MOLDING MACHINE AND HEATED MANIFOLD

RELATED APPLICATIONS

[001 ] The disclosures of all of the following are incorporated by reference in their entirety as if fully set forth herein: PCT/US2012/043944 published as WO2012178145, U.S. Patent No. 5,894,025, U.S. Patent No. 6,062,840, U.S. Patent No. 6,294,122, U.S. Patent No. 6,309,208, U.S. Patent No. 6,287,107, U.S. Patent No. 6,343,921 , U.S. Patent No.

6,343,922, U.S. Patent No. 6,254,377, U.S. Patent No. 6,261 ,075, U.S. Patent No.

6,361 ,300 (7006), U.S. Patent No. 6,419,870, U.S. Patent No. 6,464,909 (7031 ), U.S.

Patent No. 6,599,1 16, U.S. Patent No. 6,824,379, U.S. Patent No. 7,234,929 (7075US1 ), U.S. Patent No. 7,419,625 (7075US2), U.S. Patent No. 7,569,169 (7075US3), U.S. Patent Application Serial No. 10/214,1 18, filed August 8, 2002 (7006), U.S. Patent No. 7,029,268 (7077US1 ), U.S. Patent No. 7,270,537 (7077US2), U.S. Patent No. 7,597,828 (7077US3), U.S. Patent Application Serial No. 09/699,856 filed October 30, 2000 (7056), U.S. Patent No. 6,005,013, U.S. Patent No. 6,051 ,174, U.S. Patent application publication no.

20020147244, U.S. Patent Application Serial No. 10/269,927 filed October 1 1 , 2002 (7031 ), U.S. Application Serial No. 09/503,832 filed February, 15, 2000 (7053), U.S. Application Serial No. 09/656,846 filed September 7, 2000 (7060), U.S. Application Serial No.

10/006,504 filed December 3, 2001 , (7068) and U.S. Application Serial No. 10/101 ,278 filed March, 19, 2002 (7070).

BACKGROUND OF THE INVENTION

[002] Stack injection molding equipment has been designed and implemented such that a hot runner is disposed in the center of a mold assembly with injection nozzles mounted to opposing upstream and downstream ends of fluid distribution manifold, with nozzles extending upstream towards the barrel of an injection molding machine and downstream away from the machine for a double simultaneous injection into a pair of opposing mold cavities disposed on the upstream and downstream sides of the manifold. Such systems are typically configured such that the center of the mold assembly moves. In this way, when the first parting line opens, so does the second. The typical manner in which fluid is routed from the barrel of the machine to the manifold is either through the center of the mold assembly or off center employing a long inlet tube extending from the outlet of the machine barrel to the inlet to the manifold. When the mold assembly is opened to eject the formed parts, the inlet tube has to be physically translated or moved away from the outlet of the machine nozzle or barrel. Thus, the fluid flow connection between the inlet tube and the machine nozzle is opened. Various apparatuses are needed to shut-off flow emanating from the machine barrel when the inlet tube is disconnected from the outlet of the machine barrel or nozzle, as failure to do so will result in fluid or polymer loss. Even with such shut- off mechanisms, some fluid or polymer is lost as shut-off mechanisms are inherently imperfect. The present invention provides an apparatus that enables uninterrupted fluid flow interconnection between the outlet of a machine barrel or nozzle and the inlet aperture to the manifold thus minimizing or eliminating loss of injection fluid or polymer and maintaining interconnection or contact of the inlet tube with the exit or outlet of the machine nozzle or barrel.

SUMMARY OF THE INVENTION

[003] In accordance with the invention there is provided an injection molding apparatus (7) comprised of first (50a, 50b) and second (60a, 60b) mold assemblies, a fluid distribution manifold (40) having a master fluid distribution channel (40c), upstream and downstream ends and one or more injection nozzles (50n) mounted to each of the upstream and downstream ends for fluid sealed interconnection to first and second mold assemblies (50a, 50b, 60a, 60b) that are adapted to travel together with the fluid distribution manifold (40) at each respective upstream and downstream end of the fluid distribution manifold between open and closed mold positions,

an injection molding machine (10) that is comprised of a barrel (12) that outputs an injection fluid (500) through a fluid inlet tube (30) that has an outlet port (30o) that delivers injection fluid to the fluid distribution manifold (40),

a first arm (90) having a first arm flow channel (90c) pivotably and fluid sealably interconnected (90p) at an upstream end to the outlet port (30o) of the inlet tube (30) and a second arm (100) having a second arm flow channel (100c) that is pivotably and fluid sealably interconnected (200p) to the first arm flow channel (90c) and pivotably and fluid seably interconnected (100p) to a master fluid distribution channel (40c) of the fluid distribution manifold (40),

wherein the first and second arms (90, 100) articulate around the pivotable interconnections (90p, 200p, 100p) between a collapsed position and one or more extended positions that follow travel of the manifold (40) and the first and second mold assemblies (50a, 50b, 60a, 60b) between the open and closed mold positions.

[004] Most preferably, an inlet port (32) of the inlet tube (30) remains fluid sealably interconnected to an output port (20) of the barrel (12) between injection cycles. Most preferably the inlet port (32) of the inlet tube (30) remains fluid sealably interconnected to the output port (20) of the barrel (12) during travel of the manifold (40) and first and second mold assemblies (50a, 50b, 60a, 60b) between the open and closed mold positions.

[005] Preferably, the outlet port (30o) of the inlet tube and the first arm flow channel (90c) remain fluid sealably interconnected between injection cycles. Preferably, the outlet port (30o) of the inlet tube and the first arm flow channel (90c) remain fluid sealably

interconnected during travel of the manifold and the first and second mold assemblies between the open and closed mold positions.

[006] The outlet port of the inlet tube is typically fluid sealably interconnected to the first arm flow channel through an inlet manifold.

[007] The outlet port of the inlet tube preferably remains fluid sealably interconnected to the first arm flow channel during travel of the manifold and the first and second mold assemblies between the open and closed mold positions.

[008] The master fluid distribution channel typically includes one or more injection ports (40n) and the mold assemblies (50a, 50b, 60a, 60b) typically include one or more complementary gate ports (50n, 60n), the first and second arms (90, 100) being arranged such that the injection ports (40n) sealably mate with the complementary gate ports (50n, 60n) on articulation of the arms (90, 100) around the pivotable interconnections (90p, 200p, 100p) from the one or more open or extended positions to the collapsed or closed positions.

[009] In another aspect of the invention there is provided a method of injecting an injection fluid (500) from a barrel (12) of an injection molding machine (10) to a fluid distribution manifold (40) of an injection molding apparatus (7) comprised of first and second mold assemblies (50a, 50b, 60a, 60b), wherein the fluid distribution manifold (40) has a master fluid distribution channel (40c), upstream and downstream ends and one or more injection nozzles (50n) mounted to each of the upstream and downstream ends for fluid sealed interconnection to the first and second mold assemblies, the first and second mold assemblies being adapted to travel together with the fluid distribution manifold at each respective upstream and downstream end of the fluid distribution manifold between open and closed mold positions, wherein the barrel outputs the injection fluid through a fluid inlet tube (30) that has an outlet port (30o) that delivers injection fluid to the fluid distribution manifold (40),

the method comprising:

pivotably and fluid sealably interconnecting (90p) a first arm (90) having a first arm flow channel (90c) to the outlet port (30p) of the inlet tube (30),

pivotably and fluid sealably interconnecting (200p) a second arm (100) having a second arm flow channel (100c) to the first arm flow channel (90c) and pivotably and fluid seably interconnecting (100p) the second arm flow channel (100c) to the master fluid distribution channel (40c) of the fluid distribution manifold,

articulating the first and second arms (90, 100) around the pivotable interconnections (90p, 100p, 200p) between a collapsed position and one or more extended positions that follow travel of the manifold and first and second mold assemblies between the open and closed mold positions

injecting the injection fluid (500) from the barrel to the fluid distribution manifold when the first and second mold assemblies are in the closed position.

[010] Such a method can further comprise adapting the apparatus such that the inlet tube remains fluid remains fluid sealably interconnected to an output port of the barrel during travel of the manifold and first and second mold assemblies between the open and closed mold positions and such that the outlet port of the inlet tube and the first arm flow channel remain fluid sealably interconnected during travel of the manifold and first and second mold assemblies between the open and closed mold positions. Brief Description of the Drawings

[011] The above and further advantages of the invention may be better understood by referring to the following description in conjunction with the accompanying drawings in which:

[012] Fig. 1 A is a side partial sectional view of a prior art stacked mold apparatus with the apparatus in an opened position

[013] Fig. 1 B is a view similar to Fig. 1 A showing the prior art apparatus in a closed part forming position.

[014] Fig. 2 is a side view of a molding apparatus according to the invention showing the molds and hotrunner or manifold in a closed injection ready position, the apparatus having an articulating arm assembly that maintains a fluid sealed interconnection between the fluid inlet of a heated manifold which is moved between injection cycles to the outlet of an injection molding machine.

[015] Fig. 3 is view similar to Fig. 2 showing the apparatus in an opened position for molded part ejection.

[016] Fig. 4 is top sectional perspective view of the Figs, 2, 3 apparatus showing the arrangement of flow channels extending through the articulating arm and other flow distribution components of the apparatus.

[017] Fig. 5 is a top sectional view of a subset of components shown in Fig. 3 showing the articulating arms and the heated manifold components in a position prior to being fluid sealably mated.

[018] Fig. 6 is a side sectional view of the fluid channel connection between the distribution manifold and one of the arms of the articulating arm assembly.

DETAILED DESCRIPTION

[019] Figs. 1 A, 1 B show a prior art stacked mold apparatus 5 comprised of manifold that is translatably or movable mounted on rods 5r for driven movement between first, an open position Fig. 1 A in which fluid injection is shut-off or stopped at the outlet port 20 of the nozzle or barrel 12 of an injection molding machine 10 at the beginning of an injection cycle and second, a closed position, Fig. 1 B, where the mold halves 50a, 50b, 60a, 60b and the manifold 40 and a fluid inlet tube 30 have all been drivably moved or translated into a position where the inlet port 32 of the inlet tube has been sealably engaged with the outlet port 20 such that an injection cycle can be initiated to deliver injection fluid through the inlet tube 30 to the distribution manifold 40 and in turn to the nozzles and the closed cavities 50c, 60c of the molds 50a, 50b, 60a, 60b. As shown, the inlet port 32 of the inlet tube 30 travels a lateral distance D away from the outlet port 20 of the machine barrel or nozzle 12 when the apparatus is transitioned from the open non-injecting position, Fig. 1 A, and the injection operational position, Fig. 1 B.

[020] Fig. 2 shows a stacked mold injection molding apparatus 7 in a fully closed position. Figs. 3, 4 shows the apparatus in an expanded or arm extended position. As shown in Figs. 2, 3, 4 the apparatus 7 has an articulating arm assembly comprised of a pair of arms 90, 100 that are pivotably interconnected to each other via a pivotable

interconnection or connection 200p that also connects the internal fluid flow channels 90c, 100c of each arm 90, 100 to each other at, during and when the arms 90, 100 are pivoted or articulated to any position between the fully collapsed position 300 shown in Fig. 2 and the fully open or extended position 400 shown in Figs. 3-7.

[021] The apparatus 7 includes an injection molding machine 10 that injects injection fluid 500 under pressure out of the exit port 20 of an injection molding machine barrel or barrel nozzle 12 into and through the inlet aperture or port 32 of an inlet or delivery tube 30. The apparatus 7 can be adapted such that the exit port 20 of the barrel or nozzle is sealably mated with the inlet aperture or port 32 during the course of and preferably remains so mated throughout and between successive injection cycles.

[022] The so injected fluid 500 is further delivered downstream through an outlet aperture 30o of the inlet fluid delivery tube 30 through an inlet aperture or port 1 10i of a flow channel 1 10c, Fig. 7 that is formed within a downstream inlet manifold 1 10. Preferably the exit port 20 of the barrel or nozzle is sealably mated with the inlet aperture or port 32 during the course of and preferably remains so mated between successive injection cycles. The apparatus 7 is preferably adapted such that the exit port or aperture 30o of the inlet tube 30 is sealably mated with the inlet aperture or port 32 and remains so mated during the course of, throughout and between successive injection cycles. [023] As shown, the apparatus includes a pair of mold assemblies 50a, 50b and 60a, 60b that have cavities that are fed respectively by nozzles 50n and 60n when the arm assembly 90, 100 and system is in the closed position of Fig. 2 and the apparatus 7 is operated to inject fluid 500 from the machine 10. In operation, when the apparatus is closed and the machine 10 is operated to begin injection of fluid 500, the fluid 500 flows under pressure through the inlet tube channel 30c, downstream through the inlet manifold channel 1 10c downstream through the articulable platen arm channel 90c, downstream through the articulable center arm channel 100c, downstream through the heated distribution manifold channel 40c which distributes the fluid 500 to each individual nozzle 50, 60n which in turn deliver and route the fluid 500 into the cavities formed by the mold assemblies 50a, 50b, 60a, 60b.

[024] At an upstream end, arm 90 is pivotably interconnected to inlet manifold 1 10 such that the inlet channel 1 10c is pivotably and fluid sealably connected 90p to the flow channel 90c disposed within arm 90. At a downsteam end, arm 90 is pivotably interconnected to an upstream end of arm 100 such that the arm flow channel 90c is pivotably and fluid sealably connected 200p to the flow channel 100c disposed within arm 100. At a downstream end, arm 100 is pivotably interconnected to distribution manifold 40 such that the arm channel 90c is pivotably and fluid sealably interconnected to the distribution channel 40c disposed within distribution manifold 40. As shown in Figs. 2-7, the articulating or articulable or pivotable arm assembly 90, 1 10, 40 can be driven between the closed position, Fig. 2, and the open, eject part, position, Figs. 3-7 between injection cycles such that the manfold 40 and mold assemblies 50a, 50b, 60a, 60b are physically moved and travel a selected back and forth distance relative to the stationary machine 10 and stationary inlet 30 and inlet manifold 1 10 with the mated and fluid sealed engagement between the outlet 30o of the inlet tube and the inlet 1 10i of the inlet manifold is maintained.

[026] As shown by Figs. 2 - 6, the inlet tube 30 remains stationary and does not travel relative to the barrel 12 of the machine 10 between successive injection cycles when the mold assemblies (50a, 50b, 60a, 60b) and the manifold 40 are moved between the open and closed positions. Thus the fluid sealed connection between the tube 30 and the barrel 12 is maintained at all times during operation of the apparatus 7. More particularly, the inlet port (32) of the inlet tube (30) remains fluid sealably interconnected to the output port (20) of the barrel (12) between injection cycles. And, the inlet port (32) of the inlet tube (30) remains fluid sealably interconnected to the output port (20) of the barrel (12) during travel of the manifold (40) and first and second mold assemblies (50a, 50b, 60a, 60b) between the open and closed mold positions.

[027] Preferably also the inlet tube remains stationary and does not travel relative to the mechanisms that connect the tube 30 to the manifold between injection cycles, namely the tube 30 remains stationary relative to the inlet manifold 1 10, the arm 90 and the arm 100. Most preferably the outlet port (30o) of the inlet tube and the first arm flow channel (90c) remain fluid sealably interconnected between injection cycles. And most preferably, the outlet port (30o) of the inlet tube and the first arm flow channel (90c) remain fluid sealably interconnected during travel of the manifold and the first and second mold assemblies between the open and closed mold positions.

[028] Thus, the articulating arm apparatus 7 as shown and described is adapted to and enables continuous fluid channel flow connection between the barrel 12 or inlet tube 30 or both and the distribution manifold 40, at all times during and between successive injection cycles even though the distribution manifold 40 and mold assemblies 50a, 50b, 60a, 60b are moved and travel selected pivotable distances and linear distances between mold open and mold closed positions.

[029] The fluid sealed pivotable connection 90p between moving arm 90 and stationary inlet manifold 1 10 enables a continuous fluid sealed flow path from and between the inlet channel 1 10c and the arm flow channels 90c, 100c during the course of articulation and pivoting of the arms 90, 100 and movement of the manifold 40 and mold assemblies 50a, 50b, 60a, 60b between open and closed position. Similarly, the fluid sealed pivotable connection 200p between moving arms 90, 100 enable a continuous fluid sealed flow path from and between the arm flow channels 90c and 100c during the course of articulation and pivoting of the arms 90, 100 and movement of the manifold 40 and mold assemblies 50a, 50b, 60a, 60b between open and closed position. Similarly the fluid sealed pivotable connection 100p between moving arm 100 and the manifold 40 enable a continuous fluid sealed flow path from and between the arm flow channel 100c and the manifold distribution flow channel 40c during the course of articulation and pivoting of the arms and movement of the manifold 40 and mold assemblies 50a, 50b, 60a, 60b between open and closed position.

[030] As shown in Figs. 2-5, the apparatus comprised of a pair of stacked molds 50a, 50b, 60a, 60b and a downstream manifold 40 is movable between a fully mold half closed position as in Fig. 2 and a mold half separated or open position as shown in Figs. 3-5. In order to facilitate precise alignment of the mold halves 50a, 50b, 60a, 60b on closure, alignment pins 5p and complementary receiving apertures 5a can be provided to better ensure alignment and mating of the portions of the mold cavities 50c, 60c contained in the mold halves 50a, 50b, 60a, 60c upon closure, as well as precise alignment and mating of downstream manifold injection ports 40n with the mold gate ports 50n, 60n on closure of the apparatus from an open position as in Figs. 3-5 to a position as in Fig. 2.