Collapsible core for injection molding apparatus

Abstract

A collapsible core portion for forming a core for use in an injection molding operation forming a molded part is disclosed. The collapsible core portion includes a housing and a plurality of outer surface-defining portions disposed for displacement relative to the housing. Each one of the outer surface-defining portions defines a portion of a molding surface of the mold core. An actuator is operably coupled to the outer surface-defining portions for transitioning the collapsible core portion from a first configuration wherein the outer surface-defining portions are disposed in a first position relative to the housing such that the collapsible core portion is configured for use in the injection molding operation, to a second configuration wherein the outer surface-defining portions are disposed in a second position relative to the housing such that the collapsible core portion is disposed in a collapsed configuration for de-molding of the molded part.

Description

COLLAPSIBLE CORE FOR INJECTION MOLDING APPARATUSCROSS-REFERENCE TO RELATED APPLICATION(S)

[0001] This application claims the benefit of U.S. Provisional Application No. 63 / 743,857, filed January 10, 2025, the contents of which are hereby incorporated by reference in their entirety.TECHNICAL FIELD

[0002] This application relates to a collapsible core for use in injection molding applications for producing molded workpieces.BACKGROUND

[0003] Injection molding operations for producing molded workpieces or products use cooperating mold plates that are displaceable relative to one another. When the mold plates are disposed in a closed configuration, the mold plates, together, define a mold cavity corresponding to the shape of the workpiece or product to be molded. At least one of the mold plates defines a cavity, often referred to as a cavity plate, while one or more other mold plates cooperate to define a mold core. The mold core is configured for disposition within the cavity defined by the cavity plate when the mold plates are brought together into the closed configuration. While the mold plates are disposed in the closed configuration, molten material is injected into the mold cavity defined by the cooperating mold plates for forming the workpiece. The mold plates are then cooled to cause solidification of the molded part. To remove or “eject” the finished workpiece from the mold, the mold plates are separated from one another, and the mold core is retracted from within the cavity defined by the molded workpiece allowing the molded workpiece or product to be demolded or ejected from the mold.

[0004] When the molded product includes undercuts formed within a cavity defined by the finished product, de-molding of the molded part (or finished product) can present challenges as the mold core must define both the largest diameter associated with the molded profile of the product that is defined by the mold core, as well as the smallest diameter associated with the molded profile, which defines the undercut (or material overhang), and must be able to retract past the smallest diameter, or smallest opening, defined by the product for the finished product to be successfully de-molded or ejected from the mold. For products that include one or more undercuts,removal of the molded product is more challenging as the male and female components of the mold cannot simply be moved apart to release the molded product. To allow for proper de-molding of a finished product having one or more undercuts, mold cores that are capable of collapsing to a size that is smaller than the smallest opening (or largest undercut) defined by the finished product are often used. Collapsible cores allow the core (or male) portion of the mold to collapse during the de-molding process thereby bringing the mold core into a configuration wherein the outermost dimension of the mold core is smaller than the smallest opening defined by the largest undercut formed on the molded product. Once the mold core is disposed in the collapsed configuration, the core can be retracted relative to the finished product thereby freeing the finished product from the mold.

[0005] While collapsible cores for de-molding finished products having undercuts are known, the size of undercut that can be successfully de-molded using collapsible core technology is typically limited given that only a certain degree of collapse of the mold core can be achieved within the standard range of travel of the mold plates in standard injection molding apparatuses and due to other spacing and size constraints associated with moving components of the mold core. For example, conventional collapsible cores are often limited to forming molded parts wherein the length of the undercut or the distance by which the undercut projects or extends into the internal cavity or space defined by the molded product is within the range of about 12-17% of the outside diameter, or outer dimension of the molded part that defines, in part, the cross-sectional area of the molded part. In general, the undercut is limited to about 12% of the outer dimension (or outer diameter) for mold cores formed from six segments, while larger undercuts of about 17% of the outer dimension (or outer diameter) are generally achievable for mold cores comprising twelve segments. Accordingly, molded products having larger undercuts are difficult to produce due to challenges associated with the de-molding of the product. Therefore, collapsible cores that allow for a greater degree of collapse for forming products having larger undercuts are desirable. Collapsible cores that allow for a greater degree of collapse within standard range of travel of mold plates in typical injection molding operations are also desirable.BRIEF SUMMARY OF SOME EXAMPLE EMBODIMENTS

[0006] According to a broad aspect of the present disclose there is provide a collapsible core portion for use in forming a mold core for an injection molding operation for forming a molded part, comprising: a guide housing, a plurality of outer surface-defining portions mounted to the guide housing and disposed for displacement relative to the guide housing, each one of the plurality of outer surface-defining portions, independently, defining an outermost molding surface that forms part of a molding surface of the mold core, and an actuator operably coupled to each one of the plurality of outer surface-defining portions for transitioning the collapsible core portion from: (i) a first configuration, wherein the plurality of outer surface-defining portions are disposed in a first position relative to the guide housing and together define a first outer dimension of the collapsible core portion, wherein the first outer dimension defines a first cross-sectional area in a plane that extends perpendicular to a central axis of the collapsible core portion, wherein the first cross-sectional area is bounded, in part, by the outermost molding surface of each one of the plurality of outer surface-defining portions, to (ii) a second configuration, wherein the plurality of outer surface-defining portions are disposed in a second position relative to the guide housing and together define a second outer dimension of the collapsible core portion that is less than the first outer dimension, wherein the second outer dimension defines a second cross-sectional area in the plane that extends perpendicular to the central axis of the collapsible core portion, wherein the second cross-sectional area is bounded, in part, by the outermost molding surface of each one of the plurality of outer surface-defining portions such that the second-cross-sectional area is less than the first cross-sectional area. While the collapsible core portion is disposed in the first configuration, the collapsible core portion is configured for cooperating with a supporting center core portion to define the molding surface of the mold core, wherein the molding surface corresponds to a shape defined by an interior surface of the molded part, and while the collapsible core portion is disposed in the second configuration, the collapsible core portion is configured for removal from within the molded part. The guide housing, the plurality of outer surface-defining portions and the actuator are cooperatively configured such that: transitioning of the collapsible core portion from the first configuration to the second configuration is in response to rotation of the actuator relative to the guide housing about the central axis of the collapsible core portion, which rotation effects linear displacement of each one of the plurality of outer surface-defining portions relative to the guide housing along a respective outer surface-defining portion displacement axis from the first position to the second position, each outer surface-defining portiondisplacement axis, independently, extending in a plane that is perpendicular to the central axis of the collapsible core portion about which the actuator rotates.

[0007] According to another broad aspect of the present disclosure, there is provided a mold plate for use in an injection molding operation for forming a molded part comprising: a collapsible core portion mounted to the mold plate, wherein the collapsible core portion includes: a guide housing, a plurality of outer surface-defining portions mounted to the guide housing and disposed for displacement relative to the guide housing, each one of the plurality of outer surface-defining portions, independently, defining an outermost molding surface for forming a part of a molding surface of a mold core for forming the molded part, and an actuator operably coupled to each one of the plurality of outer surface-defining portions for transitioning the collapsible core portion from: (i) a first configuration, wherein the plurality of outer surface-defining portions are disposed in a first position, relative to the guide housing, and together define a first outer dimension of the collapsible core portion, wherein the first outer dimension defines a first cross-sectional area in a plane that extends perpendicular to a central axis of the collapsible core portion, wherein the first cross-sectional area is bounded, in part, by the outermost molding surface of each one of the plurality of outer surface-defining portions, and a (ii) second configuration, wherein the plurality of outer surface-defining portions are disposed in a second position, relative to the guide housing, and together define a second outer dimension of the collapsible core portion that is less than the first outer dimension, wherein the second outer dimension defines a second cross-sectional area in the plane that extends perpendicular to the central axis of the collapsible core portion, wherein the second cross-sectional area is bounded, in part, by the outermost molding surface of each one of the plurality of outer surface-defining portions such that the second-cross-sectional area is less than the first cross-sectional area, wherein an actuation mechanism is operably coupled to the collapsible core portion for transitioning the collapsible core portion from the first configuration to the second configuration. While the collapsible core portion is disposed in the first configuration, the mold plate is configured for cooperating with at least a second mold plate, the at least a second mold plate including a supporting center core portion configured for mating relationship with the collapsible core portion such that disposition of the mold plate in a stacked arrangement with the at least second mold plate is with effect that the supporting center core portion extends through a central opening defined by the collapsible core portion and is disposed in mating relationship with the plurality of outer surface-defining portions for forming a mold corethat defines a molding surface corresponding to a shape defined by an interior surface of the molded part. While the collapsible core portion is disposed in mating relationship with the supporting center core portion, while the mold plate and the at least a second mold plate are disposed in the stacked relationship, there is an absence of gaps between the plurality of outer surface-defining portions of the collapsible core portion with the supporting center core portion, and while the mold plate and the at least a second mold plate are disposed in the stacked relationship such that the collapsible core portion is disposed in mating relationship with the supporting center core portion, displacement of the core mold plate relative to the at least a second mold plate along a mold core plate axis of displacement that extends parallel to a central axis of the collapsible core portion such that the mold plate is displaced away from the at least a second mold plate by a first distance is with effect that: the collapsible core portion is axially displaced away from at least a portion of the supporting center core portion by a first distance such that a plurality of gaps are formed between surfaces of the outer surface-defining portions and adjacent surfaces defined by at least a portion of the supporting center core portion such that further axial displacement of the core mold plate relative to the at least a second mold core plate such that the collapsible core portion is displaced farther away from the supporting center core portion is permissible, and displacement of the mold plate relative to the at least a second mold plate by a second distance along the mold plate axis of displacement such that there is an absence of projecting of the supporting center core portion into the central opening defined by the collapsible core portion is with effect that the mold plate is disposed in an actuation-effective position relative to the at least second core mold plate such that actuation of the actuation mechanism for transitioning the collapsible core portion from the first configuration to the second configuration is permissible; and actuation of the actuation mechanism is with effect that the actuator rotates relative to the guide housing for effecting displacement of the plurality of outer surface-defining portions from the first position to the second position such that the cross-sectional area defined, in part, by an outer dimension of the outer surface-defining portions is reduced from the first cross-sectional area to the second cross-sectional area.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Reference will now be made, by way of example, to the accompanying drawings which show an example embodiment of the present application, and in which:

[0009] Figure 1 is a perspective view of an example embodiment of a collapsible mold core including a collapsible core portion according to an example embodiment of the present disclosure while the collapsible mold core is in an operational molding configuration.

[0010] Figure 1A is a perspective view of an example embodiment of a collapsible mold core including a collapsible core portion according to an example embodiment of the present disclosure while the collapsible mold core is in an operational molding configuration wherein the guide housing and actuator housing of the collapsible core portion are removed for ease of illustration.

[0011] Figure 2 is an exploded perspective view of the collapsible mold core of Figure 1 wherein the supporting center core portion and the actuator housing of the collapsible core portion are removed for ease of illustration.

[0012] Figure 3 is a top perspective view of the collapsible mold core of Figure 2 in an assembled configuration including the actuator housing and with the supporting center core portion removed for ease of illustration.

[0013] Figure 4 is a top plan view of the collapsible mold core of Figure 3 in an assembled stated wherein the collapsible core portion is disposed in an operable, molding configuration and configured for mating with the supporting center core portion.

[0014] Figure 5 is a top plan view of the mold core of Fig. 3 while disposed in a fully collapsed configuration.

[0015] Figure 6 is a bottom plan view of a mold plate including a plurality of collapsible mold cores according to the example embodiments of the present disclosure.

[0016] Figure 7 is a front, perspective view of the mold plate of Fig. 6.

[0017] Figure 8 is a detail view of a portion of the actuation mechanism for actuating the collapsible mold cores mounted to the mold plate of Figures 6 and 7.

[0018] Figure 9 is a bottom view of the actuation mechanism, as viewed from the bottom of the mold plate of Figure 6, with the mold plate removed for ease of illustration.

[0019] Figure 10 is a detail rear perspective view of the portion of the mold plate actuation mechanism of Figure 8.

[0020] Figure 11 is a top plan view of the collapsible mold core according to the present disclosure in the “closed” or operational molding configuration.

[0021] Figure 12 is a top plan view of the collapsible mold core according to the present disclosure in a first or partially collapsed configuration wherein the collapsible core portion and the outer core portions of the supporting center core portion have been axially displaced relative to the inner core portion.

[0022] Figure 13 is a top plan view of the collapsible mold core according to the present disclosure wherein the collapsible core portion has been axially displaced relative to the outer core portions of the supporting center core portion such that the collapsible core portion axially clear of the supporting center core portion.

[0023] Figure 14 is a top plan view of the collapsible mold core according to the present disclosure wherein the collapsible core portion has been rotated about the longitudinal axis of the mold core such that the collapsible core portion is in a second or fully collapsed configuration.

[0024] Figure 15 is a side elevation view of the collapsible mold core as shown in Fig. 11.

[0025] Figure 16 is a side elevation view of the collapsible mold core as shown in Fig. 12.

[0026] Figure 17 is a side elevation view of the collapsible mold core as shown Fig. 13.

[0027] Figure 18 is a side elevation view of the collapsible mold core as shown in Fig. 14.

[0028] Figure 19 is a top perspective view of the collapsible mold core as shown in Figs. 11 and 15.

[0029] Figure 20 is a top perspective view of the collapsible mold core as shown in Figs. 12 and 16.

[0030] Figure 21 is a top perspective view of the collapsible mold core as shown in Figs. 13 and 17.

[0031] Figure 22 is a top perspective view of the collapsible mold core as shown in Figs. 14 and 18 wherein the collapsible core portion is in the second or fully collapsed state.

[0032] Figure 23 is a top plan view of an exemplary finished molded product formed using the collapsible mold core according to the present disclosure.

[0033] Figure 24 is a cross-sectional view of the molded product of Figure 23 taken along section line A- A as shown in Figure 23.

[0034] Similar reference numerals may have been used in different figures to denote similar components.DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

[0035] Referring to Figure 1, there is shown a top perspective view of a mold core 100 incorporating a collapsible core portion 10 according to an example embodiment of the present disclosure. The mold core 100 is shown in a closed, or operational molding configuration wherein the collapsible core portion 10 is disposed in a co-operative configuration with a supporting, center core portion 20 for forming the mold core 100. While the collapsible core portion 10 is disposed in cooperation with the supporting center core portion 20 in the closed or operational molding configuration, the collapsible core portion 10 and the center core portion 20, together, define an outer molding surface 12 that corresponds in shape to an interior surface of the product to be molded. In some embodiments, for example, the outer molding surface 12 includes at least one recessed surface 14 for defining an undercut of a molded product.

[0036] While the collapsible mold core portion 10 is disposed in cooperation with the center core portion 20, such that the mold core 100 is disposed in the closed or operational molding configuration, the mold core 100 is configured for co-operating with a corresponding cavity defined by a cavity mold plate (not shown). In use, while the mold core 100 disposed in the closed, or operational molding configuration, the mold core 100 is brought into a cooperating arrangement with the corresponding cavity mold plate such that the mold core 100 becomes disposed within the cavity defined by the cavity mold plate with effect that a mold cavity (not shown) is formed by the space provided between the outer molding surface 12 defined by the mold core 100 and a surface defined by the cavity of the cavity mold plate. The mold cavity defined by the mold core 100 and the corresponding cavity, together, define the overall shape of the product to be molded.

[0037] For use in an injection molding application, the mold core 100 is mounted to a mold plate that is disposed in reciprocating arrangement with the cavity mold plate (not shown) such that the mold core plate and the mold cavity plate can be brought together into a closed configuration to form the mold cavity. Once the mold core plate and mold cavity plate are brought together to define the mold cavity, molten material is injected into the mold cavity to form the molded product. The mold is then cooled to allow for solidification of the molten material in the mold cavity. Once cooled, the mold cavity plate and mold core plates must be separated or moved away from each other, such that the mold core is retracted from within the molded product to allow for de-molding or extraction of the molded part from the mold.

[0038] Referring now to Figures 20 and 21 there is shown an example embodiment of a molded product 200 that may be formed by the mold core 100 illustrated in Fig. 1 or Fig. 1A. In the subject example embodiment, the molded product 200 is a generally cylindrical body having a base 201 that defines a closed end of the product 200 and a sidewall 202 extending upwardly from the base 201 and terminating at an open end 204. Accordingly, the base 201 and sidewall 202 of the molded product 200 together define an open interior space 203 wherein the maximum diameter or the maximum cross-sectional area of the open interior space 203 is defined by the inner surface of the sidewall 202. In the subject example embodiment, the molded product 200 includes a projection or overhang of material 206 that extends into the open interior space 203 from the inner surface of the sidewall 202 (see, for instance, Fig. 21) thereby defining an undercut in the finished molded product, the extent of the undercut formed in the molded product 200 corresponding to the distance, Du, by which the projection 206 extends into the open interior space 203, relative to the inner surface of the side wall 202. The projection 206 is formed, in part, by the recessed surface 14 defined by the mold core 100 during the injection molding operation when the mold core 100 is brought into co-operation with the cavity of the cavity plate to define the mold cavity for receiving the molten material. Accordingly, in a molded product 200 having an internal projection 206 that defines an undercut, the interior space 203 defined by the molded product 200 has a maximum internal cross-sectional area defined by the largest internal dimension, Dmax, of the inner surface of the side wall 202 and a minimum internal cross-sectional area defined by the minimum internal dimension, Dmin, of the molded product 200, wherein the minimum internal dimension, Dmin, is defined by the largest undercut or largest projection 206 that extends into the open interior space 203. In some embodiments, for example, the distance, Du, defined by the overhang or internal projection 206 is at least 20% of Dmax,

[0039] To allow for proper de-molding or extraction of a molded part in instances where the molded part includes one or more undercuts, the mold core 100 must be able to collapse such that the overall outer dimension of the mold core 100 is smaller than the smallest opening defined by molded product, the smallest opening defined by the molded product defined by the largest undercut formed on molded part. In the example embodiment of the molded product 200 illustrated in Figs. 23 and 24, the mold core 100 must be able to collapse to an overall outer dimension that is less than the minimum internal dimension, Dmin, defined by the projection 206, to ensure that the mold core 100 can be successfully removed from the molded product 200 through the openingdefined by the projection 206 (or undercut). Accordingly, the cross-sectional area occupied by the components of the mold core 100 must be reduced from a first cross-sectional area defined by the maximum cross-sectional area defined by the mold core 100 (defined in part by the maximum outer dimension Dmax) to a second cross-sectional area that is less than the first cross-sectional area and less than the cross-sectional area defined by the cross-sectional area at the recessed surface 14 of the mold core 100, i.e. Dmin. In some embodiments, for example, the collapsible core portion 10 is configured to allow for a reduction in the area defined by the first cross-sectional area (defined in part by the maximum outer dimension defined by the configuration of the outer surface-defining portions 18 while the collapsible core portion 10 is disposed in the first configuration) such that the area defined by the second cross-sectional (defined in part by the maximum outer dimension defined by the configuration of the outer surface-defining portions 18 while the collapsible core portion 10 is disposed in the collapsed configuration) is reduced relative to the first cross-sectional area by a minimum of 23%. However, it will be understood that the collapsible core portion 10 is configured to provide for a reduction in the largest cross-sectional area defined by the collapsible core portion 10 such that the cross-sectional area is reduced to allow passage of the collapsible core portion 10 through the smallest opening defined by the molded part 200.

[0040] To enable collapsing of the mold core 100 to allow for retraction of the mold core 100 from the molded part and / or removal of the molded part from the mold core 100, the mold core 100 includes a collapsible mold core portion 10 and a supporting center core portion 20 that are cooperatively configured for relative movement relative to one another to allow for collapsing of the collapsible core portion 10, relative to the center core portion 20 to allow the entirety of the components that form the mold core 100 to be removed from within the molded part 200. Accordingly, in the subject example embodiment, the collapsible core portion 10 is disposed for axial displacement relative to the center core portion 20 along a core displacement axis 101 that extends parallel to a direction of travel of the mold plate to which the mold core 100 is mounted, and parallel to a central axis 110 of the mold core 100. In addition to the collapsible core portion 10 being disposed for axial displacement relative to the center core portion 20, the collapsible core portion 10 includes an actuator 16 that is configured for rotation about the central axis of the mold core 101 such that once the collapsible core portion 10 is axially displaced relative to the center core portion 20, rotation of the actuator 16 is with effect that the overall outer dimension definedby the outer surface of the collapsible core portion 10, which defines part of the outer molding surface 12 of the mold core 100, is reduced relative to the overall outer dimension defined by the collapsible core portion 10 while the collapsible core portion 10 is disposed in the operational molding configuration together with the center core portion 20. Accordingly, actuation of the actuator 16 is with effect that the collapsible core portion 10 is disposed in a collapsed configuration wherein the collapsible core portion 10 can be removed from within the molded product 200.

[0041] Referring now to Figs. 1-5 and Figs. 11-19, the collapsible core portion 10 will be described in further detail. The collapsible core portion 10 includes a plurality of outer surfacedefining portions 18 arranged in spaced apart relationship to one another about a central axis 110 of the collapsible core portion 10, which extends parallel to and co-axial with the central axis 101 of the mold core. Each one of the outer surface-defining portions 18, independently, defines a portion or segment of the outer molding surface 12 defined by the mold core 100. In the subject example embodiment, the collapsible core portion 10 includes four (4) outer surface-defining portions 18. However, it will be understood that, in some embodiments, the total number of outer surface-defining portions 18 could be greater than four (4), depending on the particular configuration and overall size of the mold core 100. For example, in some embodiments the collapsible core portion 10 could include eight (8), twelve (12) or sixteen (16) outer surfacedefining portions 18 depending on the particular design and / or application of the mold core.

[0042] Each one of the outer surface-defining portions 18, independently, extends upwardly from a base portion 22. The base portion 22 of each one of the outer surface-defining portions 18, independently, is configured for co-operating with a collapsible core guide housing 24 (see, for example, Fig. 2). The collapsible core guide housing 24 is configured for supporting and positioning each one of the outer-surface defining portion 18 relative to the other ones of the outersurface defining portions 18 about a central opening 25 defined by the collapsible core guide housing 24. In this respect, the collapsible core guide housing 24 includes a plurality of guide slots 26 disposed at spaced apart intervals about the central opening 25 wherein each guide slot 26 is configured for receiving the base portion 22 of a respective one of the plurality of outer surfacedefining portions 18. The guide slots 26 are each, independently, configured such that disposition of the base portion 22 of one of the outer surface-defining portions 18 into the corresponding guide slot 26 is such that the outer surface-defining portion 18 is disposed for sliding displacement alongthe guide slot 26 along an outer surface-defining portion displacement axis 126 that is respective to the corresponding guide slot 26. Accordingly, each guide slot 26 includes guide surfaces 28 along which corresponding sliding surfaces 30, defined by the base portion 22, slide as the base portion 22 is displaced along the guide slot 26 thereby moving the outer surface-defining portion 18 inwardly towards the central axis 110 of the collapsible core portion 10 along the guide slot 26, or outwardly away from the central axis 110 of the collapsible core portion 10 long the slot 26, as will be described in further detail below.

[0043] In order to secure the plurality of outer surface-defining portions 18 in position within the guide slots 26 of the collapsible core guide housing 24, an actuator housing 32 (see Fig. 2) is arranged over top of the collapsible core guide housing 24 thereby enclosing and / or sandwiching the base portions 22 of the outer surface-defining portions 18 in their mating relationship with the collapsible core guide housing 24. The actuator housing 32 includes a central opening 34 such that when the actuator housing 32 is arranged over top of and in mating relationship with the collapsible core guide housing 24, the central opening 34 defined by the actuator housing 32 aligns with the central opening 25 of the collapsible core guide housing 24 with the outer surface defining-portions 18 extending upwardly through the central opening 34 of the actuator housing 32 and away from the collapsible core guide housing 24.

[0044] To ensure that the actuator housing 32 is accurately arranged relative to the collapsible core guide housing 24 such that the central opening 34 of the actuator housing 32 is axially aligned with the central opening 25 of the collapsible core guide housing 24, the collapsible core guide housing 24 includes a locator 27 arranged around the central opening 25 of the collapsible core guide housing 24. In some embodiments, for example, the locator 27 serves as a diametrical locator for the actuator housing 32. When the actuator housing 32 is arranged relative to the collapsible core guide housing 24, while the outer surface-defining portions 18 are disposed within the corresponding guide slots 26, an internal opening 33 defined by the actuator housing 32 is configured to receive the locator 27 such that an inner edge surface 35 defined by the actuator housing 32 is disposed in abutment with an outer edge surface 29 defined by the locator 27 with effect that the central opening 34 of the actuator housing 32 is axially aligned with the central opening 25 defined by the collapsible core guide housing 24. In some embodiments, for example, the locator 27 is defined by a boss or protrusion that extends from a front face 31 of the collapsible core guide housing 24, the outer edge surface 29 being defined by the edge surface that extendsaround the perimeter of boss or protrusion. In some embodiments, for example, the guide slots 26 that are configured for receiving the base portion of the outer surface-defining portions 18 are disposed at space apart intervals about and extend through portions of the locator 27 and into the body of the collapsible core guide housing 24.

[0045] To effect displacement of the plurality of outer surface-defining portions 18 relative to the collapsible core guide housing 24, the base portion 22 of each one of the outer surface-defining portions 18, independently, includes a linking protrusion 45 that extends upwardly away from an upper surface portion 36 of the base portion 22. The linking protrusion 45 is configured for cooperating with a corresponding one of a plurality of actuating slots 38 defined within the interior of the actuator housing 32. Each one of the actuating slots 38, independently, extends from a first end 40 to a second, opposite end 42. In some embodiments, for example, each actuating slot 38 is a curvilinear slot defining an arcuate path between the first end 40 and the second end 42. The actuating slots 38 are each, independently, configured such that while the plurality of outer surfacedefining portions 18 are arranged within the guide slots 26 and the actuator housing 32 is positioned over top of and in mating relationship with the collapsible core guide housing 24, the linking protrusion 45 of each one of the outer surface-defining portions 18 is, independently, disposed within a corresponding one of the actuator slots 38 at the first end 40 thereof. Accordingly, disposition of the actuator housing 32 in mating relationship with the collapsible core housing 24 such that the inner edge surface 35 defined by the housing 32 is disposed in abutting relationship with the outer edge surface 29 defined by the locator 27 is also with effect that each one of the actuator slots 38, independently, is aligned with a corresponding linking protrusion 45 of one of the outer surface-defining portions 18 of the collapsible core portion 10.

[0046] Disposition of the linking protrusion 45 of each one of the outer surface-defining portions 18 within the corresponding actuator slot 38 is such that, rotation of the actuator housing 32 relative to the collapsible core guide housing 24 is with effect that the linking protrusion 45 is guided through the corresponding actuator slot 38 as the actuator housing 32 rotates relative to the collapsible core housing 24. Due to the arcuate shape and positioning of the actuator slot 38 within the actuator housing 32, as the actuator housing 32 rotates, a displacement force is applied against the linking protrusion 45 by the corresponding surfaces defined by the actuator slot 38 as it is guided along the surfaces that define the actuator slot 38, which displacement force effects sliding movement of the corresponding base portion 22 along the corresponding guide slot 26 of thecollapsible core guide housing 24 thereby causing the outer surface-defining portion 18 to move inwardly relative to the central axis 110 of the collapsible core portion 10 until the linking protrusion 45 becomes disposed at the second end 42 of the actuator slot 38 which coincides with the end of the rotation of the actuator housing 32. The inwards displacement of each one of the plurality of outer surface-defining portions 18 relative to the central axis 110 of the collapsible core portion 10 results in a reduction to the overall outer dimension defined by the outer surfacedefining portions 18 of the collapsible core portion 10 relative to the overall outer dimension defined by the outer surface-defining portions 18 of the collapsible core portion 10 while the collapsible core portion 10 is in the fully expanded position and in cooperation with the center core portion 20 for defining the overall mold core 100. In some embodiments, for example, the inwards displacement of each one of the outer surface-defining portions 18 relative to the central axis of the collapsible core guide housing 24 includes an inward radial displacement of the outer surfacedefining portions 18 relative to the central axis of the collapsible core portion 10 which effects a reduction in the overall outer diameter defined by the outer surface-defining portions 18 of the collapsible core portion 10.

[0047] To effect rotation of the actuator housing 32 relative to the collapsible core guide housing 24, in some embodiments, for example, the actuator housing 32 includes gear teeth 46 formed along an outer edge of at least a portion of the actuator housing 32. The gear teeth 46 are configured for meshing with teeth 48 provided on a corresponding linear actuator 50 that forms part of the overall actuation mechanism 16. In some embodiments, for example, the linear actuator 50 is in the form of a rack that forms part of the overall mold (see, for example, Figs. 6-10), the rack incorporating teeth 48 for meshing with the teeth 46 provided on the actuator housing 32. In some embodiments, for example, the linear actuator or rack 50 is operably coupled to a motor 52 that is co-operatively configured with the mold core plate 1000 for actuating the collapsible core portion 10 of the mold core 100. In some embodiments, for example, the motor 52 is operably coupled with an electrical box 52A that houses electrical components for operation of the motor 52. In this respect, operation of the motor 52 effects linear displacement of the linear actuator or rack 50 along an axis that extends perpendicular to the central axis 110 of the collapsible core portion 10 which linear displacement effects rotation of the actuator housing 32 due to the meshing relationship between the teeth 48 provided on the rack 50 and the gear teeth 46 formed on the outer edge of the actuator housing 32. In some embodiments, for example, the linear actuator or rack 50 isconfigured for cooperating with a plurality of mold cores 100, each of which include a collapsible core portion 10. Accordingly, in some embodiments, the linear actuator or rack 50 includes a plurality of sets of rack teeth 48 disposed at spaced apart intervals along the length of the linear actuator or rack 50, each set of rack teeth 48, independently, configured for meshing with the gear teeth 46 of an actuator housing 32 of a corresponding one of the plurality of collapsible core portions 10. Operation of the motor 52 in a first direction, effects linear displacement of the linear actuator or rack 50 in a first linear direction which effects rotation of the corresponding actuator housing 32 in a first direction about the central axis of the collapsible core portion 10. See, for instance, directional arrow 53 illustrated in Figure 4 which illustrates the direction of rotation of the actuator housing 32 to transition the collapsible core portion 10 from an expanded configuration to a collapsed configuration. Operation of the motor 52 in a second, or reverse, direction effects linear displacement of the linear actuator or rack 50 in a second linear direction, opposite to the first linear direction, which effects rotation of the corresponding actuator housing 32 in a second direction about the central axis 110 of the collapsible core portion 10, that is opposite to the first direction of rotation. See, for instance, directional arrow 53 illustrated in Figure 4 which illustrates the first direction of rotation of the actuator housing 32 to transition the collapsible core portion 10 from an expanded configuration to a collapsed configuration and directional arrow 55 in Figure 5 which illustrates the second direction of rotation of the actuator housing 32 to transition the collapsible core portion 10 from the collapsed configuration back to the expanded configuration.

[0048] With reference in particular to Figures 1, 1A and Figures 11-22, as described above, to form the mold core 100, the collapsible core portion 10 is disposed in mating with the supporting center core portion 20. As shown in the example embodiment of Figs. 1, 1 A and Figs. 11-22, the center core portion 20 includes an inner core portion 21 and a plurality of center core outer portions 23 wherein the center core outer portions 23 are arranged at spaced apart intervals about the inner core portion 21. The center core portion 20 is configured to be arranged relative to the collapsible core portion 10 such that the center core portion 20 extends through the central opening 25 of the collapsible core guide housing 24 and the central opening 34 of the actuator housing 32, while the outer surface-defining portions 18 are disposed in their expanded configuration. Accordingly, while the center core portion 20 extends through the aligned central openings 25, 34 of the guide housing 24 and the actuator housing 32, the outer core portions 23 of the center core portion 20are disposed in alternating arrangement with the outer surface-defining portions 18 of the collapsible core portion 10 such that side surfaces 70 of the outer surface-defining portions 18 of the collapsible core portion 10 are disposed in abutting, mating relationship with corresponding side surfaces 72 defined by the outer core portions 23 while an inner end surface 74 of the outer surface-defining portions 18 is disposed in abutting relationship with a corresponding edge surface 76 defined by the inner core portion 21 of the center core portion 20. Therefore, the plurality of outer core portions 23 are arranged relative to the supporting center core portion 20 such that when the supporting center core portion 20 is arranged in mating relationship with the collapsible core portion 10, the outer surface-defining portions 18 of the collapsible core portion 10 are arranged in alternating arrangement with the outer core portions 23 of the supporting center core portion 20 such that side faces or side surfaces 70 of the outer surface-defining portions 18 are disposed in face-to-face arrangement with corresponding side surfaces 72 defined by the outer core portions 23 while an end face or end surface 74 of the outer surface-defining portions 18 is disposed in face-to-face abutting relationship with a corresponding edge surface 76 defined by the inner core portion 21.

[0049] The alternating arrangement of the outer-surface-defining portions 18 and the outer core portions 23 of the supporting center core portion 20 is such that the outer core portions 23 together with the outer-surface defining portions 18 of the collapsible core portion 10 define the entirety of the outer perimeter of the sidewall of the outer molding surface 12 of the mold core 100 while the mold core 100 is disposed in the “closed” or operational molding configuration. Accordingly, while the mold core 100 is disposed in the “closed” or operational molding configuration, as illustrated in Fig. 1, Fig. 1A, Fig. 11, Fig. 15 and Fig. 19, the inner core portion 21, the plurality of outer core portions 23 and the plurality of outer surface defining portions 18 of the collapsible core portion 10 are cooperatively configured in mating relationship such that the outer contour of the mold core 100 defines the shape or contour of an inner surface of the part to be molded. See, for example, the example molded part 200 illustrated in Figures 23-24. The mating relationship between the inner core portion 21, the plurality of outer core portions 23 and the plurality of outer surface defining portions 18 of the collapsible core portion 10 is such that there is an absence of gaps between the mating faces of the inner core portion 21, the plurality of outer core portions 23 and the outer surface defining portions 18 to mitigate against potential leakage of molten material into spaces between various components that make-up the mold core 100. Therefore, the pluralityof outer core portions 23 and the plurality of outer surface-defining portions 18 of the collapsible core portion 10 are formed with tight tolerances to ensure that there are no spaces between the components of the mold core 100 when the mold core 100 is disposed in the “closed” or operational molding configuration. See, for example, the example embodiment illustrated in Fig. 1 wherein there is an absence of gaps between adjacent faces of the inner core portion 21, the outer core portions 23 and the outer surface-defining portions 18. Similarly, the inner core portion 21 and the plurality of outer core portions 23 that are arranged around the inner core portion 21 in mating relationship with the inner core portion 21 are also formed with tight tolerances, while disposed in the “closed” configuration to minimize any potential for gaps between the outer core portions 23 and the inner core portion 21 at their mating interfaces.

[0050] The cooperative configuration of the supporting center core portion 20 and the collapsible core portion 10 is such that the collapsible core portion 10 and the outer core portions 23 of the supporting center core portion 20 are disposed in mating relationship when the mold core 100 is disposed in the operational molding configuration wherein the outer surface-defining portions 18 of the collapsible core portion 10 are disposed in abutting relationship with the outer core portions 23 of the supporting center core portion 20 to define an outer surface corresponding to an interior surface of the molded part. The cooperative configuration of each one of the supporting center core portion 20 and the collapsible core portion 10, independently, with respective, corresponding mold plates within the overall mold structure, is such that during the demolding process and / or operation of the mold, displacement of a corresponding mold plate effects displacement of a corresponding portion of the mold core 100. For example, during the de-molding operation, displacement of a mold plate within the overall mold structure will push against the base 80 that supports the outer core portions 23 of the supporting center core portion 20 causing displacement of the outer core portions 23 relative to the inner core portion 23. Due to the stacked, cooperating arrangement of the plurality of mold plates that co-operate to form the mold core 100, displacement of the mold plate that is effective for displacing the outer core portions 23 relative to the inner core portion 21 is also effective for displacing the collapsible core portion 10, relative to the inner core portion 21, together with the outer core portions 23. In some embodiments, for example, the base 80 that supports the outer core portions 23 includes a first base portion 80(1) and a second base portion 80(2) that are arranged in stacked relationship with each other with a bottom portion of each of the outer portions 23 sandwiched between or otherwise connected to the first base portion80(1) and 80(2) in accordance with principles known in the art. This first stage of displacement causes the outer core portions 23 of the supporting center core portion 20 to be displaced relative to the inner core portion 21 of the supporting center core portion 20 together with the collapsible core portion 10. See, for instance, the transition between the configurations illustrated in Figures 15 & 16 and Figures 19 & 20. As illustrated, the collapsible core portion 10 and the outer surface portions 23 of the supporting center core portion 20 are disposed for displacement relative to inner core portion 21 of the supporting center core portion 20 by a first displacement distance along an axis of displacement 101 that extends parallel to the central axis of the mold core 110.

[0051] The collapsible core portion 10 is also disposed for a second displacement relative to both the outer core portions 23 and the inner core portion 21 of the supporting center core portion 20 along the mold core axis of displacement 101. The first displacement of the collapsible core portion 10 relative to the supporting center core portion 20 is effective for transitioning the mold core 100 into a first collapsed state (see, for instance, Figs. 12, 16 and 20), while the second displacement of the collapsible core portion 10 relative to the supporting center core portion 20 allows the collapsible core portion 10 to clear both the inner core portion 21 and the outer core portions 23 of the supporting center core portion 20 such that neither the inner core portion nor the outer core portions 23 extend through the central opening defined by the collapsible core guide housing or actuator housing, see for instance the configuration of the mold core 100 illustrated in Figs. 13, 17 and 21. Once the collapsible core portion 10 is axially clear of the supporting center core portion 20, the collapsible core portion 10 is ready to transition to a second or fully collapsed state (see, for instance, Figs. 14, 18 and 22). The cooperative configuration of the supporting center core portion 20 with the collapsible core portion 10 is such that, for the first displacement of the collapsible core portion 10 along the mold core displacement axis 101, a mold plate pushes against the base 80 of the plurality of outer core portions 23 to effect displacement of the outer core portions 23 and the collapsible core portion 10, relative to the inner core portion 21.

[0052] The inner core portion 21 of the supporting center core portion 20 includes grooves, or recesses, 84 that extend longitudinally along the outer surfaces of the inner core portion 21. The grooves or recesses 84 are each, independently, configured for mating with a corresponding protrusion and / or mating surface 86 formed along a corresponding surface defined by a corresponding one of the outer core portions 23. Accordingly, the cooperative configuration of the inner core portion 21 with the outer core portions 23 is such that the protrusions 86 defined by theouter core portions 23 are disposed in mating relationship with the grooves / recesses 84 defined by the inner core portion 21 such that the outer core portions 23 are disposed for sliding displacement relative to the inner core portion 21 (or vice versa) via sliding movement of the protrusions 86 of the outer core portions 23 along the corresponding groove 84 defined by the inner core portion 21. The grooves / recesses 84 formed on the inner core portion 21 and the protrusions 86 formed on the outer core portions 23 are machined or otherwise formed, or configured, to ensure that no open gaps are provided therebetween while the mold core 100 is disposed in the operational molding configuration while still allowing for sliding movement of the outer core portions 23 relative to the inner core portion 21. The grooves / recesses 84 and the corresponding protrusions 86 are also cooperatively configured and shaped with corresponding angled surfaces such that displacement of the collapsible core portion 10 in a first direction along the mold core displacement axis 101 (or retraction of the inner core portion 21 relative to the outer core portions 23 and the collapsible core portion 10 in a second, opposite direction along the mold core axis of displacement 101) is with effect that the outer core portions 23 slide along the inner core portion 21 and are inwardly displaced relative to the central axis of the mold core 110. The displacement of the collapsible core portion 10 and the outer core portions 23 along the inner core portion 21 is a controlled displacement ensuring proper alignment between the outer core portions 23, the outer surfacedefining portions 18 and the inner core portion 21, due to the engagement between the protrusions 86 defined by the outer core portions 23 within the grooves / recesses 84 defined by the inner core portion 21. The corresponding surfaces defined by the protrusions 86 and grooves / recesses 84 are shaped such that as the outer core portions 23 are displaced relative to the inner core portion 21, together with the collapsible core portion 10, the outer core portions 23 collapse towards each other such that the outer core portions 23 become more inwardly disposed relative to the core displacement axis 101, relative to the positioning of the outer core portions 23 while the mold core 100 is disposed in the operational molding configuration. The inwards displacement of the outer core portions 23 towards the core displacement axis 101 is also with effect that the outer core portions 23 become inwardly displaced relative to the outer surface-defining portions 18 of the collapsible core portion 10. See, for instance, the transition of the mold core 100 from the closed or operational molding configuration illustrated in Figs. 11, 15 and 19, to the first collapsed configuration 100’ of the mold core 100 illustrated in Figs. 12, 16 and 20. Accordingly, displacement of the collapsible core portion 10 relative to the inner core portion 21 by the firstdisplacement distance is with effect that the mating relationship between the outer surface-defining portions 18 and the outer core portions 23 is defeated such that gaps 88 are now formed between adjacent surfaces 70, 72 of the outer surface-defining portions 18 and the outer core portions 23. The gaps 88 that are created as a result of the first displacement and the transition from the closed or operational molding configuration of the mold core 100 to the first collapsed configuration 100’ provide sufficient clearance between the outer surface-defining portions 18 of the collapsible core portion 10 and the outer core portions 23 of the supporting center core portion 20 to allow for the further second displacement of the collapsible core portion 10 relative to the supporting center core portion 20.

[0053] Once the mold core 100 is disposed in the first collapsed state or first collapsed configuration 100 wherein the collapsible core portion 10 and the outer core portions 23 of the supporting center core portion 20 are axially displaced relative to the inner core portion 21, further displacement of the collapsible core portion 10 relative to the supporting center core portion 21 along the mold core axis of displacement 101 is such that portions of the side faces of the outer surface-defining portions 18 that remain disposed in surface-to-surface contact with the corresponding surfaces of the outer core portions 23 slide along the corresponding surfaces. The axial displacement of the collapsible core portion 10 relative to the center core portion 20 by the second displacement distance is such that the collapsible core portion 10 is disposed above the supporting center core portion 20 with effect that outer core portions 23 and the inner core portion 21 of the supporting center core portion 20 no longer extend through the central openings defined by the collapsible core guide housing 24 and actuator housing 32. Once the collapsible core portion 10 is clear of the supporting center core portion 20, actuation of the collapsible core portion 10 is permissible for transitioning the collapsible core portion 10 into the fully collapsed state or second collapsed configuration 100”. Accordingly, once the collapsible core portion 10 is clear of the supporting center core portion 20, actuation of the actuator 16 such that the actuator housing 32 rotates relative to the collapsible core guide housing 24 is with effect that the outer surface-defining portions 18 are displaced along their respective guide slots 26 such that they become further inwardly displaced towards to the central axis 110 of the mold core 100. Accordingly, transitioning of the mold core 100 from the first collapsed configuration 100’ to the second collapsed configuration 100” includes axial displacement of the collapsible core portion 10 relative to the supporting center core portion 20 and rotation of the actuator housing 32 relative to the collapsiblecore guide housing 24 to collapse the outer surface-defining portions 18 from their fully expanded configuration to their fully collapsed configuration. As the transition to the fully collapsed configuration of the outer surface-defining portions 18 of the collapsible core portion 10 of the mold core 100 is effectuated via rotation of the actuator housing 32, rather than simply axial sliding of components along tapered mating surfaces, a greater reduction in the overall outer dimensions of the mold core 100 can be achieved for the same range of axial displacement of components of the mold core that is typically achievable in standard injection molding de-molding operations. Once the collapsible core portion 10 is disposed in the fully collapsed state, the outer surfacedefining portions 18 can be retracted from within the molded part (or the molded part removed from over top of the outer surface-defining portions 18) past any undercuts and through the smallest opening defined by the molded part.

[0054] In use in an injection molding operation, in some embodiments, for example, the collapsible mold core 10 is mounted to a mold plate 1000 (see, for example, the mold plate 1000 of Figures 6 and 7) that forms part of the overall mold (not shown) for a particular injection molding operation. In some embodiments, for example, the mold plate 1000 to which the collapsible core portion 10 is mounted is one of a series of co-operating mold plates arranged in a stacked configuration (not shown) wherein some of the mold plates are disposed for displacement relative to one another along the mold core axis of displacement 101 which extends parallel to the stacking arrangement of the plurality of mold plates and parallel to the central axis 110 of the collapsible mold core 10. In some embodiments, for example, the collapsible mold core 10 is mounted to a first mold plate 1000, within a stack of co-operating mold plates, while the base 80 of the outer portions 23 of the supporting central core portion 20 is mounted to a second mold plate (not shown) such that displacement of the second mold plate moves the outer core portions 23, together with the collapsible core portion 10, relative to the inner core portion 21, while displacement of the first mold plate 1000 effects displacement of the collapsible core portion 10 relative to the outer core portions 23 of the supporting center core portion 20. The inner core portion of the supporting center core portion 20 is mounted to third, or stationary mold plate (not shown), such that displacement of the first and second mold plates relative to the stationary mold plate effects displacement of the collapsible core portion 10 and outer core portions 23 of the supporting center core portion 20 relative to the inner core portion 21 of the supporting center core portion 20, as is known in the art of molding operations. In such example embodiments, the firstmold plate 1000 with the collapsible mold core 10 is arranged in a stacked relationship with the second mold plate, that includes the outer core portions 23 of the supporting center core portion 20 and the third stationary plate with the inner core portion 21, such that the supporting central core portion 20 extends through the central opening 25 of the collapsible core guide housing 24 and the opening 34 defined by the actuator housing 32 such that the supporting center core portion 20 is disposed in mating relationship with the outer surface defining portions 18 of the collapsible core portion 10. The first mold plate 1000 and the second mold plate (not shown) are disposed for displacement relative to the stationary mold plate as well as to one another such that, for example, displacement of the first mold plate 1000 and the second mold plate (not shown) away from the stationary mold plate effects displacement of the outer core portions 23 and the collapsible mold core 10, relative to the inner core portion 21 of the supporting central core portion 20, and displacement of the first mold plate 1000 relative to the second mold plate (not shown), effects displacement of the collapsible core portion 10 relative to the outer core portions 23 and the inner core portion 21 of the supporting center core portion 20, as described above.

[0055] In some embodiments, for example, the collapsible core portion 10 is mounted to the mold plate 1000 via mounting screws 60 that extend upwardly through the collapsible core guide housing 24, from the bottom surface thereof, to secure the collapsible core portion 10 in position on the mold plate 1000. In example embodiments wherein a plurality of collapsible core portions 10 are mounted to mold plate 1000, as illustrated for example in Figs. 6 and 7, the plurality of collapsible core portions 10 are arranged in one or more rows that extend along the length of the mold plate 1000. In the example embodiment illustrated in Figs. 6 and 7, the mold plate 1000 includes two rows of collapsible core portions 10, each row including four (4) collapsible core portions 10. The collapsible core portions 10 in each row are aligned with one another along a common axis that extends parallel to a longitudinal axis of the mold plate 1000 such that each one of the collapsible core portions 10, in a row of the collapsible core portions 10, can be actuated simultaneously via the same linear actuator or rack 50. In example embodiments wherein more than one row of collapsible core portions is provided, as in the example embodiment of Figs. 6 and 7, each row of collapsible core portions is actuated via a separate linear actuator or rack 50, both of which are operated by a common motor 52. Accordingly, operation of the motor 52 effects rotation of a drive shaft 54 of the motor 52, which in turn, effects rotation of a drive gear 56 that is disposed in engagement with each one of the linear actuators 50, each linear actuator 50 of thepair of linear actuators 50 being arranged one on either side of the of the drive gear 56 (or pinion). Each linear actuator 50 is configured to include teeth 49 that are configured for meshing with the drive gear 56 (or pinion) such that rotation of the drive gear 56 effects linear displacement of the corresponding linear actuator or rack 50 due to the meshing engagement between the teeth 49 on the rack 50 with the teeth of the drive gear 56. The linear actuators 50 are arranged relative to one another such that rotation of the drive shaft 54 and corresponding drive gear 56in a first direction effects displacement of a first linear actuator 50(1) of the pair of linear actuators 50 in a first direction parallel to the longitudinal axis of the mold plate 1000 and displacement of the second linear actuator 50(2) in the pair of linear actuators in a second direction, opposite to the first direction. Accordingly, in some embodiments, for example, the collapsible core portions 10 are mounted to the mold plate 1000 such that actuation of the collapsible core portions 10 in a first row of collapsible core portions is due to rotation of the actuator housing 32 of the respective ones of the collapsible core portions 10 in a first direction about the central axis of the corresponding one of the collapsible core portions 10, while actuation of the collapsible core portions 10 in a second row of collapsible core portions is due to rotation of the actuator housing 32 of the respective ones of the collapsible core portions 10 in a second direction about the central axis of the corresponding one of the collapsible core portions 10. Similarly, to return the collapsible core portions 10 to their expanded position for use in a subsequent molding operation, operation of the motor 52 in a reverse direction effects displacement of the first linear actuator 50(1) in the second direction and displacement of the second linear actuator 50(2) in the first direction such that the actuator housings 32 of the corresponding ones of the collapsible core portions 10 are rotated in the opposite directions to return the outer surface-defining portions 18 to their expanded positions relative to their respective collapsible core guide housing 24.

[0056] When the mold plate 1000 including the one or more collapsible core portion 10 is brought into a cooperating configuration with the mold plate including the corresponding one or more supporting center core portions 20 to form the one or more individual mold cores 100, the one or more mold cores 100 are brought into a cooperating configuration with a corresponding cavity mold plate such that each one of the one or more mold cores 100, independently, is disposed within a corresponding cavity defined by the cavity mold plate such that a mold cavity (not shown) is formed between the outer molding surface 12 defined by the respective one of the one or more mold cores 100 and the inner surface defined by the corresponding cavity of the cavity mold plate,the mold cavity defining the shape of the product to be molded. Once mold core plate and the mold cavity plate are brought into cooperating configuration, molten material is injected to the each one of the mold cavities for forming the molded part. Once cooled, the mold core plate and the mold cavity plate are moved away from each other and the de-molding operation for ejecting or demolding each of the mold parts can begin. As described, de-molding includes displacement of the various plates that form the mold core plate relative to one another to effect axial displacement of the collapsible core portion 10 relative to the supporting center core portion 20 such that the collapsible core portion 10 is clear of any mating relationship with the components of the supporting center core portion 20. Once clear of the supporting center core portion 20, the actuation mechanism for effecting rotation of the actuator housing 32 of each one of the collapsible core portions 10, transitions each one of the collapsible core portions 10, independently, to the fully collapsed configuration to allow for retraction of the outer surface-defining portions 18 of each one of the one or more collapsible core portions 10 from within the molded part 200, thereby allowing a molded part 200 with an undercut to be successfully removed and / or de-molded from the mold.

[0057] While various embodiments of the collapsible core portion have been described, it will be understood that certain adaptations and modifications of the described embodiments can be made. Therefore, the above discussed embodiments are considered to be illustrative and not restrictive.

Claims

CLAIMSWhat is claimed is:

1. A collapsible core portion for use in forming a mold core for an inj ection molding operation for forming a molded part, comprising:a guide housing;a plurality of outer surface-defining portions mounted to the guide housing and disposed for displacement relative to the guide housing, each one of the plurality of outer surfacedefining portions, independently, defining an outermost molding surface that forms part of a molding surface of the mold core; andan actuator operably coupled to each one of the plurality of outer surface-defining portions for transitioning the collapsible core portion from:(i) a first configuration, wherein the plurality of outer surface-defining portions are disposed in a first position relative to the guide housing and together define a first outer dimension of the collapsible core portion, wherein the first outer dimension defines a first cross-sectional area in a plane that extends perpendicular to a central axis of the collapsible core portion, wherein the first cross-sectional area is bounded, in part, by the outermost molding surface of each one of the plurality of outer surface-defining portions, to (ii) a second configuration, wherein the plurality of outer surface-defining portions are disposed in a second position relative to the guide housing and together define a second outer dimension of the collapsible core portion that is less than the first outer dimension, wherein the second outer dimension defines a second cross-sectional area in the plane that extends perpendicular to the central axis of the collapsible core portion, wherein the second cross- sectional area is bounded, in part, by the outermost molding surface of each one of the plurality of outer surface-defining portions such that the second-cross-sectional area is less than the first cross-sectional area;wherein:while the collapsible core portion is disposed in the first configuration, the collapsible core portion is configured for cooperating with a supporting center core portion to define the molding surface of the mold core, wherein the molding surface corresponds to a shape defined by an interior surface of the molded part; andwhile the collapsible core portion is disposed in the second configuration, the collapsible core portion is configured for removal from within the molded part;andthe guide housing, the plurality of outer surface-defining portions and the actuator are cooperatively configured such that:transitioning of the collapsible core portion from the first configuration to the second configuration is in response to rotation of the actuator relative to the guide housing about the central axis of the collapsible core portion, which rotation effects linear displacement of each one of the plurality of outer surface-defining portions relative to the guide housing along a respective outer surface-defining portion displacement axis from the first position to the second position, each outer surface-defining portion displacement axis, independently, extending in a plane that is perpendicular to the central axis of the collapsible core portion about which the actuator rotates.

2. The collapsible core portion as claimed in claim 1, wherein:each one of the plurality of outer surface-defining portions, independently, includes:a base portion configured for cooperating with the guide housing; anda molding surface-defining portion that extends away from the base portion such that, while the plurality of outer surface-defining portions are disposed in their co-operating relationship with the guide housing, the molding surface-defining portion extends away from the base portion along an axis that extends parallel to the central axis of the collapsible core portion.

3. The collapsible core portion as claimed in claim 1 or 2, wherein:the guide housing includes a central opening configured for receiving the supporting center core portion.

4. The collapsible core portion as claimed in claim 3, wherein:the guide housing includes a plurality of guide slots arranged at spaced apart intervals about the central opening, each guide slot, independently, configured for receiving thebase portion of a respective one of the plurality of outer surface-defining portions and defining the outer surface-defining portion displacement axis respective to the one of the plurality of outer surface-defining portions disposed within the guide slot;wherein:while the plurality of outer surface-defining portions are mounted to the guide housing such that the base portion of each one of the plurality of outer surface-defining portions, independent, is disposed in a corresponding guide slot of the plurality of guide slots, each one of the outer surface-defining portions is disposed for displacement along the outer surface-defining portion displacement axis that is respective to the corresponding guide slot via sliding movement of the base portion along the guide slot.

5. The collapsible core portion as claimed in claim 4, wherein:the actuator includes an actuator housing configured for disposition in mating relationship with the guide housing while the plurality of outer surface-defining portions are mounted to the guide housing, the actuator housing including:a central opening such that while the actuator housing is disposed in mating relationship with the guide housing while the plurality of outer surface-defining portions are mounted to the guide housing, the molding surface-defining portion of each one of the plurality of outer surface-defining portions extends through the central opening of the actuator housing; anda plurality of actuating slots, each actuating slot, independently, configured for cooperating with a corresponding one of the plurality of outer surface-defining portions wherein the co-operation is effective for effecting displacement of the corresponding one of the plurality of outer surface-defining portions from the first position to the second position in response to rotation of the actuator housing relative to the guide housing.

6. The collapsible core portion as claimed in claim 5, whereineach one of the plurality of outer surface-defining, independently, includes a linking protrusion projecting from the base portion and configured such that, while the actuatorhousing is disposed in mating relationship with the guide housing, while the plurality of outer surface-defining portions are mounted to the guide housing, the linking protrusion of each one of the plurality of outer surface-defining portions, independently, is disposed in mating relationship with a corresponding one of the plurality of actuating slots.

7. The collapsible core portion as claimed in claim 6, wherein:each one of the plurality of actuating slots, independently, extends from a first end to a second end and defines an arcuate path extending therebetween;andwhile the actuator housing is disposed in mating relationship with the guide housing with the plurality of outer surface-defining portions are mounted to the guide housing and the collapsible core portion is disposed in the first configuration wherein the plurality of outer surface-defining portions are disposed in the first position relative to the guide housing, the linking protrusion of each one of the plurality of outer surface defining portions, independently, is disposed at the first end of the corresponding actuator slot; andtransitioning of the collapsible core portion from the first configuration to the second configuration, in response to rotation of the actuator housing relative to the guide housing in a first direction about the central axis of the collapsible core portion, is with effect that:the linking protrusion of each one of the plurality of outer surface-defining portions is displaced along the corresponding actuating slot from the first end to the second end; andthe displacement of the linking protrusion from the first end to the send end of the actuating slot effects sliding displacement of the base portion of the corresponding one of the plurality of outer surface-defining portion along the corresponding guide slot such that the outer surface-defining portion is displaced, relative to the guide housing from the first position to the second position.

8. The collapsible core portion as claimed in claim 7, wherein:the displacement of the plurality of outer surface defining portions from the first position to the second position is in response to a displacement force exerted by the actuator housing against each one of the linking protrusions via interference between each one of the actuating slots and the corresponding linking protrusion generated in response to rotation of the actuator housing which effects inwards displacement of each one of the plurality of outer surface-defining portions relative to the guide housing.

9. The collapsible core portion as claimed in claim 8, wherein:while the collapsible core portion is disposed in the second configuration wherein the plurality of outer surface-defining portions are disposed in the second position relative to the guide housing such that the linking protrusion of each one of the plurality of outer surface-defining portions, independently, is disposed at the second end of the corresponding actuating slot, rotation of the actuator housing relative to the guide housing in a second direction of rotation about the central axis of the collapsible core portion that is opposite to the first direction of rotation is with effect that the collapsible core portion transitions from the second configuration to the first configuration.

10. The collapsible core portion as claimed in claim 9, wherein:rotation of the actuator housing in the second direction of rotation is with effect that a displacement force is exerted by the actuator housing against each one of the linking protrusions via interference between each one of the actuating slots and the corresponding linking protrusion which displacement force effects outwards displacement of each one of the plurality of outer surface-defining portions relative to the guide housing.

11. The collapsible core portion as claimed in any one of claims 5 to 10, wherein:the actuator housing is configured for coupling with an actuation mechanism, wherein the actuation mechanism is operable to effect rotation of the actuator housing relative to the guide housing.

12. The collapsible core portion as claimed in claim 11, wherein:the actuator housing includes gear teeth formed along at least a portion of an outer surface of the actuator housing, the gear teeth configured for meshing with corresponding gear teeth of the actuation mechanism.

13. The collapsible core portion as claimed in claim 12, wherein:the actuation mechanism includes a linear actuator comprising the gear teeth configured for meshing with the gear teeth defined by the actuator housing, the linear actuator disposed for reciprocating movement relative to actuator housing such that:displacement of the linear actuator in a first linear direction effects rotation of the actuator housing in the first direction of rotation for transitioning the collapsible core portion from the first configuration to the second configuration, via meshing engagement of the gear teeth of the linear actuator with the gear teeth of the actuator housing; anddisplacement of the linear actuator in a second linear direction effects rotation of the actuator housing in the second direction of rotation for transitioning the collapsible core portion from the second configuration to the first configuration via meshing engagement of the gear teeth of the linear actuator with the gear teeth of the actuator housing.

14. The collapsible core portion as claimed in claim 13, wherein:the actuation mechanism includes a motor for driving the linear actuator in either the first linear direction or the second linear direction.

15. The collapsible core portion as claimed in any one of claims 1 to 14, wherein:the second cross-sectional area is reduced relative to the first cross-sectional area by at least 23%.

16. The collapsible core portion as claimed in claim 5, wherein:the guide housing includes a locator for locating the actuator housing relative to the guide housing, the locator including an outer edge surface such that, while the actuator housingis disposed in mating relationship with the guide housing, an inner edge surface defined by the actuator housing is disposed in abutting relationship with the outer edge surface defined by the actuator housing with effect that the central opening of the actuator housing is aligned with the central opening defined by the guide housing.

17. The collapsible core portion as claimed in claim 16, wherein:the locator is a diametrical locator.

18. A mold plate for use in an injection molding operation for forming a molded part comprising:a collapsible core portion mounted to the mold plate, wherein the collapsible core portion includes:a guide housing;a plurality of outer surface-defining portions mounted to the guide housing and disposed for displacement relative to the guide housing, each one of the plurality of outer surface-defining portions, independently, defining an outermost molding surface for forming a part of a molding surface of a mold core for forming the molded part; and an actuator operably coupled to each one of the plurality of outer surface-defining portions for transitioning the collapsible core portion from:(i) a first configuration, wherein the plurality of outer surface-defining portions are disposed in a first position, relative to the guide housing, and together define a first outer dimension of the collapsible core portion, wherein the first outer dimension defines a first cross-sectional area in a plane that extends perpendicular to a central axis of the collapsible core portion, wherein the first cross-sectional area is bounded, in part, by the outermost molding surface of each one of the plurality of outer surface-defining portions; anda second configuration, wherein the plurality of outer surface-defining portions are disposed in a second position, relative to the guide housing, and together define a second outer dimension of the collapsible core portion that is less than the first outer dimension, wherein the second outer dimension defines a second cross-sectional area in the plane that extends perpendicular to the central axis of thecollapsible core portion, wherein the second cross-sectional area is bounded, in part, by the outermost molding surface of each one of the plurality of outer surfacedefining portions such that the second-cross-sectional area is less than the first cross-sectional area;andan actuation mechanism operably coupled to the collapsible core portion for transitioning the collapsible core portion from the first configuration to the second configuration; wherein:while the collapsible core portion is disposed in the first configuration, the mold plate is configured for cooperating with at least a second mold plate, the second mold plate including a supporting center core portion configured for mating relationship with the collapsible core portion such that disposition of the mold plate in a stacked arrangement with the second mold plate is with effect that the supporting center core portion extends through a central opening defined by the collapsible core portion and is disposed in mating relationship with the plurality of outer surface-defining portions for forming a mold core that defines a molding surface corresponding to a shape defined by an interior surface of the molded part;while the collapsible core portion is disposed in mating relationship with the supporting center core portion, while the mold plate and the at least a second mold plate are disposed in the stacked relationship, there is an absence of gaps between the plurality of outer surface-defining portions of the collapsible core portion with the supporting center core portion;andwhile the mold plate and the at least a second mold plate are disposed in the stacked relationship such that the collapsible core portion is disposed in mating relationship with the supporting center core portion, displacement of the mold plate relative to the at least a second mold plate along a mold plate axis of displacement that extends parallel to a central axis of the collapsible core portion such that the mold plate is displaced away from the at least a second mold plate by a first distance is with effect that:the collapsible core portion is axially displaced away from at least a portion of the supporting center core portion by a first distance such that a plurality of gapsare formed between surfaces of the outer surface-defining portions and adjacent surfaces defined by at least a portion of the supporting center core portion such that further axial displacement of the mold plate relative to the at least a second mold plate such that the collapsible core portion is displaced farther away from the supporting center core portion is permissible;anddisplacement of the mold plate relative to the at least a second mold plate by a second distance along the mold plate axis of displacement such that there is an absence of projecting of the supporting center core portion into the central opening defined by the collapsible core portion is with effect that the mold plate is disposed in an actuationeffective position relative to the at least second mold plate such that actuation of the actuation mechanism for transitioning the collapsible core portion from the first configuration to the second configuration is permissible; andactuation of the actuation mechanism is with effect that the actuator rotates relative to the guide housing for effecting displacement of the plurality of outer surface-defining portions from the first position to the second position such that the cross-sectional area defined, in part, by an outer dimension of the outer surface-defining portions is reduced from the first cross-sectional area to the second cross-sectional area.

19. The mold plate as claimed in claim 18, wherein:the actuation mechanism includes a motor operably coupled to the actuator of the collapsible core portion such that operation of the motor effects rotation of the actuator for transitioning the collapsible core portion from the first configuration to the second configuration.

20. The mold plate as claimed in claim 19, wherein:the actuator of the collapsible core portion includes an actuator housing configured for disposition in mating relationship with the guide housing while the plurality of outer surface-defining portions are mounted to the guide housing, the actuator housing including:a central opening such that while the actuator housing is disposed in mating relationship with the guide housing while the plurality of outer surface-defining portions are mounted to the guide housing, the molding surface-defining portion of each one of the plurality of outer surface-defining portions extends through the central opening of the actuator housing; anda plurality of actuating slots, each actuating slot, independently, configured for cooperating with a corresponding one of the plurality of outer surface-defining portions wherein the co-operation is effective for effecting displacement of the corresponding one of the plurality of outer surface-defining portions from the first position to the second position in response to rotation of the actuator housing relative to the guide housing;andthe actuating mechanism includes a linear actuator, operably coupled with the motor and operably coupled with the actuator housing such that operation of the motor effects: (i) displacement of the linear actuator along an axis that extends perpendicular to the central axis of the collapsible core portion; and (ii) rotation of the actuator housing in response to the displacement of the linear actuator due to the operable coupling between the linear actuator and the actuator housing.

21. The mold plate as claimed in claim 20, wherein:the actuator housing includes gear teeth formed along at least a portion of an outer surface of the actuator housing, the gear teeth configured for meshing with corresponding gear teeth formed on the linear actuator.

22. The mold plate as claimed in claim 21, wherein:the collapsible core portion is one of a plurality of collapsible core portions mounted to the mold plate, wherein the plurality of collapsible core portions are arranged in a row along a length of the mold plate;the linear actuator includes a plurality of sets of gear teeth, each set of gear teeth, independently, is configured for meshing engagement with the gear teeth of the actuator housing of a corresponding one of the plurality of collapsible core portions; andoperation of the motor to effect displacement of the linear actuator is with effect that each one of the plurality of collapsible core portions, independently, transitions from the first configuration to the second configuration.

23. The mold plate as claimed in claim 20, wherein:the plurality of collapsible core portions includes:a first set of collapsible core portions mounted to the mold plate in a first row extending along a length of the mold plate; anda second set of collapsible core portions mounted to the mold plate in a second row that extends along the length of the mold plate parallel to the first row;andthe actuation mechanism includes:a first linear actuator operably coupled to each one of the collapsible core portions of the first set of collapsible core portions; anda second linear actuator operably coupled to each one of the collapsible core portions of the second set of collapsible core portions;wherein the first linear actuator and the second linear actuator are each, independently, coupled to the motor such that operation of the motor is with effect that:the first linear actuator is displaced in a first linear direction along an axis that extends parallel to the first row of collapsible core portions which effects rotation of the actuator housing of each one of the collapsible core portions in the first set of collapsible core portions in a first direction of rotation about the central axis of the respective collapsible core housing for transitioning each one of the collapsible core portions in thefirst set of collapsible core portions from the first configuration to the second configuration; andthe second linear actuator is displaced in a second linear direction, opposite to the first linear direction which effects rotation of the actuator housing of each one of the collapsible core portions in the second set of collapsible core portions in a second direction of rotation about the central axis of the respective collapsible core portion that is opposite to the first direction of rotation for transitioning each one of the collapsible core portions in the second set of collapsible core portions from the first configuration to the second configuration.

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