INJECTION MOLD FRICTION PULLER

CROSS REFERENCE TO RELATED APPLICATION This Patent Application is a continuation-in-part patent application of U.S. Patent Application No. 12/107,060, filed on 21 April 2008, which is the co-pending parent application and which is incorporated by reference herein and is made a part hereof, including but not limited to those portions which specifically appear in this Patent Application. BACKGROUND OF THE INVENTION

Field of the Invention

The present invention relates to injection molding devices, and more specifically to a friction puller of a multiple plate injection mold.

Discussion of Related Art Friction pullers are used in injection mold application to help control the sequential movements of various plates during mold operations. One such friction puller is shown in German Patent No. DE 2815698, which is assigned to the HASCO Company. Friction pullers made according HASCO have a bolt which has a substantially conical shaped shank. The bolt is inserted into a resin jacket that has a corresponding substantially conical shaped passage for receiving the bolt shank. When the bolt is tightened, the bolt head compresses the jacket lengthwise and the shank presses laterally on the jacket. The result is that under the load from the tightened bolt, the jacket has an increased diameter compared to when it is in an unloaded condition.

Another type of friction puller is also produced by HASCO. In these friction pullers, a bolt with a straight set of threads is used. The bolt is secured into a key member that passes through one of the mold plates. The key has at least one flat surface to prevent the key from rotating inside the mold plate. The end of the key that receives that bolt has a hemispherical wedge section integral to or fixed to the key member. A resin jacket is again used. The jacket has a hemispherical cup inside one end of the jacket to correspond to the hemispherical wedge on the key member. The other end of the jacket has a second hemispherical cup for receiving a hemispherical washer used between the bolt head and the jacket. Again, when the bolt is tightened, the hemispherical washer and hemispherical wedge compress the jacket lengthwise forcing the jacket to increase slightly in diameter.

A problem encountered with both of these types of friction pullers is that they do not accommodate typical manufacturing conditions with respect to installation or operational environments, which results in inconsistent performance. For example, these products are fix mounted into the mold plates. Thermal expansion, build tolerances and the like can lead to the pullers not being centered with respect to the respective pockets in the opposing mold plates. While small, these misalignments can cause the mold to lock because of different force levels exerted by each of the friction pullers in the mold. Typically, multiple friction pullers are used in a single mold.

Another problem encountered with both of the types of friction pullers described above is the creation of air pressure differentials during use. As the pullers are designed to friction fit into the pockets that receive them, often the puller creates an air tight seal against the pocket. During mold close, the mold has to compress the air in the pocket to close the mold. This compressed air wants to push the puller out of the pocket. Alternatively, if the air escapes the pocket during mold closure, but the jacket creates an air tight seal once the mold is fully closed, a vacuum is created in the pocket when the puller attempts to pull out from the pocket. Neither of the friction pullers described above provide for air to flow in and out of the pocket during mold open an mold closure operations. Accordingly, either the compressed air or vacuum conditions can occur randomly, creating an undesirable variation in the force exerted by the friction pullers. Thus, there remains a need for an improved friction puller. There remains a need for a self-aligning friction puller. There remains a need for a friction puller to controllably allow air to pass into and out of the pocket that receives the friction puller.

SUMMARY OF THE INVENTION

In view of the deficiencies described above, it is an object of the present invention to provide an improved friction puller.

It is a further object of the present invention to provide a friction puller that is self-aligning.

It is a further object of the present invention to provide a friction puller that controllably allows air to pass into and out of the pocket that receives the friction puller. The present invention is a friction puller for an injection mold. The friction puller has a bolt, the bolt has a head portion and a threaded portion. The friction puller also has a first substantially hemispherical wedge. The first substantially hemispherical wedge has a first

passage running through it for the bolt. The first passage allows the first substantially hemispherical wedge a first predetermined amount of lateral float relative to the bolt. In some embodiments of the present invention, the friction puller has only one substantially hemispherical wedge. In other embodiments according to the present invention, the friction puller also has a second substantially hemispherical wedge. The second substantially hemispherical wedge has a second passage running through it for the bolt. The second passage allows the second substantially hemispherical wedge a second predetermined amount of lateral float relative to the bolt.

The friction puller also has a deformable jacket. The jacket has a third passage running through it for the bolt. In some embodiments of the present invention, the jacket has only a first substantially hemispherical cup for receiving the one substantially hemispherical wedge. In other embodiments according to the present invention, the jacket has a first substantially hemispherical cup for receiving the first substantially hemispherical wedge and a second substantially hemispherical cup for receiving the second substantially hemispherical wedge.

Preferably, the first hemispherical wedge has a least one vent relief notch disposed in a top surface of the first hemispherical wedge. The vent relief notch allows air to pass through during mold operation. Likewise the deformable jacket preferably has at least one jacket vent notch disposed in a top surface of the deformable jacket. The jacket vent notch also allows air to pass through during mold operation.

Preferably, the head portion of the bolt has at least one bolt alignment indicator mark in it. Likewise, the deformable jacket has at least one jacket alignment indicator mark on it.

Preferably, the threads on the threaded portion of the bolt have a variable pitch diameter.

In a typical three-plate injection molding machine, as the name implies, there are three plates involved in the molding operation. Typically these plates are referred to as the X plate, the B plate, and the A plate. A mold pattern is formed between a portion of the B plate and the A plate. A runner pattern is formed on the A plate which faces the X plate. The B plate is bolted to a support plate. The support plate is further secured to an ejector box or housing. The ejector box is clamped to a movable platen of the molding machine. The X plate is bolted to a

top clamp plate, usually with two or more shoulder bolts. The top clamp plate is fixed to the opposing platen of the injection molding machine.

During the molding operation, the mold and runner patterns are filled with heated plastic injected from a reservoir connected to the top clamp plate. When the plastic has cooled, the moving platen pulls the ejector box and the associated support plate and B plate away from the A plate, thus initiating the sequential opening of the mold plates and the eventual removal of the molded parts and runner.

As the mold opens, the B plate and associated support plate are pulled away. At least one friction puller is secured to the B plate. The deformable jacket of the friction puller engages, via an interference fit, with a pocket in the A plate. The friction puller holds the A plate and the B plate together as the mold clamping force is removed. Springs between the A plate and the X plate begin to expand and separate the A plate and X plate at a first parting line. The runner breaks free from the A plate and remains attached to the sucker pins. Sucker pins are pins secured to the top plate and pass through an opening in the X plate. The sucker pins serve to hold the runner in place while the A plate, B plate, and the support plate are moved away from the X plate. Further movement of the X plate away from the top clamp plate causes the runner to be stripped from the sucker pins.

When the shoulder bolts reach the end of their travel, the shoulder bolts hold the A plate in position and the B plate is moved further away. The A plate and the B plate separate at a second parting line.

BRIEF DESCRIPTION OF THE DRAWINGS

Other features and advantages of the invention will be apparent from the following detailed description taken in conjunction with the following figures, wherein like reference numerals represent like features. Fig. 1 shows an exploded front view of a friction puller according to one embodiment of the present invention.

Fig. IA shows a close up front view of the bolt threads of a friction puller according to the present invention.

Fig. IB shows an exploded front view of a friction puller according to another embodiment of the present invention.

Fig. 2 shows an exploded perspective view of a friction puller according to one embodiment of the present invention.

Fig. 2A shows an exploded perspective view of a friction puller according to another embodiment of the present invention.

Fig. 3 shows an assembled perspective view of a friction puller according to the present invention. Fig. 4 shows a top view of a friction puller according to the present invention.

Figs. 5A - 5C show a three plate mold having a friction puller according to the present invention installed therein going through an opening sequence.

DETAILED DESCRIPTION OF THE INVENTION

While this invention is susceptible of embodiments in many different forms, there are shown in the drawings and will herein be described in detail, preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

The present invention is a friction puller 100 for an injection mold. Fig. 1 shows an exploded front view of a friction puller according to the present invention. Fig. 2 and Fig. 2A each shows an exploded perspective view of a friction puller, each according to a different embodiment of the present invention. Fig. 3 shows an assembled perspective view of a friction puller according to the present invention. The friction puller 100 has a bolt 110, and the bolt 110 has a head portion 105 and a threaded portion 120. The friction puller 100 also has a first substantially hemispherical wedge 130.

The first substantially hemispherical wedge 130 has a first passage 150 running through it for the bolt 110. The first passage 150 allows the first substantially hemispherical wedge 130 a first predetermined amount of lateral float relative to the bolt 110. That is, the diameter of the first passage 150 is larger than the diameter of the threaded portion 120 of the bolt 110. In various preferred embodiments, the first substantially hemispherical wedge 130 has about 0.010 inches of lateral float. This allows the friction puller 100 to self-align, or self-center itself during use. Additionally, this allows for thermal expansion differences between the mold plates. hi some embodiments according to the present invention, such as shown in Fig.

IB and Fig.2A, the friction puller 100 has only one substantially hemispherical wedge 130. The only one substantially hemispherical wedge 130 can be in a position such as shown in Fig. IB and Fig. 2A, or can be positioned at an opposite end of a deformable jacket 160. In other embodiments according to the present invention, the friction puller 100 also has a second

substantially hemispherical wedge 210, such as shown in Figs. 1 and 2. The second substantially hemispherical wedge 210 has a second passage 220 running through it for or to accommodate the bolt 110. The second passage 220 allows the second substantially hemispherical wedge 210 a second predetermined amount of lateral float relative to the bolt 110. In various preferred embodiments, the second substantially hemispherical wedge 210 has about 0.010 inches of lateral float. This allows the friction puller 100 to self-align, or self-center itself during use. Additionally, this allows for thermal expansion differences between the mold plates.

The friction puller 100 also has the deformable jacket 160. The jacket 160 has a third passage 190 running through it for or to accommodate the bolt 110. The jacket 160 has a first substantially hemispherical cup 180 for receiving the first substantially hemispherical wedge 150 and a second substantially hemispherical cup 200 for receiving the second substantially hemispherical wedge 210. The jacket 160 preferably includes a step in outer diameter, as can be seen in Fig. 1. The step in outer diameter further enables lateral float of the jacket 160. Preferably, the first hemispherical wedge 130 has a least one vent relief notch 140 disposed in a top surface of the first hemispherical wedge 130. The vent relief notch 140 allows air pass through or by the first hemispherical wedge 130 during mold operation. Likewise the deformable j acket 160 preferably has at least one j acket vent notch 170 disposed in a top surface of the deformable jacket 160. The jacket vent notch 170 also allows air to pass through or by deformable jacket 160 during mold operation. By allowing air to pass through or by each necessary element during mold operation, the adverse compressed air and vacuum conditions described above are avoided.

Preferably, the head portion 105 of the bolt 110 has at least one bolt alignment indicator mark 250 in it or on a corresponding surface. Likewise, the deformable jacket 160 has at least one jacket alignment indicator mark 260 on it or on a corresponding surface. The alignment indicator marks 250 and 260 allow the mold engineer and mold builder to see, and hopefully record, how many turns or rotations of the bolt 110, such as relative to the deformable jacket 160, have been made during installation or maintenance of the mold. For example, each bolt 110 could be turned or rotated the same number of revolutions to achieve the same friction force. Additionally, any adjustments made to the bolt, e.g., a fraction of a turn, could also be seen and recorded. In various preferred embodiments, the bolt alignment indicator mark 250 is an arrow or other similar mark or structure disposed on a top surface of the head portion 105 of

the bolt 110 and the jacket alignment indicator mark 260 comprises an arrow or other similar mark or structure disposed on a top surface of the deformable jacket 160. Any suitable number of alignment marks 250 and 260 can be used. In various preferred embodiments, there are four jacket alignment indicator mark comprises 260. Fig. IA shows a close up front view of the bolt threads of a friction puller 100 according to the present invention. Preferably, the threads on the threaded portion 120 of the bolt 110 have a variable pitch diameter. That is, the threaded portion 120 of the bolt 110 has a first pitch diameter at a first section 125 of the threaded portion 120 and a second pitch diameter at a second section 127 of the threaded portion 120. The first pitch diameter can be different from the second pitch diameter.

This variable pitch diameter is different from other fasteners. Typically a fastener is engineered to stretch when the fastener head is limited from travel. The stretching is what creates the tightening torque. Although the bolt 110 of the present invention resembles a typical fastener installation, the bolt head 105 is never mating to a solid that limits its travel and produces the tightening torque. The variable pitch diameter resists unintentional rotational movement or backing out of the bolt 110 during operation. Furthermore, when the bolt 110 is unscrewed a specified amount for mold maintenance or other reasons the bolt 110 will hold its position without any force being exerted on it from the jacket 160.

Figs. 5A - 5C show a three plate mold having a friction puller according to the present invention installed therein going through an opening sequence. In a typical three-plate injection molding machine, as the name implies, there are three plates involved in the molding operation. Typically these plates are referred to as the X plate 310, the B plate 320, and the A plate 330. A mold pattern 370 is formed between a portion of the B plate 320 and the A plate 330. A runner pattern 335 is formed on the A plate 330 which faces the X plate 310. TheB plate 320 is bolted to a support plate 350. The support plate 350 is further secured to an ejector box or housing (not shown). The ejector box is clamped to a movable platen of the molding machine. The X plate 310 is bolted to a top clamp plate 360, usually with two or more shoulder bolts 345. The top clamp plate 360 is fixed to the opposing platen of the injection molding machine. Fig. 5 A shows the mold in a closed position. During the molding operation, the mold 370 and runner patterns 335 are filled with heated plastic injected from a reservoir 380 connected to the top clamp plate. When the plastic has cooled, the moving platen pulls the ejector box and the associated support plate 350

and B plate 320 away from the A plate 330, thus initiating the sequential opening of the mold plates and the eventual removal of the molded parts and runner 340.

As the mold opens, the B plate 320 and associated support plate 350 are pulled away, shown in Fig. 5B. At least one friction puller 100, corresponding to any one of the different embodiments according to the present invention, is secured to the B plate 320. The deformable jacket 160 of the friction puller 100 engages, via an interference fit, a pocket 325 in the A plate 330. The friction puller 100 holds the A plate 330 and the B plate together as the mold clamping force is removed. Springs between the A plate 330 and the X plate 310 begin to expand and separate the A plate 330 and X plate 310 at a first parting line. The runner 340 breaks free from the A plate 330 and remains attached to the sucker pins 390. Sucker pins 390 are pins secured to the top plate 360 and pass through an opening in the X plate 310. The sucker pins 390 serve to hold the runner 340 in place while the A plate 330, B plate 320, and the support plate 350 are moved away from the X plate 310. Further movement of the X plate 310 away from the top clamp plate 360 causes the runner 340 to be stripped from the sucker pins 390. When the shoulder bolts 345 reach the end of their travel, shown in Fig. 5C, the shoulder bolts 345 hold the A plate 330 in position and the B plate 320 is moved further away. The A plate 330 and the B plate 320 separate at a second parting line.

While specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention and the scope of protection is limited by the scope of the accompanying claims. These modification include, but are not limited to, replacing other types of friction pullers with friction pullers made according to the present invention and or retrofitting other types of friction pullers using the principles of the present invention.