BACKGROUND
[0001] The present disclosure relates to blow systems for blow molding a container.
More particularly, the embodiments relate to a modular system for blow molding a
container and methods for making the same.
BRIEF SUMMARY
[0002] Some embodiments are directed to a modular system for blow molding a container
comprising a first portion, a second portion, and a third portion. The first portion may
comprise a first shell, a first mold removably coupled to the first shell, a first top plate
removably coupled to the first shell, and a first filler material disposed in a volume
defined by the first shell, the first mold, and the first top plate. The second portion may
comprise a second shell, a second mold removably coupled to the second shell, a second
top plate removably coupled to the second shell, and a second filler material disposed in a
volume defined by the second shell, the second mold, and the second top plate. The first
mold and second mold may be 3D printed. The third portion may comprise a base and a
base mold. The base may be removably coupled to the first shell and the second shell.
The first mold, second mold, and the base mold together may define a blow mold cavity
when the first portion is coupled to the second portion.
[0003] In any of the various embodiments disclosed herein, the system further comprises
a first cavity retainer removably coupled to the first shell, and a second cavity retainer
removably coupled to the second shell.
[0004] In any of the various embodiments disclosed herein, each of the first mold, the
second mold, and the base mold is 3D printed.
[0005] In any of the various embodiments disclosed herein, the first shell, the first top
plate, the second shell, and the second top plate are made of CNC machined metal.
[0006] In any of the various embodiments disclosed herein, each of the first mold, the
second mold, and the base mold is isotropic.
[0007] In any of the various embodiments disclosed herein, the filler material has an
elastic modulus of at least 6300 MPa.
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[0008] In any of the various embodiments disclosed herein, the first mold,the second
mold, and the base mold are made of a polymer comprising cyanate ester.
[0009] In any of the various embodiments disclosed herein, the system further comprises
at least one cooling channel within each of the first mold and the second mold.
[0010] In any of the various embodiments disclosed herein, the system further comprises
a locking ring removably coupled to the first shell. In any of the various embodiments
disclosed herein, the base is configured to releasably engage with the locking ring to
secure the third portion.
[0011] In any of the various embodiments disclosed herein, the system further comprises
a plurality of vertically aligned recesses configured to receive the locking ring such that
the vertical position of the third portion may be adjusted.
[0012] In any of the various embodiments disclosed herein, the first shell, the first top
plate, the second shell, and the second top plate are made of CNC machined metal.
[0013] Some embodiments are directed to an interchangeable mold for blow molding a
container. The mold may comprise a first 3D printed mold portion, a second 3D printed
mold portion, and a 3D printed base portion. The first 3D printed mold portion, the
second 3D printed mold portion, and the 3D printed base mold portion together may
define a blow mold cavity. The first 3D printed mold portion, the second 3D printed mold
portion, and the 3D printed base portion may be isotropic. The first 3D printed mold
portion, the second 3D printed mold portion, and the 3D printed base portion are
configured to engage with a shell, the shell being compatible with a blow mold system to
form blow-molded containers within the blow mold cavity.
[0014] In any of the various embodiments disclosed herein, the firstfiller portion
comprises a first side configured to mate with a back of the first 3D printed mold portion
and a second side configured to mate with an interior side of the shell. In any of the
various embodiments discloses herein, the second filler portion comprises a first side
configured to mate with a back of the second 3D printed mold portion and a second side
configured to mate with the interior side of the shell.
[0015] In any of the various embodiments disclosed herein, the first 3D printed mold
portion, the second 3D printed mold portion, and the 3D printed base mold portion are
made of a polymer comprising cyanate ester.
[0016] In any of the various embodiments disclosed herein, the mold further comprises a
first filler portion and a second filler portion. In any of the various embodiments disclosed
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herein, the first filler portion has a first side in contact with a back of the first 3D printed
mold portion and a second side configured to contact an interior side of the shell and the
second filler portion has a first side in contact with a back of the second 3D printed mold
portion and a second side configured to contact the interior side of the shell.
[0017] In any of the various embodiments disclosed herein, the first filler material and the
second filler material are both a plaster.
[0018] In any of the various embodiments disclosed herein, the first mold portion and the
second mold portion each comprise cooling channels.
[0019] In any of the various embodiments disclosed herein, the mold further comprises a
first cavity retainer and a second cavity retainer for securing the first filler portion and the
second filler portion, respectively.

WHAT IS CLAIMED IS:
1. A modular system for blow molding a container, the system comprising:
a first portion comprising:
a first shell;
a first mold removably coupled to the first shell;
a first top plate removably coupled to the first shell; and
a first filler material disposed in a volume defined by the first shell, the
first mold, and the first top plate;
a second portion removably coupled to the first portion, the second portion
comprising:
a second shell;
a second mold removably coupled to the second shell;
a second top plate removably coupled to the second shell; and
a second filler material disposed in a volume defined by the second shell,
the second mold, and the second top plate;
a third portion comprising a base and a base mold, wherein the base is removably
coupled to the first shell and the second shell,
wherein the first mold, the second mold, and the base mold together define a blow
mold cavity when the first portion is coupled to the second portion.
2. The system of claim 1, further comprising a first cavity retainer removably coupled to the
first shell, and a second cavity retainer removably coupled to the second shell.
3. The system of claim 2, wherein each of the first mold, the second mold, and the base
mold is 3D printed.
4. The system of claim 3, wherein the first shell, the first top plate, the second shell, and the
second top plate are made of CNC machined metal.
5. The system of claim 3, wherein each of the first mold, the second mold, and the base
mold is isotropic.
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6. The system of claim 1, wherein each of the first and second filler material has an elastic
modulus of at least 6300 MPa.
7. The system of claim 1, wherein the first mold, the second mold, and the base mold are
made of a polymer comprising cyanate ester.
8. The system of claim 1, further comprising at least one cooling channel within each of the
first mold and the second mold.
9. The system of claim 1, further comprising:
a locking ring removably coupled to the first shell,
wherein the base is configured to releasably engage with the locking ring to secure
the third portion.
10. The system of claim 9, further comprising a plurality of vertically aligned recesses
configured to receive the locking ring such that the vertical position of the third portion
may be adjusted.
11. An interchangeable mold for blow molding a container, the mold comprising:
a first 3D printed mold portion;
a second 3D printed mold portion; and
a 3D printed base mold portion,
wherein the first 3D printed mold portion, the second 3D printed mold portion,
and the 3D printed base mold portion are configured to together define a blow mold
cavity,
wherein the first 3D printed mold portion, the second 3D printed mold portion,
and the 3D printed base mold portion are isotropic, and
wherein the first 3D printed mold portion, the second 3D printed mold portion,
and the 3D printed base mold portion are configured to engage with a shell, the shell
being compatible with a blow mold system to form blow-molded containers within the
blow mold cavity.
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12. The mold of claim 11, wherein the first 3D printed mold portion, the second 3D printed
mold portion, and the 3D printed base mold portion are made of a polymer comprising
cyanate ester.
13. The mold of claim 11, further comprising:
a first filler portion having a first side in contact with a back of the first 3D printed
mold portion and a second side configured to contact an interior side of the shell; and
a second filler portion having a first side in contact with a back of the second 3D
printed mold portion and a second side configured to contact the interior side of the shell.
14. The mold of claim 13, wherein the first filler material and the second filler material are
both a plaster.
15. The mold of claim 13, further comprising a first cavity retainer and a second cavity
retainer for securing the first filler portion and the second filler portion,respectively.
16. The mold of claim 11, wherein the first 3D printed mold portion and the second 3D
printed mold portion each comprise cooling channels.
17. A method of making a modular blow mold system, the method comprising:
3D printing a first mold portion, a second mold portion, and a base portion;
coupling the first mold portion to a first shell to form a first half, the first half
comprising a first volume defined by the first mold portion and the first shell;
coupling the second mold portion to a second shell to form a second half, the
second half comprising a second volume defined by the second mold portion and the
second shell;
pouring a filler material in the first volume;
pouring the filler material in the second volume; and
cooling the filler material for form a solid filler.
18. The method of claim 17, wherein the first mold portion, the second mold portion, and the
base portion are made of a polymer comprising cyanate ester.
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19. The method of claim 17, wherein the filler material comprises a plaster.
20. The method of claim 19, wherein the plaster is a liquid before the cooling.
21. The method of claim 17, wherein the cooling comprises cooling the filler material at
room temperature.
22. The method of claim 17, wherein the 3D printing step comprises forming at least one
channel in the first mold portion and the second mold portion.
23. The method of claim 17, further comprising coupling the first half and the second half to
form a blow mold comprising a blow mold cavity defined by the first mold portion and
the second mold portion.