This invention relates generally to molding apparatus and associated methods. More specifically, although not exclusively, this invention relates to mold stacks, mold assemblies, molds, molding systems for molding preforms and other articles, for example tubular articles, and to associated methods.

BACKGROUND OF THE INVENTION

Molding is a process by virtue of which a molded article can be formed from molding material, such as a plastics material, by using a molding system, such as an injection molding system or a compression molding system. Various molded articles can be formed by using such molding processes including, for example, preforms which can be formed from polyethylene terephthalate (PET) material. Such preforms are capable of being subsequently blown into a container, for example a beverage container, bottle, can or the like.

As an illustration, injection molding of preforms involves heating PET material (or other suitable molding material for that matter) to a homogeneous molten state and injecting, under pressure, the so-melted material into a molding cavity defined, at least in part, by a female cavity piece and a male core piece. Typically, the female cavity piece is mounted to a cavity plate and the male core piece is mounted to a core plate of a mold. The cavity plate and the core plate are urged together and are held together by clamp force, the clamp force being sufficient to keep the cavity and the core pieces together against the pressure of the injected material. The molding cavity has a shape that substantially corresponds to a final cold-state shape of the molded article to be molded. The so-injected material is then cooled to a temperature sufficient to enable removal of the so-formed molded article from the molding cavity. When cooled, the molded article shrinks inside of the molding cavity and, as such, when the cavity and core plates are urged apart, the molded article tends to remain associated with the core piece.

Accordingly, by urging the core plate away from the cavity plate, the molded article can be subsequently demolded by ejecting it off the core piece. Ejection structures are known to assist in removing the molded articles from the core halves. Examples of the ejection structures include stripper plates, stripper rings and neck rings, ejector pins, etc.

When dealing with molding a preform that is capable of being subsequently blown into a beverage container, one consideration that needs to be addressed is forming a so-called "neck region". Typically and as an example, the neck region includes (i) engaging features, such as threads (or other suitable structure), for accepting and retaining a closure assembly (ex. a bottle cap), and (ii) an anti-pilferage assembly to cooperate, for example, with the closure assembly to indicate whether the end product (i.e. the beverage container that has been filled with a beverage and shipped to a store) has been tampered with in any way. The neck region may comprise other additional elements used for various purposes, such as to cooperate with parts of the molding system (ex. a support ledge, etc.). As is appreciated in the art, the neck region cannot be formed easily by using the cavity and core halves. Traditionally, split mold inserts (sometimes referred to by those skilled in the art as "neck ring") have been used to form the neck region.

A typical molding insert stack assembly that can be arranged (in use) within a molding machine includes a split mold insert pair that, together with a mold cavity insert, a gate insert and a core insert, defines a molding cavity. Molding material can be injected into the molding cavity from a source of molding material via a receptacle or port in the gate insert to form a molded article. In order to facilitate forming of the neck region of the molded article and subsequent removal of the molded article therefrom, the split mold insert pair comprises a pair of complementary split mold inserts that are mounted on adjacent slides of a slide pair. The slide pair is slidably mounted on a top surface of a stripper plate.

As commonly known, the stripper plate is configured to be movable relative to the cavity insert and the core insert, when the mold is arranged in an open configuration. As such, the slide pair, and the complementary split mold inserts mounted thereon, can be driven laterally, via a cam arrangement or any other suitable known means, for the release of the molded article from the molding cavity. One of the functions performed by the split mold insert pair is to assist in ejecting the molded article off the core insert by "sliding" the molded article off the core insert.

SUMMARY OF THE INVENTION

The present invention seeks to provide a means of directing the clamping load through a mold along predetermined load paths, with a view to reducing complexity and/or cost. This invention is directed, in particular but not exclusively, to mold stacks, molds, mold assemblies, molding systems and associated methods for molding articles, specifically but not exclusively tubular articles such as preforms. In the case of tubular articles such as preforms, the articles may have a base portion at a closed end, a neck finish at an open end and a body portion therebetween. The neck finish may include one or more radial flanges, which may extend outwardly. The neck finish may include engaging features, such as threads or a snap fit finish. The preform and/or neck finish may comprise any one or more other features described above in relation to known preform designs. In addition, any of the foregoing features described in relation to known mold stacks, molds and molding systems may be incorporated within mold stacks, molds and molding systems according to the invention, insofar as they are consistent with the disclosure herein.

According to a first broad aspect of the present invention, there is provided a mold, e.g. an injection mold, comprising: a core plate assembly, a cavity plate assembly and a stripper plate assembly arranged between the core and cavity plate assemblies; a plurality of mold stacks, each of which includes a core insert, a cavity insert and a split mold insert pair arranged therebetween; the core plate assembly including a core plate having a plurality of the core inserts mounted thereon; the stripper plate assembly including a stripper plate with a bearing surface upon which a plurality of slide pairs are slidably supported, each slide pair being configured to retain a subset of the split mold inserts thereon; the cavity plate assembly including a cavity plate having a plurality of the cavity inserts mounted thereon; wherein the mold comprises a molding configuration in which the mold stacks are closed to define molding cavities and the stack height is configured such that a clamping load applied, in use, to urge the core plate toward the cavity plate is directed substantially entirely through the mold stacks.

The mold may be configured such that a gap may be provided between the slides and the bearing surface, e.g. when the mold is in the molding configuration. Additionally or alternatively, a gap may be provided between the core plate and the stripper plate, e.g. when the mold is in the molding configuration.

Another aspect of the invention provides a mold, e.g. an injection mold, comprising: a core plate assembly, a cavity plate assembly and a stripper plate assembly arranged between the core and cavity plate assemblies; a plurality of mold stacks, each of which includes a core insert, a cavity insert and a split mold insert pair arranged therebetween; the core plate assembly including a core plate having a plurality of the core inserts mounted thereon; the stripper plate assembly including a stripper plate with a bearing surface upon which a plurality of slide pairs are slidably supported, each slide pair being configured to retain a subset of the split mold inserts thereon; the cavity plate assembly including a cavity plate having a plurality of the cavity inserts mounted thereon; wherein the mold comprises a molding configuration in which the mold stacks are closed to define molding cavities and a gap is provided between the core plate and the stripper plate such that a clamping load applied, in use, to urge the core plate toward the cavity plate is directed substantially entirely through the mold stacks.

The distance between the split mold inserts and the core plate may be greater than the thickness of stripper plate assembly, or parts thereof, which are received therebetween, e.g. when the mold is in the molding configuration. The distance between the split mold inserts and the core plate may be configured to prevent the clamping load from being directed through the stripper plate assembly. The distance between the split mold inserts and the core plate may be greater than the combined thickness of the slide pairs, stripper plate and bearing surface, e.g. when the mold is in the molding configuration, for example to prevent the clamping load from being directed through the stripper plate assembly and/or to provide the gap.

The distance between the slides and the core plate may be greater than the thickness of the stripper plate or the combined thickness of the stripper plate and bearing surface, e.g. when the mold is in the molding configuration, for example to prevent the clamping load from being directed through the stripper plate assembly and/or to provide the gap.

At least one or each cavity insert may comprise a spigot, which may be received in a respective seat of the cavity plate. At least one or each cavity insert may comprise a shoulder, e.g. surrounding at least part of the spigot and/or engaging a front face of the cavity plate. The spigot may be shorter than the depth of the cavity plate, e.g. such that some, most or substantially all of the applied clamping load is directed from the core plate through the mold stack, e.g. via the shoulder of the cavity insert, to the cavity plate and/or such that none of the applied clamping load is directed through the spigot.

The cavity plate may comprise a front face and/or a rear face. At least one or each seat may comprise a first seat portion, which may extend from the front face. At least one or each seat may comprise a second seat portion, which may extend from the rear face. The first seat portion may be larger than the second seat portion, e.g. with a shoulder described therebetween. The front face may comprise a mounting interface adjacent each seat, e.g. to which each cavity insert is mounted. The spigot of the cavity insert may be received within the first seat portion and/or may abut against the shoulder. In some examples, some or most of the applied clamping load is directed from the core plate through the mold stack, e.g. via the spigot of the cavity insert, to the cavity plate and/or some or most of the applied clamping load is directed from the core plate through the mold stack via the shoulder of the cavity insert to the cavity plate.

The mold may comprise a gate insert, which may be at least partially received within each seat of the cavity plate. Additionally or alternatively, each cavity insert may comprise a gate insert seat within which each gate insert is at least partially received. The or each gate insert may cooperate with the cavity insert spigot received in the seat, e.g. to enable molten material to be injected into the cavity. The or each gate insert may extend from the spigot and/or into the or a respective second seat portion. The or each gate insert may be recessed with respect to a rear side or face, e.g. a melt distributor mounting side or face, of the cavity plate, for example to substantially inhibit the applied clamping load from being directed from the melt distributor through the gate inserts. The or each gate insert may be shorter than the depth of the second seat portion.

The or each gate insert may include a nozzle seat or nozzle tip recess, e.g. for receiving a nozzle tip of a melt distributor. The gate insert may comprise a body, which may be substantially cylindrical. The gate insert or body may describe a nozzle seat, e.g. in a first end of the body. The gate insert may comprise a molding cavity portion, e.g. in a second end of the body. The gate insert may comprise a gate, which may join the nozzle seat to the molding cavity portion.

In some cases, only a portion of the clamping load is directed through the mold stacks if or once a predetermined threshold clamping load is exceeded. The mold may comprise one or more columns, e.g. between the core plate and cavity plate. At least a portion of the clamping load may be directed through the one or more columns, e.g. if or once the predetermined clamping load is exceeded. At

least a portion of the clamping load may be directed through the stripper plate assembly, e.g. if or once the predetermined clamping load is exceeded.

Another aspect of the invention provides a mold stack, e.g. for use in an injection mold as described above, the mold stack comprising a core insert, a cavity insert and a split mold insert pair arranged therebetween, wherein the mold stack comprises a closed, molding configuration in which molding cavities are defined therebetween and in which a clamping load applied, in use, to urge a core plate, to which the core insert is mounted, toward a cavity plate, to which the cavity insert is mounted, is directed substantially entirely through the mold stacks.

The core may be for mounting or mountable to a core plate or core plate assembly. The cavity may be for mounting or mountable to a cavity plate or cavity plate assembly. The split mold insert pair may be for mounting or mountable to a stripper plate or stripper plate assembly, which may be arranged, in use, between the core and cavity plate assemblies. The stack height may be configured such that a clamping load applied, in use, to urge the core plate toward the cavity plate is directed substantially entirely through the mold stacks.

The split mold insert pair may describe a first taper, e.g. a male taper, which may be on a first side thereof. The first taper may comprise a radial surface and a tapered surface. The split mold insert pair may describe a second taper, e.g. a female taper, which may be on a second side thereof. The split mold insert pair may describe a lateral or radial surface, which may extend from the second taper.

The cavity insert may comprise a taper, e.g. a female taper, which may be on a split mold insert facing side thereof. The cavity insert taper may comprise a radial surface and a tapered surface. The first taper of the split mold insert pair may engage the cavity insert taper, which may be a corresponding taper of the cavity insert. The core insert may comprise a taper, e.g. a male taper. The second taper of the split mold insert pair may engage the core insert taper, which may be a corresponding taper of the core insert. The core may comprise an annular support surface, which may extend radially, e.g. from the core insert taper. A portion of the lateral or radial surface may engage the annular support surface of the core insert.

The first taper may comprise a projected area, which may be in the direction of the clamping load, for example it may comprise a load transmission area or projected load transmission area. The second

taper may comprise a projected area, which may be in the direction of the clamping load, for example it may comprise a load transmission area or projected load transmission area. The second taper and radial surface portion that engages the annular support surface of the core insert may together comprise a projected area, which may be in the direction of the clamping load, for example it may comprise a load transmission area or projected load transmission area.

The projected area of the first taper may be substantially the same as that of the second taper and radial surface.

The stripper assembly may comprise one or more guide shafts mounted on or secured to the stripper plate. The stripper plate assembly may comprise a pair of guide shafts mounted or secured, e.g. in parallel, across opposing sides of the stripper plate. Each slide of each slide pair may slidably receive at least one of the guide shafts. Each slide of each slide pair may slidably receive one of the guide shafts through each of its ends. Each slide may be movable along the guide shaft(s) relative to the stripper plate and/or relative to one another.

Another aspect of the invention provides a stripper assembly, comprising: a stripper plate; a pair of guide shafts secured, in parallel, across opposing sides of the stripper plate; and a plurality of slide pairs slidably supported on a bearing surface of the stripper plate; wherein each slide of each slide pair slidably receives one of the guide shafts through each of its ends such that each slide is movable along the pair of guide shafts relative to the stripper plate and relative to one another.

The stripper plate assembly may comprise a guide shaft mounted on or secured to an upper portion of the stripper plate. The stripper plate assembly may comprise a guide shaft mounted on or secured to a lower portion of the stripper plate. Each slide pair may comprise a first slide and a second slide. The first and second slides of each slide pair may be movable along the guide shaft(s) relative to the stripper plate and/or relative to one another.

The mold may comprise a pair of connecting bars, which may be mounted to the slides. Each connecting bar may secure together a respective one of the slides of each slide pair, e.g. for synchronized movement thereof. The mold may comprise a pair of, e.g. first and second, connecting bars mounted at each end of the slide pairs. Each connecting bar of each pair may secure together a respective one of the slides of each slide pair, e.g. for synchronized movement thereof. For example, the connecting bars may include a first connecting bar secured to each first slide of each slide pair. The connecting bars may include a second connecting bar secured to each second slide of each slide pair. The first connecting bar may synchronize movement of all of the first slides and/or the second connecting bar may synchronize movement of all of the second slides. The connecting bars may be mounted to the front of the slides. The connecting bars may have a substantially square or rectangular, e.g. featureless, cross-section.

At least one or each guide shaft may be mounted to the stripper plate by a plurality of guide brackets. The guide brackets may comprise a pair of end brackets, each of which may be secure or mount a respective end of the guide shaft. The guide brackets may comprise one or more intermediate brackets, which may secure or mount respective intermediate portions of the guide shaft. At least one or each guide bracket may comprise a base and/or a clamp member. The base may comprise a cradle or support surface, which may be curved or semi-cylindrical, for receiving the guide shaft. The base may comprise a block with a recess providing or forming the cradle or support surface. The base may comprise one or more, e.g. a pair of, mounting holes, which may extend through its thickness. The base may comprise a mounting hole on either side of the cradle or support surface.

The clamp member may comprise a curved or semi-cylindrical clamping surface, e.g. for receiving the guide shaft. The clamp member may comprise a block with a recess providing or forming the clamping surface. The clamp member may comprise one or more, e.g. a pair of, mounting holes, which may extend through its thickness. The clamp member may comprise a mounting hole on either side of the clamping surface. Each guide bracket may comprise a pair of fasteners, such as bolts, each of which may extend through a hole in the clamp member and through a hole in the base to threadedly engage a threaded hole in the stripper plate.

Another aspect of the invention provides a mold part or half, e.g. a moving part or half of a mold, comprising the stripper plate assembly described above and a core plate assembly comprising a core plate having a plurality of the core inserts mounted thereon.

Another aspect of the invention provides a mold, e.g. a preform mold or an injection mold, comprising the stripper plate assembly described above.

The mold may comprise an injection mold, e.g. a preform injection mold.

Another aspect of the invention provides a molding system comprising a mold as described above. The molding system may comprise one or more of a melt distributor, an injection molding machine, a material supply system and a part removal and/or post mold cooling apparatus.

Another aspect of the invention provides a computer program element comprising and/or describing and/or defining a three-dimensional design for use with a simulation means or a three-dimensional additive or subtractive manufacturing means or device, e.g. a three-dimensional printer or CNC machine, the three-dimensional design comprising one or more mold components described above.

Another aspect of the invention provides a method of assembling a mold assembly or mold as described above. Various steps and features of the method will be apparent to the skilled person.

Another aspect of the invention provides a method of molding articles. The method may comprise the use of one of the aforementioned mold stacks, molds, mold assemblies or molding systems. The method may comprise any one or more features or steps relevant to or involving the use of any feature of any of the aforementioned mold stacks, molds, mold assemblies or molding systems.

For the avoidance of doubt, any of the features described herein apply equally to any aspect of the invention. Within the scope of this application it is expressly intended that the various aspects, embodiments, examples and alternatives set out in the preceding paragraphs, in the claims and/or in the following description and drawings, and in particular the individual features thereof, may be taken independently or in any combination. That is, all embodiments and/or features of any embodiment can be combined in any way and/or combination, unless such features are incompatible. For the avoidance of doubt, the terms“may”,“and/or”,“e.g.”,“for example” and any similar term as used herein should be interpreted as non-limiting such that any feature so-described need not be present. Indeed, any combination of optional features is expressly envisaged without departing from the scope of the invention, whether or not these are expressly claimed. The applicant reserves the right to change any originally filed claim or file any new claim accordingly, including the right to amend any originally filed claim to depend from and/or incorporate any feature of any other claim although not originally claimed in that manner.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings in which:

FIG. 1 depicts a preform mold assembly according to an embodiment of the invention;

FIG. 2 depicts the preform mold assembly of FIG. 1 with the melt distributor omitted;

FIG. 3 depicts the core plate assembly of the preform mold assembly of FIGs 1 and 2 with one core omitted and another core assembly shown exploded;

FIG. 4 depicts an enlarged view of the region of FIG. 3 which includes the exploded core assembly;

FIG. 5 depicts a side view of part of the core plate assembly of FIGs. 3 and 4 illustrating the mounting of one of the cores to the core plate;

FIG. 6 depicts a section view through one of the core assemblies and an adjacent portion of the core plate to which the core assembly is secured;

FIG. 7 depicts a core cooling tube assembly of the core assembly of FIG. 6 shown from a first side;

FIG. 8 depicts the core cooling tube assembly of FIG. 7 shown from a second side;

FIG. 9 depicts an alternative, unitary core cooling tube assembly shown from a first side;

FIG. 10 depicts the core cooling tube assembly of FIG. 9 shown from a second side;

FIG. 11 depicts a section view along a central, axial plane through the core cooling tube assembly of FIGs. 9 and 10;

FIG. 12 depicts a further alternative, unitary core cooling tube assembly shown from a first side;

FIG. 13 depicts the core cooling tube assembly of FIG. 12 shown from a second side;

FIG. 14 depicts a section view along a central, axial plane through the core cooling tube assembly of FIGs. 12 and 13;

FIG. 15 depicts a yet further alternative, unitary core cooling tube assembly shown from a first side;

FIG. 16 depicts the core cooling tube assembly of FIG. 15 shown from a second side;

FIG. 17 depicts a section view along a central, axial plane through the core cooling tube assembly of FIGs. 15 and 16;

FIG. 18 depicts an alternative, two-part core insert for use in the preform mold assembly of

FIGs. 1 and 2;

FIG. 19 depicts the two-part core insert of FIG. 18 in an exploded view;

FIG. 20 depicts a section view of a stack assembly incorporating the two-part core insert of

FIGs. 18 and 19 along a central, axial plane;

FIG. 21 depicts the moving part of the preform mold assembly of FIGs. 1 and 2, including the core plate assembly and stripper plate assembly;

FIG. 22 depicts the stripper plate of the stripper plate assembly of the moving part shown in FIG. 21;

FIG. 23 depicts an exploded view of a pair of slides of the stripper plate assembly of FIG. 18;

FIG. 24 depicts three neck ring halves and their associated retaining assemblies that secure them to the slides;

FIG. 25 depicts an enlarged view of part of the stripper plate assembly of the moving half of FIG. 21 with the neck ring pairs omitted to expose the slides;

FIG. 26 depicts an enlarged view of FIG. 25 with the connecting bars omitted and illustrating the insertion of the guide shaft;

FIG. 27 depicts the cavity plate assembly of the preform mold assembly of FIGs. 1 and 2 with one of the cavity assemblies removed therefrom;

FIG. 28 depicts one of the cavity assemblies of the cavity plate assembly of FIG. 27;

FIG. 29 depicts the cavity insert of the cavity assembly of FIG. 28 with the gate insert omitted;

FIG. 30 illustrates the cooling channels in segment A-A of the cavity insert of FIG. 29;

FIG. 31 depicts the gate insert of the cavity assembly of FIG. 28;

FIG. 32 depicts one of the retaining pins of the cavity assembly of FIG. 28;

FIG. 33 depicts a partial section view of the cavity plate assembly through a column of cavity inserts of the cavity plate assembly of FIG. 27;

FIG. 34 depicts a partial section view of the cavity plate assembly through a row of cavity inserts of the cavity plate assembly of FIG. 27;

FIG. 35 depicts an enlarged view of the bypass and retaining pin region of the partial section view of FIG. 34;

FIG. 36 depicts a similar view to FIG. 35 illustrating an alternative bypass channel configuration;

FIG. 37 depicts a similar view to FIGs. 35 and 36 illustrating an alternative retaining pin configuration in which the bypass channel is described between the retaining pin and the cavity insert;

FIG. 38 depicts a partial section view of the gate region of an alternative cavity plate assembly in which a gate pad is provided between the nozzle tip and gate insert;

FIG. 39 depicts an exploded view of the gate pad and gate insert of FIG. 38;

FIG. 40 depicts a partial section view of the mold of FIG. 1 illustrating one mold stack, but with the melt distributor and core cooling tube assembly both omitted;

FIG. 41 depicts an enlarged view of area B of FIG. 39 illustrating the gap between the stripper plate and the core plate;

FIG. 42 depicts the cavity plate assembly of FIG. 27 being lowered onto the moving part illustrated in FIG. 21 during assembly; and

FIG. 43 depicts part of the alignment procedure for aligning the cores and neck rings relative to the cavities of the cavity plate assembly.

DETAILED DESCRIPTION OF THE INVENTION

With reference to FIGs. 1 and 2, there is depicted a non-limiting embodiment of a preform mold assembly 100 according to the invention, which includes forty-eight cavities in this embodiment. The mold assembly 100 includes a first, moving part 110 for mounting to the moving platen (not shown) of an injection molding machine (not shown) and a second, stationary part 120 for mounting to the stationary platen (not shown) in the usual way. The first, moving part 110 includes a core plate assembly 200 and a stripper plate assembly 300. The second, stationary part 120 includes a cavity plate assembly 400 and a melt distributor 500, commonly referred to as a hot runner. In this embodiment, the melt distributor 500 is of a conventional type. This invention is particularly concerned with the product specific assembly 130 shown in FIG. 2, commonly referred to as the‘cold half 130. The cold half 130 includes the core plate assembly 200, stripper plate assembly 300 and cavity plate assembly 400.

As shown more clearly in FIGs. 3 and 4, the core plate assembly 200 includes a core plate 210, a pair of cam plates 220, four guide pins 230 and a plurality of core assemblies 240. The core plate 210 is substantially rectangular in plan with scalloped comers 211, for accommodating the tiebars (not shown) of an injection molding machine (not shown) within which the mold is mounted. The core plate 210 also includes four guide pin holes 212 through its thickness, which are horizontally inboard of each scalloped comer 211 and securely receive the guide pins 230. The core plate 210 also includes a plurality of ejector holes 213 through its thickness, for accommodating ejector pins (not shown).

A network of cooling channels 214a, 214b is included within the core plate 210, which feed into a plurality of cooling channel seats 215 in a front face CRF of the core plate 210 (as illustrated in FIG. 6). The cooling channel seats 215 are arranged in an array of six vertical columns and eight horizontal rows. Each seat 215 is surrounded by three core mounting holes 216, which extend through the thickness of the core plate 210 and are counterbored on a rear face CRR of the core plate 210. An array of coupling bolts 217 are also inserted into holes in the core plate 210, which are also counterbored on the rear face CRR. One of the cam plates 220 is bolted to a central, lower region of the front face CRF of the core plate 210 and includes a pair of cam slots 221 on its upper surface. The other cam plate 220 is bolted to a central, upper region of the front face CRF of the core plate 210 and includes a similar pair of cam slots 221 on its lower surface. Both cam plates 220 have the same configuration, varying only in their orientation. The cam slots 221 of each cam plate 220 extend perpendicularly from the front face CRF and converge toward the free end of the cam plate 220.

As illustrated more clearly in FIGs. 4 to 8, each core assembly 240 includes a hollow core insert 250 and a core cooling tube assembly 260, 270. In this example, the core cooling tube assembly 260, 270 includes a coolant diverter 260 received in one of the cooling channel seats 215 of the core plate 210 and a core cooling tube 270 releasably secured to the coolant diverter 260 and received within the hollow core insert 250.

Each core insert 250 includes a substantially cylindrical base 251 and a molding portion 252 joined to the base 251 by a taper 253. The molding portion 252 has an outer molding surface 252a, for molding an inner surface of a preform in the usual way, a tapering transition region 252b for molding a

transition region between neck and body regions of the preform and a top sealing surface portion TSS for molding part of the top sealing surface of a preform. The core taper 253 extends from the top sealing surface portion TSS to a front surface 251a of the base 251 and includes a single, male taper 253 for a stack configuration known in the art as a so-called‘cavity-lock’ design. However, it will be appreciated that the core insert 250 may be of the so-called‘core-lock’ design without departing from the scope of the invention.

In this example, each core insert 250 includes a substantially planar mounting surface 254 and three threaded blind holes 255 extending from the mounting surface 254. The core inserts 250 are therefore mounted from the rear, or rear mounted, whereby bolts 218 are inserted into the core mounting holes 216 from the rear face CRR of the core plate 210 and threadedly engage the threaded holes 255 of the core inserts 250. This is illustrated in FIG. 5. This rear mounting enables the core inserts 250 to be secured from the rear of the core plate 210. As such, the pitch between the core inserts 250 can be reduced without obstructing access to the bolts 218, as would be the case with traditional core inserts having a flange with through holes for receiving front mounted bolts 218.

As discussed in more detail below, this rear mounting, in combination with the substantially planar mounting surface 254, also enables the core inserts 250 to be mounted loosely to the front face CRF of the core plate 210 in a floating manner and fixed securely relative thereto after the mold 100 or cold half 130 is fully assembled. More specifically, by loosely tightening the bolts 218, the clearances between them and the core mounting holes 216 allow a degree of sliding movement between the mounting surfaces 254 of the core inserts 250 and the front face CRF. The mounting surface 254 describes a terminal end of the core insert 250 and is free of any projections, thereby to enable the core inserts 250 to slide relative to the core plate 210. With the mold 100 or cold half 130 in an assembled condition, the bolts 218 are still accessible from the rear face CRR of the core plate 210 and can therefore be torqued to fix the core inserts 250 securely to the core plate 210.

It is also envisaged, however, that the core insert 250 could be provided with a spigot that extends from the mounting surface 254. In some cases, the spigot (not shown) could be smaller than the seat 215 in the core plate 210 to enable some sliding movement therebetween. In other examples, the spigot may be substantially the same size as the seat 215 in the core plate 210.

Referring now to FIG. 6, each core insert 250 includes a central bore 250a extending from the mounting surface 254 to a hemispherical or domed, closed end adjacent the free end of the molding portion 252. The central bore 250a includes a tapering, intermediate region 250b corresponding to the tapering transition region 252b of the outer molding surface 252a. As such, the wall thickness between the central bore 250a and the outer molding surface 252a remains substantially constant along the entire molding portion 252. The mounting surface 254 also includes a shallow recess 256 surrounding the central bore 250a and defining therebetween a shutoff surface 257. The shutoff surface 257 also includes an O-ring groove 258 between the recess 256 and the central bore 250a, within which an O-ring 259 is received for sealing the interface between the central bore 250a and the core plate 210.

Each coolant diverter 260, shown in FIGs. 6 to 8, is substantially cylindrical and includes an axial blind bore 261, a radial bore 262 orthogonal to the axial bore 261 and a peripheral recess 263 parallel to the axial bore 261. The axial bore 261 extends from an upper surface 264 of the diverter 260 and terminates adjacent a lower surface 265 thereof. The axial bore 261 includes an enlarged portion 261a extending from the upper surface 264 and is threaded along part of its length to provide a connector for the core cooling tube 270. The radial bore 262 extends from the blind end of the axial bore 261 to a circumferential surface 266 on the opposite side of the diverter 260 to the peripheral recess 263. The axial bore 261 and radial bore 262 together provide a first cooling channel 261, 262 of the coolant diverter 260.

The peripheral recess 263 extends about approximately half of the circumference of the diverter 260 from the upper surface 264 toward the lower surface 265, terminating on an opposite side to the axial bore 261 such that the circumferential surface 266 extends around the entire periphery of the lower end of the diverter 260. The peripheral recess 263 cooperates with a facing surface of the cooling channel seat 215 to describe a second cooling channel of the coolant diverter 260, with an inlet described at the front face CRF of the core plate 210 and an outlet corresponding to the opening of the facing cooling channel 214b in the cooling channel seat 215.

Each coolant diverter 260 also includes a locator in the form of a retaining lip 267, which projects from the circumferential surface 266 about the periphery of the opening of the radial bore 262. The coolant diverter 260 is formed of a resilient plastics material, such that the retaining lip 267 is resiliently deformable. As such, insertion of the diverter 260 into the cooling channel seat 215 causes the retaining lip 267 to deform resiliently until both the depth and orientation of the diverter 260 within the cooling channel seat 215 are such that the radial bore 262 is aligned with a facing cooling channel 214a. Upon alignment between the radial bore 262 and the cooling channel 214a, the retaining lip 267 snaps into the cooling channel 214a and returns to its original shape. As a result, the retaining lip 267 provides a snap fit connector, acting both as a locating means, ensuring proper alignment of the radial bore 262 and cooling channel 214a, and as a retaining means for retaining the diverter 260 within the cooling channel seats 215. In this orientation, the peripheral recess 263 is aligned with a cooling channel 214b on the opposite side of the cooling channel seat 215. Whilst the retaining lip 267 is a convenient and preferred configuration, it may be replaced with a depression for receiving a projection on a facing surface of the cooling channel seat 215.

Each core cooling tube 270 includes first, second and third tubular segments 271, 272, 273. The first tubular segment 271 has a first outer diameter, the second tubular segment 272 has a second outer diameter, larger than the first outer diameter, and the third tubular segment 273 has a third outer diameter between the first and second outer diameters. The second tubular segment 272 also includes tapered ends 272a, 272b, which provide a transition between the three diameters. The outer surfaces of the second and third segments 272, 273 correspond broadly to the profile of the central bore 250a of the core insert 250 within which the core cooling tube 270 is received, which is configured to provide a predetermined flow area between the outer surface of the core cooling tube 270 and the central bore 250a to maximise cooling effectiveness.

The first tubular segment 271 includes an externally threaded lower end 271a, which is received within, and threadedly engages the internal threads of, the enlarged axial bore portion 261a of one of the coolant diverters 260. The inner diameter of the second tubular segment 272 is larger than that of the first tubular segment 271, an upper end of which is received in the second tubular segment 272. The inner diameters of the second and third tubular segments 272, 273 are substantially the same. The third tubular segment 273 is secured at its lower end to the second tubular segment 272 and includes an upper, free end which has a jagged-toothed profile including four pointed teeth 273a. The third tubular segment 273 also includes spacing vanes 273b in an intermediate portion thereof, adjacent but spaced from the teeth 273 a and aligned between each pair of teeth 273 a.

The teeth 273a ensure that any unintended forward movement of the core cooling tube 270 caused by fluid pressure flowing therethrough does not close off the flow between the core cooling tube 270 and the internal, domed end of the central bore 250a of the core insert 250. The spacing vanes 273b ensure that the core cooling tube 270 is also located centrally within the core insert 250. These spacing vanes 273b are configured to restrict radial movement of the core cooling tubes 270 by engaging against facing surfaces of the central bore 250a of the core insert 250. This arrangement maintains the position of the core cooling tube 270 within the central bore 250a, thereby ensuring that the flow profile of the cooling fluid is distributed substantially evenly therealong.

The flow direction of cooling fluid from the cooling channels 214a, 214b is indicated by the arrows in FIG. 6. As shown, cooling fluid flows from a first, inlet cooling channel 214a into the radial bore 262 of the coolant diverter 260, which acts as an inlet portion of first cooling channel 261, 262, then flows up and out of the axial bore 261, which acts as an outlet portion. The cooling fluid then flows through and out of the core cooling tube 270 to impact the center of the domed end of the central bore 250a of the core insert 250. The domed end of the core insert 250 then causes the flow to reverse, in an umbrella-like fashion to the annular gap between the outer surface of the core cooling tube 270 and the central bore 250a. However, it will be appreciated that the cooling fluid flow could otherwise flow through in the opposite direction.

The outer surface of the core cooling tube 270 corresponds broadly to the profile of the central bore 250a of the core insert 250 within the molding portion 252, thereby to provide a predetermined annular flow area, which is less than the flow area within the core cooling tube 270. As such, the cooling fluid is throttled along this annular flow area to create a turbulent flow to increase heat transfer between the molding portion 252 and the cooling fluid. The cooling fluid then flows into the peripheral recess 263 of the coolant diverter 260 and out of the cooling channel 214b on the opposite side of the cooling channel seat 215. As such, the peripheral recess 263 acts as an outlet for the cooling fluid back into the network of cooling channels 214a, 214b.

The coolant diverter 260 is formed of a resilient plastics material, such as by molding or additive manufacturing. However, the skilled person will appreciate that it is also possible to form the coolant diverter 260 from a different, more rigid plastics or metallic material, with the retaining lip 267 being provided either as an insert made of a resilient material or formed by overmolding the body of the coolant diverter 260 with a resilient material. In addition, the core cooling tube 270 is formed of stainless steel, with the tubular segments 271, 272, 273 and spacing vanes 273b being brazed together. However, the core cooling tube 270 may instead be formed as a unitary body, such as by an additive

manufacturing technique. The core cooling tube 270 may be formed of a different material, which may be a metallic or plastics material, and/or may be formed by any other suitable process.

FIGs. 9 to 11 illustrate an alternative core cooling tube assembly 1260, 1270, which is similar to the core cooling tube assembly 260, 270 described above, wherein like features are labelled with like references with the addition of a preceding‘ . As shown, this core cooling tube 1270 differs, inter alia, in that the first, second and third tubular segments 1271, 1272, 1273 and the coolant diverter 1260 are all formed integrally. The third tubular segment 1273 of the core cooling tube 1270 also includes an open end 1273a described by a truncated dome 1273a, in place of the jagged-toothed end of the core cooling tube 270 described above.

The provision of a jagged-toothed end is not necessary in this example, since the core cooling tube 1270 and coolant diverter 1260 are integral in this example and there is little risk of separation. In addition, the truncated dome 1273a includes an aperture A having a smaller diameter than the bore in the third tubular segment 1273, thereby describing a flow area which is less than the flow area through the third tubular segment 1273. As a result, cooling fluid flowing through the core cooling tube 1270 accelerates as it flows out through the aperture A. This configuration also focuses the flow directly toward a central region of the domed end of the central bore 250a of the core insert 250, before the flow is reversed as described above. This reduction in flow area to provide an accelerated, directed flow has been found to improve cooling performance.

In contrast, the teeth 273a in the core cooling tube 270 described above provide an effective increase in the flow area as compared with the flow area through the third tubular segment 273. Indeed, some of the flow of coolant fluid from the third tubular segment 273 will exit through the spaces between the teeth 273 a and be entrained with the reversed flow through the annular gap between the outer surface of the core cooling tube 270 and the central bore 250a of the core insert 250, thereby avoiding the domed end of the central bore 250a of the core insert 250.

It will be appreciated by those skilled in the art that this, end region of the core insert 250 is exposed to the highest temperatures, since molten plastic introduced into the cavity impinges directly on it during the molding process. As such, the reduction in flow area and directed flow toward this region of the core insert 250, which are provided by the core cooling tube 1270 according to this example, are particularly beneficial.

The coolant diverter 1260 is a continuation of the first tubular segment 1271, with a gradual, curved tubular transition portion 1263 between the axial bore 1261 and the radial bore 1262. The coolant diverter 1260 also includes three spacer fins 1266, which center it within the cooling channel seat 215 of the core plate 210. The radial bore 1262 and curved transition joining it to the axial bore 1261 are formed by the tubular transition portion 1263, which has a substantially constant thickness, thereby maximizing the flow area around the coolant diverter 1260, as compared with the shallow recess 263 of the coolant diverter 260 shown in FIGs. 6 to 8. This alleviates the flow restriction created by the recess 263, thereby reducing the pressure drop as the cooling fluid travels out of the core insert 250 back into the network of cooling channels 214a, 214b.

A retaining lip 1267 is formed by a tapered end of the tubular transition portion 1263, which functions in a similar manner to the retaining lip 267 described above. The integral structure is formed of a suitable plastics material, which is sufficiently resilient to enable the retaining lip 1267 to deform resiliently upon insertion of the coolant diverter 1260 into the cooling channel seat 215, to snap into the cooling channel 214a and return to its original shape. However, the core cooling tube 1270 should be formed of a material that is also sufficiently rigid for it to retain its shape under the pressure of the cooling fluid. In an effort to mitigate the effects of any deformation of the core cooling tube 1270, the second tubular segment 1272 includes three spacing vanes 1272c spaced equally about its periphery and the third tubular segment 1273 includes six spacing vanes 1273b spaced equally about its periphery, with every other spacing vane 1273b being staggered axially with respect to adjacent spacing vanes 1273b. Of course, it is also possible that different parts of the integral structure are formed with different materials, thereby to provide additional rigidity where it is needed. It is preferred that the coolant diverter 2260 and core cooling tube 2270 are formed integrally to provide a seamless unitary monolithic structure. This can be via an additive manufacturing process, for example and without limitation.

Turning now to FIGs. 12 to 14, there is shown a further alternative core cooling tube assembly 2260, 2270, which is similar to the core cooling tube assembly 1260, 1270 described immediately above, wherein like features are labelled with like references with the preceding‘ 1’ replaced with a preceding ‘2’ . As shown, this core cooling tube 2270 differs in that the third tubular segment 2273 only includes three spacing vanes 2273b, which are aligned axially and distributed evenly about the periphery of the third tubular segment 2273.

In addition, the coolant diverter 2260 includes a part-circumferential wall 2268, with an outer surface akin to the circumferential surface 266 of the core cooling tube 270 according to the first example, but a retaining lip is not shown. This, part-circumferential wall 2268 is spaced from the main body of the coolant diverter 2260, which defines the axial bore 2261, and cooperates with the facing surface of the cooling channel seat 215 of the core plate 210 to provide a substantially sealed connection between the radial bore 2262 and the facing cooling channel 214a. Whilst no retaining lip is shown in FIGs 12 to 14, the skilled person will appreciate that such a retaining lip may be incorporated in this example.

The coolant diverter 2260 also includes a spacer fin 2266 on the opposite side to the part-circumferential wall 2268. As such, spacer fin 2266 and the part-circumferential wall 2268 together center the coolant diverter 2260 within the cooling channel seat 215 of the core plate 210. In addition, the bottom of the coolant diverter 2260 is provided with a locating spigot 2265 having a notch 2265a in its lower surface. The locating spigot 2265 is received in a locating recess (not shown) in the base of a variation of the cooling channel seat 215 of the core plate 210 shown in FIG. 6. The locating recess (not shown) also includes a projection, which engages the notch 2265a to ensure orientational alignment between the radial bore 2262 and the facing cooling channel 214a. Whilst the notch 2265a does not provide a retaining means in this example, it may be replaced with a radial projection that engages a facing depression in the locating recess (not shown) to provide both a locating means and a retaining means.

The tubular transition portion 2263 is joined to the part-circumferential wall 2268 about the inlet to the radial bore 2262. As such, the coolant diverter 2260 according to this example more rigidly secures the core cooling tube 2270 in the cooling channel seat 215 of the core plate 210 as compared with the coolant diverter 1260 according to the second example, whilst minimizing the reduction in flow area around the tubular transition portion 2263. As such, this arrangement maintains substantially the advantages mentioned above in relation to the coolant diverter 1260 according to the second example, namely reducing the pressure drop as the cooling fluid travels out of the core insert 250 back into the network of cooling channels 214a, 214b.

FIGs. 15 to 17 illustrate yet a further alternative core cooling tube assembly 3260, 3270, which is similar to the core cooling tube assembly 2260, 2270 described immediately above, wherein like

features are labelled with like references with the preceding‘2’ replaced with a preceding‘3’. As shown, this core cooling tube assembly 3260, 3270 differs only in that the part-circumferential wall 3268 of the coolant diverter 3260 is joined to the main body which defines the axial bore 3261 by webs 3264a, 3264b about its periphery. More specifically, the upper edge of the part-circumferential wall 3268 is joined to the main body by an annular web 3264a and the axial side edges of the part-circumferential wall 3268 are joined to the main body by a respective axial web 3264b. This produces a cavity between the part-circumferential wall 3268, the main body and the webs 3264a, 3264b.

This arrangement improves further the rigidity of the engagement between the core cooling tube 3270 and the cooling channel seat 215 of the core plate 210. However, the resulting reduction in flow area around the tubular transition portion 3263 increases the pressure drop as the cooling fluid travels out of the core insert 250 back into the network of cooling channels 214a, 214b, as compared to the core cooling tubes 1270, 2270 according to the second and third examples. As with the core cooling tube 2270 according to the third example, a retaining lip may be incorporated in this example.

An alternative, two-part core insert 1250 is shown in FIGs. 18 to 20, which can be used in the preform mold assembly 100 in place of the aforementioned core insert 250. The two-part core insert 1250 is similar to the core insert 250 described above, wherein like features are labelled with like references with the addition of a preceding‘G. As shown, this, two-part core insert 1250 differs from the core insert 250 described above in that it includes a primary core insert 1250a and a core ring 1250b.

In this example, the forwardmost part of the base 1251 of the primary core insert 1250a is recessed to provide a front face 1251a and an interface portion 1251b projecting from the front surface 1251a. The core ring 1250b includes a base portion 1251’ or flange 125G with a front surface 1251a’ corresponding to the front surface 251a of the core insert 250 described above. The core ring 1250b also includes an internal interface surface 1251b’ and a male taper 1253 corresponding to the male taper 253 of the core insert 250 described above. The interface portion 1251b is received by the core ring 1250b in contact with the internal interface surface 1251b’ thereof in a press-fit condition.

As illustrated more clearly in FIG. 20, the provision of a core ring 1250b provides a venting path from the inner corner of the neck opening of the preform cavity, between the primary core insert 1250a and the core ring 1250b. This enables the parting line between the two-part core insert 1250 and split mold inserts 350, or neck rings 350, to be moved from the top sealing surface to the outer corner of the neck opening. The reasons for this and its significance will be immediately apparent to the skilled addressee. In this example, the core ring 1250b includes a pair of vent passages CRV extending from the internal interface surface 1251b’ to a collector groove CG define through the outer surface of the male taper 1253. In operation, air venting through the vent passages is directed by the collector groove CG to which is aligned with a lower vent passages LNRV defined on mating faces of through the neck ring 350. As shown the neck ring 350 further includes upper vent passages UNRV defined on the mating faces thereof.

Turning now to FIG. 21, the moving part 110 of the mold assembly 100 is shown in isolation, with the cavity plate assembly 400 omitted to expose features of the stripper plate assembly 300. The stripper plate assembly 300 includes a stripper plate 310, six slide pairs 320 slidably mounted to the stripper plate 310, upper and lower guide assemblies 330, which guide the movement of the slide pairs 320 along the stripper plate 310 and four connecting bars 340. In this example, the mold stack includes a plurality of split mold inserts 350, or neck rings 350, arranged in pairs and mounted on the slides 320 for movement therewith.

The stripper plate 310, which is shown more clearly in FIG. 22, is substantially rectangular in plan with scalloped corners 311, which are aligned with the scalloped corners 211 of the core plate 210 for accommodating the tiebars (not shown) of an injection molding machine (not shown) within which the mold is mounted. The stripper plate 310 also includes four guide pin bushings 312 with associated holes (not shown) through its thickness, which are horizontally inboard of each scalloped corner 311 for receiving the guide pins 230 of the core plate 210. The stripper plate 310 also includes a plurality of core insert holes 313 through its thickness, upper and lower cam plate holes 314 and ten wear or bearing plates 315, hereinafter bearing plates 315, which provide bearing surfaces along and against which the slides 320 move along the stripper plate 310.

Each guide pin bushing 312 is in the form of a hollow cylinder and is bolted to the stripper plate 310 by four bolts 312a. Each guide pin bushing 312 also includes a grease nipple 312b for introducing grease onto the inner surface thereof in the usual way. The internal diameter of the guide pin bushings 312 provides a small gap between the guide pins 230 and guide pin bushings 312 within which grease introduced via the grease nipple 312b is received, such that the guide pins 230 slide freely within the guide pin bushings 312 to support the stripper plate 310 during movement between it and the core plate 210 in the usual way.

The core insert holes 313 are arranged in an array of six vertical columns and four horizontal rows and each is configured to accommodate the base 251 of one of the core inserts 250. Each core insert hole 313 is sized to provide a clearance between it and the core insert base 251 in order to prevent contact between them as the stripper plate 310 is moved toward and away from the core plate 210 along the guide pins 230. The cam plate holes 314 are obround in shape and configured to accommodate the cam plates 220. Each cam plate hole 314 is sized to provide a clearance between it and the cam plate 220 in order to prevent contact between them as the stripper plate 310 is moved toward and away from the core plate 210 along the guide pins 230. A pair of threaded guide bracket mounting holes 330a are included between each column of the core insert holes 313, both at the top and the bottom of the stripper plate 310. A pair of guide bracket dowels 330b are also included between each pair of guide bracket mounting holes 330a.

The bearing plates 315, which may also be referred to as wear plates 315, are formed of a wear resistant material. Each bearing plate 315 is substantially rectangular in plan and includes two holes

316 through its thickness and four part-circular cut-outs 317a, 317b. The pitch spacing of the bearing plate holes 316 corresponds to the pitch spacing of the core insert holes 313 along each vertical column. Two of the part-circular cut-outs 317a are at the center of the short edges of the bearing plate 315 and the pitch spacing of each part-circular cut-out 317a and its adjacent bearing plate hole 316 also corresponds to the pitch spacing of the core insert holes 313 along each vertical column. The other two part-circular cut-outs 317b are at the center of the long edges of the bearing plate 315. As such, the bearing plates 315 are symmetrical about a central, longitudinal axis.

The bearing plates 315 are placed lengthwise along one of the vertical columns, with the bearing plate holes 316 and part-circular cut-outs 317a aligned with the core insert holes 313. Three bearing plates 315 are mounted along each of the two central columns of core insert holes 313, whilst a single bearing plate 315 is mounted at the vertical center of the four outermost columns. In the mold according to this disclosure, bearing plates 315 are selectively positioned to provide balanced support for the slide pairs 320 during ejection, whilst minimising their number to reduce cost. This is made possible by virtue of the load paths which result from the overall design of the mold assembly 100, which is discussed below.

Each slide pair 320, shown more clearly in FIG. 23, includes first and second slides 320a, 320b, which have essentially the same design. Each slide 320a, 320b is in the form of a bar having a substantially square or near-square cross-section, with a plurality of semi-circular cut-outs 321 along one of its sides and a guide hole 322 at each of its ends 323a, 323b and extending from one side through to the other side. A guide bushing 322a is received in each of the guide holes 322 and is retained therein by an interference fit, although other arrangements are also envisaged. The centermost slides 320a, 320b also include a cam follower 324 (shown in FIG. 25) at each end 323a, 323b. Each cam follower 324 is in the form of a roller, which is rotatably mounted to the slide end 323a, 323b for receipt within one of the cam slots 221 of one of the cam plates 220.

Each slide 320a, 320b also includes, in its front face, a first pair of connecting bar mounting holes 325a at a first end 323a, a second pair of connecting bar mounting holes 325b adjacent, but spaced from, a second end 323b, a series of neck ring mounting hole 326 and a series of cooling channel ports 327. One of the neck ring mounting holes 326 is located between each of the semi-circular cut-outs 321 and a further neck ring mounting hole 326 is located on the outer side of each of the semi-circular cut-outs 321 adjacent the ends 323a, 323b of the slide 320a, 320b. In use, the neck rings 350 are mounted to the slides 320a, 320b by the neck ring mounting holes 326 such that the cooling channel ports 327 are aligned with cooling channel ports (not shown) on a facing surface of the neck rings 350. Each cooling channel port 327 includes an O-ring 327a (shown in FIG. 26) for sealing against the neck rings 350. The cooling channel ports 327 are connected to a network of cooling channels (not shown), which are connected to a source of cooling fluid in the usual way.

In this example, the neck rings 350 are secured to the slides 320a, 320b in a floating manner by a retainer assembly of the kind described in our co-pending application number PCT/CA2018/050693, which is incorporated herein by reference. More specifically and as shown in FIG. 24, each neck ring 350 is formed of a pair of neck ring halves 350a, 350b. A plurality of neck ring halves 350a are positioned longitudinally adjacent to each other on one slide 320a and a corresponding plurality of neck ring halves 350b are positioned longitudinally adjacent to each other on an opposed slide 320b. Each neck ring half 350a, 350b is generally configured conventionally, but is configured to be secured to a slide 320a, 320b with two retainer mechanisms 351.

Each retainer mechanism 351 includes a retainer member in the form of a bolt 352 and an insert member 353. Each bolt 352 has a head portion 352a and a threaded shaft portion 352b. Each insert

member 353 has an upper annular flange portion 353a, a cylindrical body portion 353b extending axially from the flange portion 353a and a cylindrical opening extending axially through the flange portion 353a and the body portion 353b. The bolt 352 is received within the cylindrical opening of the insert member 353 and threadedly engages the neck ring mounting holes 326 to retain the insert member 353 between the bolt 352 and facing surface of the slide 320a, 320b. This results in a fixed spacing between the flange portion 353a of the insert member 353 and the facing surface of the slide 320a, 320b.

Each neck ring half 350a, 350b has a semi-cylindrical central opening 354 such that, when a pair of neck ring halves 350a, 350b are brought together during operation of an injection molding system, the inward surfaces providing opening 354 of the neck ring halves 350a, 350b will define the profile for a neck region of a preform to be molded. Each neck ring half 350a, 350b will be held to a corresponding slide 320a, 320b by a pair of retainer mechanisms 351 at each longitudinal side of the neck ring half 350a, 350b. Each neck ring half 350a, 350b includes an upper, generally arcuate, half-ring portion 355a and a flange portion 355b. The half-ring portion 355a has a tapered side surface 355c and the flange portion 355b has a lower surface 355d and an inner taper surface 355e.

Each neck ring half 350a, 350b also has a pair of longitudinally opposed, generally stepped, semi-cylindrical side apertures 356. Each aperture 356 has a passageway that passes all the way through the flange portion 355b of the neck ring half 350a, 350b. When a pair of neck ring halves 350a, 350b are positioned longitudinally adjacent to each other on a slide 320a, 320b, a cylindrical opening is formed by the two adjacent, facing apertures 356. This opening is configured to receive one of the retainer mechanism 351 and includes a recessed platform described by the step in the facing apertures 356. The depth of this, recessed platform is specifically provided to position the flange portion of 353a of the insert member 353 such that a gap is formed between the lower surface of the flange portion 353a and the upward facing opposite surface of the recessed platform. This gap may be in the range of 0.01 to 0.03 mm, by way of example.

When the neck ring halves 350a, 350b are mounted to the slides, the pressure exerted on the flange portions 355b by the O-rings 327a urges them away from the slide 320a, 320b. The aforementioned gap between the lower surface of the flange portion 353a and the upward facing opposite surface of the recessed platform formed by the stepped side apertures 356 allows a slight (e.g. 0.01 to 0.03 mm) gap to form between the neck ring halves 350a, 350b and the front face of the slides 320a, 320b. This gap enables a degree of sliding, or floating, of the neck ring halves 350a, 350b relative to the slides 320a, 320b, whilst exerting sufficient compression of the O-rings 327a to maintain the sealed interface between the cooling channel ports 327 and the facing cooling channel ports (not shown) of the neck ring halves 350a, 350b.

As such, the neck ring halves 350a, 350b are capable of a degree of sliding movement relative to their respective slides 320a, 320b as the mold halves are brought together. This allows the pairs of neck ring halves 350a, 350b to be repositioned, thereby assisting in proper alignment with the rest of the mold stack. However, it is also envisaged that traditional, non-floating neck rings (not shown) may be used, which is described in more detail below.

FIGs. 25 and 26 illustrates the interconnection between the slide pairs 320 and the stripper plate 310, including one of the guide assemblies 330 and one pair of connecting bars 340. The guide assembly 330 includes a guide shaft 331 having a round cross-section and secured to the stripper plate 310 by seven guide brackets 332. The upper guide assembly 330 is mounted across an upper region of the stripper plate 310, immediately below the upper scalloped corners 311 and guide pin bushings 312. The lower guide assembly 330 is similarly mounted across a lower region of the stripper plate 310, immediately above the lower scalloped corners 311 and guide pin bushings 312.

Each of the upper and lower guide assemblies 330 includes a guide bracket 332 mounted between each slide pair 320 and end guide brackets 332 mounted adjacent each scalloped corner 311. The guide brackets 332 fix the guide shaft 331 in place. Each guide bracket 332 includes a base 333, a clamp member 334 and a pair of bolts 335 received within respective bolt holes 336 in each of the base 333 and clamp member 334. As illustrated in FIG. 26, each guide assembly 330 is assembled by inserting the guide shaft 331 through the guide bushings 322a at one end 323a, 323b of the slides 320a, 320b with the guide bracket base 333 held in place by the guide bracket dowels 330b. The guide bracket clamp members 334 are then placed over the guide shaft 331 and the bolts 335 are inserted into the bolt holes 336 in each of the guide bracket base 333 and clamp member 334. The bolts 335 are threadedly engaged with the guide bracket mounting holes 330a to secure the guide bracket clamp member 334 to the stripper plate 310 and to clamp the guide shaft 331 between the guide bracket clamp member 334 and base 333. As a result, the slides 320a, 320b are retained against the bearing plates 315 of the stripper plate 310, such that they are slidable along the guide shafts 331 and bearing plates 315.

The connecting bars 340 in this example are elongate with a square cross-section and each has six pairs of bolt holes 341 spaced along its length. Bolts 342 are received in each bolt hole 341 and secure the connecting bars 340 to one of the slides 320a, 320b of each slide pair 320, although only one bolt 342 is illustrated in each pair of bolt holes 341 in FIG. 25. One of the connecting bars 340 is connected to the first slide 320a of each slide pair 320 and the other of the connecting bars 340 is connected to the second side 320b of each slide pair 320. As such, sliding movement of one of the first slides 320a causes all of the first slides 320a to move therewith. Similarly, sliding movement of one of the second slides 320b causes all of the second slides 320b to move therewith.

In use, forward movement of the stripper plate 310 away from the core plate 210 causes the cam followers 324 to move along the cam slots 221, which causes the slides 320a, 320b carrying the cam followers 324 to slide along the guide shafts 331 and bearing plates 315 toward one another. This, in turn, causes each of the slide pairs 320 to move away from one another, sliding along the guide shafts 331 and bearing plates 315, to open the neck rings and in so doing eject preforms from the cores in the usual way. Similarly, rearward movement of the stripper plate 310 towards the core plate 210 causes the cam followers 324 to follow a reverse path along the cam slots 221, thereby closing the neck rings.

Turning now to FIG. 27, the cavity plate assembly 400 includes a cavity plate 410, four guide pin bushings 420 and a plurality of cavity assemblies 430. The cavity plate 410 is substantially rectangular in plan with a front face CVF, a rear face CVR and scalloped comers 411. The scalloped corners 411 are aligned with the scalloped corners 211, 311 of the core and stripper plates 210, 310, when the mold 100 is in an assembled condition, for accommodating the tiebars (not shown) of an injection molding machine (not shown) within which the mold is mounted. The cavity plate 410 includes guide pin holes (not shown) through its thickness, which are aligned with the guide pin bushings 420 and are horizontally inboard of each scalloped corner 411 for receiving the guide pins 230 of the core plate 210.

CLAIMS

1. An injection mold (100) comprising:

a core plate assembly (200), a cavity plate assembly (400) and a stripper plate assembly (300) arranged between the core and cavity plate assemblies (200, 400);

a plurality of mold stacks (MS), each of which includes a core insert (250, 1250), a cavity insert (440) and a split mold insert pair (350) arranged therebetween;

the core plate assembly (200) including a core plate (210) having a plurality of the core inserts (250, 1250) mounted thereon;

the stripper plate assembly (300) including a stripper plate (310) with a bearing surface (315) upon which a plurality of slide pairs (323a, 323b) are slidably supported, each slide pair (323a, 323b) being configured to retain a subset of the split mold inserts (350) thereon;

the cavity plate assembly (400) including a cavity plate (410) having a plurality of the cavity inserts (440) mounted thereon;

wherein the mold (100) comprises a molding configuration in which the mold stacks (MS) are closed to define molding cavities and the stack height is configured such that a clamping load (CL) applied, in use, to urge the core plate (210) toward the cavity plate (410) is directed substantially entirely through the mold stacks (MS).

2. An injection mold (100) according to claim 1, wherein the distance between the split mold inserts (350) and the core plate (210), when the mold (100) is in the molding configuration, is greater than the thickness of the stripper plate assembly (300) received therebetween, thereby to prevent the clamping load (CL) from being directed through the stripper plate assembly (300).

3. An injection mold (100) according to claim 1 or claim 2, wherein a gap (G) is provided between the core plate (210) and the stripper plate (310) when the mold (100) is in the molding configuration.

4. An injection mold (100) according to claim 1 or claim 2, wherein a gap is provided between the slides (323a, 323b) and the bearing surface (315) when the mold (100) is in the molding configuration.

5. An injection mold (100) according to claim 3 or claim 4, wherein the distance between the slides (323a, 323b) and the core plate (210), when the mold (100) is in the molding configuration, is greater than the thickness of the stripper plate (310), thereby providing the gap (G).

6. An injection mold (100) according to any preceding claim, wherein each cavity insert (440) comprises a spigot (443) received in a respective seat (412) of the cavity plate (410) and a shoulder surrounding at least part of the spigot (443) and engaging a front face (CVF) of the cavity plate (410), wherein the spigot (443) is shorter than the depth (D) of the cavity plate (410) such that substantially all of the applied clamping load (CL) is directed from the core plate (210) through the mold stack to the cavity plate (410).

7. An injection mold (100) according to claim 6 comprising a gate insert (450) received within each seat (412) of the cavity plate (410) which cooperates with the cavity insert spigot (443) received therein to enable molten material to be injected into the cavity, wherein the gate inserts (450) are recessed with respect to a rear, melt distributor mounting face (CVR) of the cavity plate (410) to substantially inhibit the applied clamping load (CL) from being directed from the melt distributor (500) through the gate inserts (450).

8. An injection mold (100) according to any preceding claim, wherein the split mold insert pair (350) describes a first taper (355c) on a first side, which engages a corresponding taper (447) of the cavity insert (440), a second taper (355e) on a second side, which engages a corresponding taper (253, 1253) of the core insert (250, 1250), and a radial surface (355d) extending from the second taper (355e), a portion of which engages an annular support surface (251a, 1251a’) of the core insert (250, 1250), the projected area of the first taper (355c) in the direction of the clamping load (CL) being substantially the same as that of the second taper (355e) and radial surface (335d) portion.

9. An injection mold (100) according to any preceding claim, wherein only a portion of the clamping load (CL) is directed through the mold stacks (MS) if a predetermined threshold clamping load (CL) is exceeded.

10. An injection mold (100) according to claim 9 comprising one or more columns between the core plate (210) and cavity plate (410), wherein at least a portion of the clamping load (CL) is directed through the one or more columns if the predetermined clamping load (CL) is exceeded.

11. An injection mold (100) according to claim 9 or claim 10, wherein at least a portion of the clamping load (CL) is directed through the stripper plate assembly (300) if the predetermined clamping load (CL) is exceeded.

12. An injection mold (100) according to any preceding claim, wherein the stripper plate assembly (300) comprises a pair of guide shafts (331) secured, in parallel, across opposing sides of the stripper plate (310), each slide (323a, 323b) of each slide pair (323a, 323b) slidably receiving one of the guide shafts (331) through each of its ends such that each slide (323a, 323b) is movable along the pair of guide shafts (331) relative to the stripper plate (310) and relative to one another.

13. An injection mold (100) according to claim 12, wherein each guide shaft (331) is mounted to the stripper plate (310) by a plurality of guide brackets (332).

14. An injection mold (100) according to claim 12 or claim 13 comprising a pair of connecting bars (340) mounted to the slide pairs (323a, 323b), wherein each connecting bar (340) secures together a respective one of the slides (323a, 323b) of each slide pair (323a, 323b) for synchronized movement thereof.

15. An injection mold (100) according to any one of claims 12 to 14 comprising a pair of connecting bars (340) mounted at each end of the slide pairs (323a, 323b), wherein each connecting bar

(340) of each pair secures together a respective one of the slides (323a, 323b) of each slide pair (323a, 323b) for synchronized movement thereof.

16. An injection mold (100) according to claim 14 or claim 15, wherein the connecting bars (340) are mounted to the front of the slides (323a, 323b).

17. An injection mold (100) comprising:

a core plate assembly (200), a cavity plate assembly (400) and a stripper plate assembly (300) arranged between the core and cavity plate assemblies (200, 400);

a plurality of mold stacks (MS), each of which includes a core insert (250, 1250), a cavity insert (440) and a split mold insert pair (350) arranged therebetween;

the core plate assembly (200) including a core plate (210) having a plurality of the core inserts (250, 1250) mounted thereon;

the stripper plate assembly (300) including a stripper plate (310) with a bearing surface (315) upon which a plurality of slide pairs (323a, 323b) are slidably supported, each slide pair (323a, 323b) being configured to retain a subset of the split mold inserts (350) thereon;

the cavity plate assembly (400) including a cavity plate (410) having a plurality of the cavity inserts (440) mounted thereon;

wherein the mold (100) comprises a molding configuration in which the mold stacks (MS) are closed to define molding cavities and a gap (G) is provided between the core plate (210) and the stripper plate (310) such that a clamping load (CL) applied, in use, to urge the core plate (210) toward the cavity plate (410) is directed substantially entirely through the mold stacks (MS).

18. A mold stack (MS) for use in an injection mold (100) according to any preceding claim, the mold stack (MS) comprising a core insert (250, 1250), a cavity insert (440) and a split mold insert pair (350) arranged therebetween, wherein the mold stack (MS) comprises a closed, molding configuration in which molding cavities are defined therebetween and in which a clamping load applied, in use, to urge a core plate (210), to which the core insert (250, 1250) is mounted, toward a cavity plate (410), to which the cavity insert (440) is mounted, is directed substantially entirely through the mold stacks (MS).

19. A mold stack (MS) according to claim 17, wherein the split mold insert pair (350) describes a first taper (355c) on a first side, which engages a corresponding taper (447) of the cavity insert (440), a second taper (355e) on a second side, which engages a corresponding taper (253, 1253) of the core insert (250, 1250), and a radial surface (355d) extending from the second taper (355e), a portion of which engages an annular support surface (251a, 1251a’) of the core insert (250, 1250), the projected area of the first taper (355c) in the direction of the clamping load (CL) being substantially the same as that of the second taper (355e) and radial surface (335d) portion..

20. A stripper assembly (300), comprising:

a stripper plate (310);

a pair of guide shafts (331) secured, in parallel, across opposing sides of the stripper plate (310); and

a plurality of slide pairs (323a, 323b) slidably supported on a bearing surface (315) of the stripper plate (310);

wherein each slide (323a, 323b) of each slide pair (323a, 323b) slidably receives one of the guide shafts (331) through each of its ends such that each slide (323a, 323b) is movable along the pair of guide shafts (331) relative to the stripper plate (310) and relative to one another.

21. A stripper plate assembly (300) according to claim 20, wherein each guide shaft (331) is mounted to the stripper plate (310) by a plurality of guide brackets (332).

22. A stripper plate assembly (300) according to claim 20 or claim 21 comprising a pair of connecting bars (340) mounted to the slide pairs (323a, 323b), wherein each connecting bar (340) secures together a respective one of the slides (323a, 323b) of each slide pair (323a, 323b) for synchronized movement thereof.

23. A stripper plate assembly (300) according to any one of claims 20 to 22 comprising a pair of connecting bars (340) mounted at each end of the slide pairs (323a, 323b), wherein each connecting bar (340) of each pair secures together a respective one of the slides (323a, 323b) of each slide pair (323a, 323b) for synchronized movement thereof.

24. A stripper plate assembly (300) according to claim 22 or claim 23, wherein the connecting bars

(340) are mounted to the front of the slides (323a, 323b).