered position located adjacent the mold top MT. The lift beam LB comprises left and right (first and second) movable lift arms R1 ,R2 that are each slidably or otherwise movably engaged with the lift bar LB and that each move between an extended or engaged position (as shown for the left I first lift arm R1) and a retracted or disengaged position (as shown for the right / second lift arm R2). When the lift bar LB is in its lowered position and located adjacent an inactive mold M located in the staging position, the lift arms R1 ,R2 are vertically positioned such that laterally inward movement of the lift arms R1 ,R2 from the retracted / disengaged position to the extended / engaged position causes the left and right lift arms R1,R2 to respectively engage the left and right lock blocks K1 ,K2 and move theAty Docket: CSAZ 200557W001 lock blocks K1 ,K2 from their extended / locked positions (see the right lock block K2 of FIG. 14 and also FIG. 15A) to the to the retracted / unlocked position (see the left lock block K1 of FIG. 14 and also FIG. 15B). The lift arms R1 ,R2 and lock blocks K1 ,K2 are configured to allow for the lift arms R1,R2 to contact and retract the lock blocks K1,K2 without the lift arms R1,R2 entering the lock recesses KR or otherwise engaging the lock bars KB1.KB2, for example, by the lift arms R1 ,R2 moving adjacent the first and second lock bars KB1 ,KB2 and contacting protruding portions of the respective lock blocks K1 ,K2. The lift bar LB comprises at least one lift arm actuator such as a pneumatic or hydraulic cylinder or an electric actuator such as a linear actuator for selectively moving the left and right lift arms R1 ,R2 to and between their retracted and extended positions. Both the left and right lift arms R1,R2 can be controlled by a single lift arm actuator and they can be moved together in unison or, as shown in the illustrated example, the lift bar LB comprises independent left and right (first and second) lift arm actuators RA1 ,RA2 that are respectively operatively connected to the left and right lift arms R1 ,R2 for selectively independently moving the left and right lift arms R1 ,R2 to and between their extended and retracted positions.

[0047] The left and right lift arms R1,R2 each comprise a mold top engagement leg RL that extends horizontally or otherwise inwardly toward the center of the inactive mold M such that when the lift arms R1 ,R2 are extended to unlock the left and right lock blocks K1 ,K2 the mold top engagement legs RL extend into engagement with the mold top MT and engage and support the mold top MT and capture the mold top MT to the lift beam LB such that upward movement of the lift bar LB from its lowered position to its raised position will result in the mold top MT being lifted vertically upward by the mold top engagement legs RL away from the mold bottom MB as shown in FIG. 16.

[0048] As shown in FIGS. 5 and 7 - 9, the multiple mold rotary system RS further comprises a rotary actuator RX connected to the frame F and operatively engaged with the rotatable mold support chassis CH for selectively rotating the mold support chassis CH in a reciprocal manner about the axis of rotation X. In one example, the rotary actuator RX comprises a hydraulically or pneumatically actuated rotary cylinder or an electrically operated rotary actuator. A stop system ST is provided to limit rotation of the mold support chassis CH in first and second opposite angular direction and to define first and secondAty Docket: CSAZ 200557 WO01 stop positions for the mold support chassis CH that are located 180 degrees away from each other, with a first stop position corresponding to the mold support chassis CH being positioned in a first operative position when the first mold M1 is located in the active position (operatively positioned in the press P) and the second mold M2 is located in the staging position (see FIG. 3), and with a second stop position corresponding to the mold support chassis CH being positioned 180 degrees angularly offset from the first operative position such that the first mold M1 is located in the staging position and the second mold M2 is located in the active position operatively positioned in the press P (see FIG. 4B). The rotary actuator RX can be operatively connected to a drive shaft DX that is coaxially positioned along the axis of rotation X and that is non-rotatably coupled or otherwise operatively engaged with the rotating mold support chassis CH to rotate the mold support chassis CH about the axis of rotation X in response to operation of the rotary actuator RX. In the illustrated example, the stop system ST comprises at least one stop arm ST1 non-rotatably connected to the drive shaft DX such that rotation of the drive shaft DX causes angular movement of the stop arm ST1 about the axis of rotation X. The stop system further comprises first and second stops ST2a,ST2b that are connected to the frame F in respective fixed positions such that the first and second stops ST2a,ST2b are respectively contacted by the stop arm ST1 when the mold support chassis CH is positioned in its first and second operative positions. The first and second stops ST2a,ST2b can each include a spring or other resilient bumper to act as a shock absorber (the stop arm ST1 can also optionally include a spring or other resilient bumper).

[0049] As seen in FIG. 7, the rotary system RS can comprise a heating platen HP connected to the platform PT and located in alignment with the staging position. The heating platen HP can include one or more heating elements HE such as electrical heating elements that heat the heating platen HT so that the inactive mold M1 ,M2 located in the staging position will be positioned on top of the heating platen HP and will be maintained at the desired elevated temperature. The rotary system S can further comprise and insulation plate IP located adjacent and covering an underside of the heating platen HP that is opposite the exposed upper surface over which the mold M1 ,M2 will be positioned to thermally insulate the heating platen to improve efficiency.Aty Docket: CSAZ 200557W001

[0050] As shown in FIG. 10 and 11, because the molds M1,M2 are moved into and out of operative position in the press P, it is necessary to ensure that the active mold operatively located in the press P is properly positioned and aligned in the press P. As such, the platen PN of the press P is configured to include one or preferably at least two centering bars CB that extend downwardly therefrom and that are adapted to be received into corresponding alignment openings AO defined in the mold top MT (see the enlarged section front view of FIG. 11) when the active mold M1 ,M2 is operatively engaged with and installed in the press P. The centering bars CB are received in the respective corresponding alignment openings AO located in the mold top MT (particularly the mold top plate MTP) when the press platen PN is moved into engagement with the active mold M1 ,M2 before the sprue cone SC mates with the injection nozzle of the press P to ensure that the mold M is properly aligned in the press P before the sprue cone SC is mated with the press injection nozzle. In the illustrated example, the centering bars CB are connected to a centering plate CT that is bolted or otherwise fastened to the press platen PN. As shown in FIGS. 10 and 12, a compound runner extension CE is connected to the mold top plate and includes an outer frustoconical projecting portion CE1 that is closely received into a corresponding opening defined in the centering plate CT and that is adapted to mate with the injection nozzle of the press P to minimize residual material between the press injection nozzle and the mold top MT.

[0051] In one example, the rotary system RS is used to overmold rubber onto a midportion of an elongated natural or synthetic rubber extrusion profile EX (FIGS. 12 & 17) to form a corner element or other irregular shape. The extrusion profile can be a sealing strip or “weather strip” for a vehicle. As shown in FIG. 17, the rotary system S can comprise at least one optional extrusion support ES that respectively associated with each mold M1 ,M2 and connected to the rotating mold support chassis CH to rotate with the rotating chassis CH relative to the platform PT about the axis of rotation X. As shown, at least one first extrusion support ES is associated with and located adjacent the first mold M1 and at least one second extrusion support ES is associated with and located adjacent the second mold M1. More particularly, in the illustrated example, left and right extrusion supports ES are associated with the first mold M1 and are respectively located on opposite left and right lateral sides of the first mold M1 , and left and right extrusionAtty Docket: CSAZ 200557W001 supports ES are associated with the second mold M2 and are respectively located on opposite left and right lateral sides of the second mold M2. When an inactive mold M2 is located in the staging area and is opened with its mold top lifted away from the mold bottom MB, an operator places the extrusion EX in the mold bottom MB and routes the extrusion EX out of the mold bottom MB onto one or more of the extrusion supports ES. Thereafter, the mold M2 can be closed by lowering the mold top MT to mate and lock onto the mold bottom MB as described above so that the inactive mold M2 can be rotated to the active position. The operator will also remove the finished part from a mold M1 ,M2 when the mold is moved to the staging area and opened.

[0052] FIG. 18 shows that each mold M1 ,M2 can include a retracting core handle CH to eliminate contact between the core handle CH and the frame F of the rotary system RS and / the press P.

[0053] The terms "include" or "may include" used in the present disclosure indicate the presence of disclosed corresponding functions, operations, elements, and the like, and do not limit additional one or more functions, operations, elements, and the like. In addition, it should be understood that the terms "include", “including”, “have” or "having" used in the present disclosure are to indicate the presence of components, features, numbers, steps, operations, elements, parts, or a combination thereof described in the specification, and do not preclude the presence or addition of one or more other features, numbers, steps, operations, elements, parts, or a combination thereof.

[0054] The terms "or" or "at least one of A or / and B" used in the present disclosure include any and all combinations of words enumerated with them. For example, "A or B" or "at least one of A or / and B" mean including A, including B, or including both A and B.

[0055] Although the terms such as "first" and "second" used in the present disclosure may modify various elements of the different exemplary embodiments, these terms do not limit the corresponding elements. For example, these terms do not limit an order and / or importance of the corresponding elements, nor do these terms preclude additional elements (e.g., second, third, etc.) The terms may be used to distinguish one element from another element. For example, a first mechanical device and a second mechanical device all indicate mechanical devices and may indicate different types of mechanical devices or the same type of mechanical device. For example, a first element may beAtty Docket: CSAZ 200557W001 named a second element without departing from the scope of the various exemplary embodiments of the present disclosure, and similarly, a second element may be named a first element.

[0056] It will be understood that, when an element is mentioned as being "connected" or "coupled" to another element, the element may be directly connected or coupled to another element, and there may be an intervening element between the element and another element. On the contrary, it will be understood that, when an element is mentioned as being "directly connected" or "directly coupled" to another element, there is no intervening element between the element and another element.

[0057] The terms used in the various exemplary embodiments of the present disclosure are for the purpose of describing specific exemplary embodiments only and are not intended to limit various exemplary embodiments of the present disclosure. As used herein, the singular forms are intended to include the plural forms as well, unless the context clearly indicates otherwise.

[0058] All of the terms used herein including technical or scientific terms have the same meanings as those generally understood by an ordinary skilled person in the related art unless they are defined otherwise. The terms defined in a generally used dictionary should be interpreted as having the same meanings as the contextual meanings of the relevant technology and should not be interpreted as having inconsistent or exaggerated meanings unless they are clearly defined in the various exemplary embodiments.

[0059] This written description uses examples to describe the disclosure, including the best mode, and also to enable any person skilled in the art to make and use the disclosure. Other examples that occur to those skilled in the art are intended to be within the scope of the invention if they have structural elements that do not differ from the same concept or that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the same concept or from the literal language of the claims. Moreover, this disclosure is intended to seek protection for a combination of components and / or steps and a combination of claims as originally presented for examination, as well as seek potential protection for other combinations of components and / or steps and combinations of claims during prosecution.Aty Docket: CSAZ 200557W001

[0060] Although specific advantages have been enumerated above, various embodiments may include some, none, or all of the enumerated advantages. Although exemplary embodiments are illustrated in the figures and description herein, the principles of the present disclosure may be implemented using any number of techniques, whether currently known or not. Moreover, the operations of the systems and apparatuses disclosed herein may be performed by more, fewer, or other components, and the methods described herein may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order.

[0061] To aid the Patent Office and any readers of this application and any resulting patent in interpreting the claims appended hereto, applicants do not intend any of the appended claims or claim elements to invoke 35 USC 112 (f) unless the words “means for” or “step for” are explicitly used in the particular claim.

[0062] The disclosure has been described with reference to the preferred embodiments. Obviously, modifications and alterations will occur to others upon reading and understanding the preceding detailed description. It is intended that the disclosure be construed as including all such modifications and alterations.

Claims

Aty Docket: CSAZ 200557W001Claims1. A multiple mold rotary system comprising: a frame; a mold support chassis rotatably supported by the frame and adapted to rotate relative to the frame about an axis of rotation; first and second injection molds connected to the mold support chassis, wherein said mold support chassis is selectively rotated about said axis of rotation relative to said frame to:(i) a first position where said first injection mold is operatively positioned for injection molding operations in an associated injection molding press and said second injection mold is located in a staging position where the second injection mold can be opened;(ii) a second position where said second injection mold is operatively positioned for injection molding operations in the associated injection molding press and said first injection mold is located in the staging position where the first injection mold can be opened.

2. The multiple mold rotary system as set forth in claim 1 , wherein said first and second positions of said mold support chassis are 180 degrees angularly offset with respect to each other.

3. The multiple mold rotary system as set forth in claim 1 , wherein the first and second injection molds are located respectively at first and second opposite ends of said mold support chassis and said axis of rotation is vertically oriented and passes through said mold support chassis between said opposite first and second ends.

4. The multiple mold rotary system as set forth in claim 1 , further comprising a rotary actuator for selectively rotating the mold support chassis to and between the first and second positions.Atty Docket: CSAZ 200557W0015. The multiple mold rotary system as set forth in claim 4, further comprising a stop system including first and second stops connected to said frame and a stop arm that rotates about the axis of rotation with the mold support chassis, wherein contact between said stop arm and said first stop defines said first position of said mold support chassis and contact between said stop arm and said second stop defines said second position of said mold support chassis.

6. The multiple mold rotary system as set forth in claim 1 , further comprising a mold opening system for opening either one of: (i) the first injection mold when the first injection mold is located in the staging position; (ii) the second injection mold when the second injection mold is located in the staging position.

7. The multiple mold rotary system as set forth in claim 6, wherein the mold opening system comprises: a lift beam connected to the frame; a lift beam actuator for selectively moving the lift beam between a raised position and a lowered position; left and right lift arms each movably connected to the lift beam and each adapted to move between a retracted position and an extended position, wherein said left and right lift arms, when moved to their respective extended positions when said lift beam is in its lowered position and located adjacent one of the first and second injection molds located in said staging position, are adapted to capture a mold top of said one of said first and second injection molds to the lift beam for movement of said mold top with said lift beam when said lift beam moves from its lowered position toward its raised position.

8. The multiple mold rotary system as set forth in claim 7, wherein the mold support chassis comprises left and right lock bars and said mold top comprises left and right lock blocks that each move between a locked position and an unlocked position, wherein said left and right lock blocks are engaged with said left and right lock bars to capture the mold top adjacent a corresponding mold bottom of said one of said first and second injection molds located in said staging position when said left and right lock blocks are respectivelyAty Docket: CSAZ 200557 WO01 located in the locked position.

9. The multiple mold rotary system as set forth in claim 8, wherein the left and right lift arms respectively move the left and right lock blocks from the locked position to the unlocked position when said lift beam is in its lowered position and located adjacent said one of the first and second injection molds located in said staging position and said left and right lift arms are moved to their respective extended positions.

10. The multiple mold rotary system as set forth in claim 9, further comprising: a left lift arm actuator operatively connected between the lift beam and the left lift arm for selectively moving the left lift arm between the extended and retracted positions of the left lift arm; and, a right lift arm actuator operatively connected between the lift beam and the right lift arm for selectively moving the right lift arm between the extended and retracted positions of the right lift arm.

11. The multiple mold rotary system as set forth in claim 1 , further comprising: at least one first extrusion support connected to and movable with the mold support chassis adjacent the first injection mold for supporting a first associated extrusion placed in the first injection mold; at least one second extrusion support connected to and movable with the mold support chassis adjacent the second injection mold for supporting a second associated extrusion placed in the second injection mold.

12. The multiple mold rotary system as set forth in claim 1, wherein each of the first and second injection molds comprises a retractable core handle to prevent contact between said core handle and said frame.

13. The multiple mold rotary system as set forth in claim 8, wherein the left and right lock bars comprise respective a lock recesses into which the left and right lock bars respectively extend when the first and second lock bars are in their respective lockedAty Docket: CSAZ 200557W001 positions.

14. The multiple mold rotary system as set forth in claim 13, further comprising: a left spring operatively positioned between the mold top MT and the left lock block for continuously biasing the left lock block toward its locked position; a right spring operatively positioned between the mold top MT and the right lock block for continuously biasing the right lock block toward its locked position.

15. The multiple mold rotary system as set forth in claim 7, wherein said frame comprises a gantry beam that extends over the staging position wherein the lift beam actuator is connected to the gantry beam.

16. The multiple mold rotary system as set forth in claim 15, further comprising a safety hook connected to the gantry beam and adapted to selectively engage a catch portion of said lift beam to prevent movement of the lift beam from its raised position to its lowered position.

17. The multiple mold rotary system as set forth in claim 16, further comprising a safety hook actuator operatively connected between the gantry beam and the safety hook for selectively moving the safety hook between an engaged position and a disengaged position, wherein said safety hook is positioned to engage the catch portion of the lift beam when the safety hook is in its engaged position and wherein said safety hook is disengaged from the catch portion of the lift beam when the safety hook is in its disengaged position.

18. The multiple mold rotary system as set forth in claim 1 , further comprising: a platform located adjacent and beneath the mold support chassis; a heating platen connected to the platform and located at said staging position to heat said second injection mold when said mold support chassis is located in said first position and to heat said first injection mold when said mold support chassis in located in said second position.Atty Docket: CSAZ 200557W00119. A method for using first and second injection molds in an associated press, said method comprising: supporting a first injection mold and a second injection mold on a rotatable chassis; selectively rotating said rotatable chassis about a vertical axis of rotation between:(i) a first position where said first injection mold is operatively positioned for injection molding operations in an associated injection molding press and said second injection mold is located in a staging position where the second injection mold can be opened;(ii) a second position where said second injection mold is operatively positioned for injection molding operations in the associated injection molding press and said first injection mold is located in the staging position where the first injection mold can be opened.

20. The method as set forth in claim 19, further comprising: unlocking and opening said second injection mold when said mold support chassis is located in said first position; unlocking and opening said first injection mold when said mold support chassis is located in said second position.

21. The method as set forth in claim 20, further comprising heating said second injection mold when said mold support chassis is located in said first position and heating said first injection mold when said mold support chassis in located in said second position.

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