MOLD WITH QUICK CONNECTION AND DISCONNECTION

RELATED APPLICATIONS

This application claims priority from U.S. Provisional patent application 62/724,790, filed August 30, 2018, U.S. Provisional Patent Application 62/770,785, filed November 22, 2018, U.S. Provisional patent application no 62/856,833, filed June 4, 2019, and U.S. Provisional patent application no. 62/856,059, filed June 25, 2019, the disclosures of which are incorporated herein by reference.

FIELD

This relates to production of plastic articles, and more particularly, to methods and apparatus for producing molten molding material.

BACKGROUND

In conventional mold assemblies, mold components are bolted together in a stack secured to a platen. Services, such as cooling, pneumatic and electrical services are provided to the mold by way of fixed channels which extend through the mold stack. For a particular mold, most or all of the mold stack and routing of the services channels must be custom-designed and fabricated according to the configuration of the mold and the articles to be produced with the mold. Components for such mold stacks tend to be very expensive because of the amount of custom machining required. Moreover, removing of components for maintenance or repair, or to change the articles being produced, is cumbersome and time consuming.

SUMMARY

An example mold assembly comprises: a service block; a plate defining at least a portion of a molding cavity; a quick connection mechanism operable to connect and disconnect the plate and the services block; wherein in operation of the mold assembly, the services block is connected to the plate with the quick connection mechanism.

In some embodiments, the plate comprises a base block and a mold cavity block; and wherein in operation of the mold assembly, the services block is connected to a platen and the services block is connected to the base block with the quick connection mechanism.

In some embodiments, the quick connection mechanism is operable to connect and disconnect the base block of the plate and the services block.

In some embodiments, the quick connection mechanism is a first connection mechanism and wherein the base block and the mold cavity block are two separate parts that are connected together with a second connection mechanism.

In some embodiments, the second connection mechanism is not a quick connection mechanism.

In some embodiments, the base block and the mold cavity block are formed as a unitary body and wherein the quick connection mechanism is operable to connect and disconnect the base block of the plate and the services block.

In some embodiments, the quick connection mechanism is operable to be selectively engaged to hold the plate and the services block together.

In some embodiments, the quick connection mechanism is operable to selectively interlock the plate and the services block.

In some embodiments, the quick connection mechanism is operable to selectively provide a clamping action between the plate and the services block.

In some embodiments, the quick connection mechanism is operable to switch between connected and disconnected states to connect and disconnect respectively the plate and the services block.

In some embodiments, the mold assemble further comprises an actuator operable to actuate the quick connection mechanism.

In some embodiments, the quick connection mechanism comprises a spring device operable to selectively bias a part of the plate against the services block.

In some embodiments, the quick connection mechanism is operable to selectively hold the services block and the plate together without the installation of a fastener.

In some embodiments, the quick connection mechanism comprises a releasable stud and a socket connector apparatus.

In some embodiments, the mold cavity block has a cavity side with a mold cavity surface topography that comprises a contact surface area and a mold cavity wall surface.

In some embodiments, the magnitude of the contact surface area is selected based on a clamping force of the mold assembly to be applied to the contact surface area.

In some embodiments, the cavity wall surface provides a longitudinal sectional surface profile of the item to be molded.

In some embodiments, the mold cavity wall surface is configured to provide a surface for forming part of a mold cavity.

In some embodiments, the mold cavity wall surface is configured to provide a surface for forming half of a mold cavity.

In some embodiments, the contact surface area of the mold cavity block is configured and operable to engage an opposed contact surface area of a corresponding mold cavity block of a corresponding engaged and mated plate.

In some embodiments, mold cavity surface topography is configured to provide at least part of a vent channel when the contact surface area of the mold cavity block is engaged with an opposed contact surface area of a corresponding mold cavity block of a corresponding engaged and mated plate.

In some embodiments, the mold cavity surface topography is configured to provide at least part of a gate area when the contact surface area of the mold cavity block is engaged with an opposed contact surface area of a corresponding mold cavity block of a corresponding engaged and mated plate.

In some embodiments, the mold cavity surface topography is configured to provide at least part of a core alignment surface located proximate to the mold cavity wall surface of the mold cavity block when the contact surface area of the mold cavity block is engaged with an opposed contact surface area of a corresponding mold cavity block of a corresponding engaged and mated plate.

In some embodiments, the mold cavity surface topography further comprises a non-contact surface area and wherein the contact surface area and the non-contact surface area are generally parallel to each other.

In some embodiments, the mold cavity surface topography further comprises a non-contact surface area that slopes inwardly toward the contact surface.

In some embodiments, the mold assembly further comprises: a first services channel located within the plate; a second services channel located within the services block; wherein the first services channel is in communication with the second services channel such that a service may be delivered from the services block to the plate.

In some embodiments, the mold assembly further comprises: a first services channel located within the base block; a second services channel located within the mold cavity block; a third services channel located within the services block; wherein the first services channel is in communication with the second services channel and the first services channel is in communication with the third services channel such that in operation a service is delivered from the services block to the base block to the mold cavity block.

In some embodiments, the service is cooling fluid operable to cool the mold cavity block.

In some embodiments, the mold cavity block has a cavity side with a mold cavity surface topography that comprises a contact surface area and a mold cavity wall surface and wherein the second services channel has a plurality of portions configured to conform at least in part to the mold cavity wall surface when extending through a body portion of the mold cavity block.

In some embodiments, the mold assembly further comprises a services connecting mechanism operable to connect the first services channel and the third services channel.

In some embodiments, the services connecting mechanism comprises a services quick connection mechanism.

In some embodiments, the mold assembly further comprises: a fourth services channel located within the base block; a fifth services channel located within the services block; wherein the fourth service channel is in communication with the second services channel and the fifth services channel is in communication with the second services channel such that in operation a service is delivered from the services block to the base block to the mold cavity block and then to the base block and then to the services block.

In some embodiments, the quick connection mechanism comprises a pneumatically biased mechanism.

In some embodiments, base block comprises pneumatic ports for operating the pneumatically biased mechanism by a mold handling device.

In some embodiments, the base block and the cavity block have substantially cylindrical mating surfaces.

In some embodiments, the mold assembly defines a mold for blow molding.

In some embodiments, mold assembly further comprises a third connection mechanism that is operable to connect the services block and the platen.

In some embodiments, the services block comprises a first services block, the plate comprises a first plate, and the quick connection mechanism comprises a first quick connection mechanism; and wherein the mold assembly further comprises: a second services block; a second plate defining another portion of the molding cavity; a second quick connection mechanism operable to connect and disconnect the second plate and the second services block; wherein in operation of the mold assembly, the second services block is connected to the second plate with the second quick connection mechanism.

In some embodiments, the first mold cavity block has a cavity side with a first mold cavity surface topography that comprises a first contact surface area and a first mold cavity wall surface and wherein the second mold cavity block has a cavity side with a second mold cavity surface topography that comprises a second contact surface area and a second mold cavity wall surface, such that in operation the first contact surface of the first mold cavity block matingly engages with the second contact surface of the second mold cavity block, the first mold cavity wall surface of the first mold cavity block co operates with the second mold cavity wall surface of the second mold cavity block to form a mold cavity for an item to be molded.

In some embodiments, the first mold cavity surface topography further comprises a first non-contact surface area and wherein the first contact surface area and the first non-contact surface area are generally parallel to each other.

In some embodiments, the second mold cavity surface topography further comprises a second non-contact surface area and wherein the second contact surface area and the second non-contact surface area are generally parallel to each other.

In some embodiments, wherein the first mold cavity surface topography further comprises a first non-contact surface area and wherein the first non-contact surface area slopes inwardly toward the first contact surface, and wherein the second mold cavity surface topography further comprises a second non-contact surface area and wherein the second non-contact surface area slopes inwardly toward the second contact surface.

In some embodiments, comprising a handling coupler projecting from an exterior surface of the plate for engagement by a handling device to remove the plate from the mold assembly.

In some embodiments, the handling coupler comprises a handling quick connection mechanism.

An example plate defining at least a portion of a molding cavity for use in a mold assembly, the plate comprises: a base block; a mold cavity block connected to the base block;a first quick connection device on the base block operable to selectively connect to and disconnect from a second quick connection device on a services block; wherein in operation of the mold assembly, the base block is connected to the services block by operation of the first and second quick connection devices.

In some embodiments, the base block and the mold cavity block are two separate parts that are connected together with a connection mechanism.

In some embodiments, the base block and the mold cavity block are formed as a unitary body.

In some embodiments, the base block further comprises: a first services channel located within the base block; a second services channel located within the mold cavity block; a third quick connection device operable to connect with a fourth quick connection device on the services block; wherein in operation, the first services channel is in communication with a third services channel in the services block, and the first services channel is in communication with the second services channel located within the mold cavity block, when the third quick connection device is operably connected with the fourth quick connection device such that a service may be delivered from the services block to the base block and on to the mold cavity block through the first services channel, the second services channel and the third services channel.

In some embodiments, the plate further comprises: a fourth services channel located within the base block; wherein the fourth services channel is in communication with the second services channel, and the fourth services channel is in communication with a fifth services channel in the services block, such that in operation a service is delivered from the services block to the base block to the mold cavity block and then back to the base block and then back to the services block.

In some embodiments, the first, second, third, fourth and fifth services channels comprise at least part of a fluid cooling circuit for supplying cooling fluid to cool the mold cavity block.

In some embodiments, the first quick connection device comprises a pneumatically biased mechanism.

In some embodiments, the base block and the cavity block have substantially cylindrical mating surfaces.

In some embodiments, a handling coupler projecting from an exterior surface of the plate for engagement by a handling device to remove the plate from a platen.

In some embodiments, the handling coupler comprises a handling quick connection mechanism.

An example molding system comprises: a services block; a first plate defining at least a portion of a first molding cavity; a first quick connection mechanism operable to connect and disconnect the first plate and the services block; a second plate defining at least a portion of a second molding cavity; a second quick connection mechanism operable to connect and disconnect the second plate and the services block; wherein the first plate is operable to be connected to and disconnected from the services block with the first quick connection mechanism and the second plate is operable to be connected to and disconnected from the services block with the second quick connection mechanism whereby the first plate can be interchanged with the second plate to be operable to modify the molding system between having the first molding cavity and the second molding cavity .

In some embodiments, the first plate comprises a base block and a first mold cavity block; the first quick connection mechanism is operable to connect and disconnect the base block of the first plate and the services block; the second plate comprises a base block and a second mold cavity block; the second quick connection mechanism is operable to connect and disconnect the base block of the second plate and the services block.

In some embodiments, the base block of the first plate and the first mold cavity block are two separate parts that are connected by a third connection mechanism.

In some embodiments, the base block of the second plate and the second mold cavity block are two

separate parts that are connected by a fourth connection mechanism.

In some embodiments, the third and fourth connection mechanisms are not quick connection mechanisms.

In some embodiments, the base block of the first plate and the first mold cavity block are formed as a unitary body and the base block of the second plate and the second mold cavity block are formed as a unitary body.

In some embodiments, the first mold cavity block has a base block facing surface connected to the base block of the first plate and an opposed first cavity side with a first cavity surface topography that comprises a first contact surface area and a first cavity wall surface; and wherein the second mold cavity block has a base block facing surface connected to the base block of the second c plate and a second cavity side with a second cavity surface topography that comprises a second contact surface area and a second cavity wall surface, and wherein the first cavity surface topography is configured differently to the second cavity surface topography.

In some embodiments, the first cavity wall surface is configured differently to the second cavity wall surface.

In some embodiments, the first contact surface is shaped differently to the second contact surface.

In some embodiments, the first contact surface and the second contact surface have substantially the same sized surface areas.

In some embodiments, the first cavity surface topography further comprises a first non-contact surface area and wherein the first contact surface area and the first non-contact surface area are generally parallel to each other; and wherein the second cavity surface topography further comprises a second non-contact surface area and wherein the second contact surface area and the second non-contact surface area are generally parallel to each other.

In some embodiments, a handling coupler projecting from an exterior surface of each of the first and second plates for engagement by a handling device to remove the plates from the mold assembly.

In some embodiments, the handling coupler comprises a handling quick connection mechanism.

An example molding system comprises: a services block; a base block; a first mold cavity block; a second mold cavity block; a first connection mechanism operable to connect and disconnect the base block and the services block; a second connection mechanism operable to connect and disconnect each of the first and second mold cavity blocks with the base block; wherein in operation the first and second mold cavity blocks can be interchangeably connected to the base block with the second connection mechanism, and wherein the base block can be connected to the services block with the first connection mechanism.

In some embodiments, the first connection mechanism is a quick connection mechanism.

An example molding system comprises: a first plate defining at least a portion of a first molding cavity that is a separate part to a services block, the first plate having a first cavity wall surface; a first quick connection mechanism operable to connect and disconnect the first plate to a services block; a second plate defining at least a portion of a second molding cavity that is a separate part to the services block, the second plate having a second cavity wall surface; a second quick connection mechanism operable to connect and disconnect the second cavity block and the services block; wherein the first cavity wall surface is configured differently to the second cavity wall surface.

In some embodiments, the first plate has a cavity side with a first cavity surface topography that comprises a first contact surface and the first cavity wall surface; the second plate has a cavity side with a second cavity surface topography that comprises a second contact surface and the second cavity wall surface, and wherein the first cavity surface topography is configured differently to the second cavity surface topography.

In some embodiments, the first contact surface is shaped differently to the second contact surface.

In some embodiments, the first contact surface and the second contact surface have substantially the same sized surface areas.

In some embodiments, the first cavity surface topography further comprises a first non-contact surface and wherein the first contact surface and the first non-contact surface are generally parallel to each other; and wherein the second cavity surface topography further comprises a second non-contact surface and wherein the second contact surface and the second non-contact surface are generally parallel to each other.

In some embodiments, the first cavity surface topography further comprises a first non-contact surface;

and wherein the second cavity surface topography further comprises a second non-contact surface and wherein the sum of the first contact surface area and the first non-contact area is substantially of the same magnitude as the sum of the second contact area and the second non-contact area.

An example mold assembly comprises: a support frame; a first platen supported by the support frame; a first services plate connected to the first platen; a first plate defining a first portion of a molding cavity; a first quick connection mechanism operable to connect and disconnect the first plate and the first services block; a second platen supported by the support frame; a second services plate connected to the second platen; a second plate defining a second portion of the molding cavity; a second quick connection mechanism operable to connect and disconnect the second plate and the second services block: wherein in operation: the first plate is connected to the first services block with the first quick connection mechanism, and the first services block is connected to the first platen; and the second plate is connected to the second services block with the second quick connection mechanism, and the second services block is connected to the second platen.

In some embodiments, the first platen is a stationary platen such that in operation, the stationary platen does not move relative to the support frame; and wherein the second platen is a moving platen such that in operation the moving platen moves relative to the support frame and the stationary platen.

In some embodiments, the first plate comprises a first base block and a first mold cavity block; and wherein in operation of the mold assembly, the first services block is connected to a first platen and the first services block is connected to the first base block with a third quick connection mechanism; and the second plate comprises as second base block and a second mold cavity block; and wherein in operation of the mold assembly, the second services block is connected to a second platen and the second services block is connected to the second base block with a fourth quick connection mechanism.

In some embodiments, the first mold cavity block has a base block facing surface operable to be secured to the first base block and a cavity side with a first cavity surface topography that comprises a first contact surface area and a first cavity wall surface and wherein the second mold cavity block has a base block facing surface operable to be secured to the second base block and a cavity side with a cavity surface topography that comprises a contact surface area and a second cavity wall surface.

In some embodiments, the mold assembly further comprises a core assembly having a core device, in operation the core device being received with a cavity formed by the cavity wall surfaces of the first and second mold cavity blocks to thereby form a mold cavity for an item to be molded.

An example apparatus comprises: a plate defining at least a portion of a molding cavity, the plate comprising a base block and a mold cavity block, the base block having a services channel therein; a connection mechanism operable to connect the mold cavity block to the base block; wherein in operation, the mold cavity block is connected to the base block with the connection mechanism;

wherein the mold cavity block has a cavity surface side and a base block facing surface opposite to the cavity surface side, and the mold cavity block has a trough area formed in the base block facing surface; the apparatus further comprising a services channel module received into the trough area, the services channel module comprising at least one services channel operable to be interconnected to the services channel in the base block.

In some embodiments, the plate is made at least in part from a metal material and the services channel module is made at least in part from a plastic material.

In some embodiments, the cavity surface side has a mold cavity wall surface, and wherein the services channel module is a channel for supplying cooling fluid which is operable to cool the mold cavity block, and wherein the services channel module comprises a cooling fluid channel having a plurality of portions configured to conform at least in part of the mold cavity wall surface when extending from an input port to an output port.

An example method of operating a mold assembly, the mold assembly comprising: a platen; a services block connected to the platen; a first plate defining at least a portion of a first molding cavity; a second plate defining at least a portion of a second molding cavity; a first quick connection mechanism operable to connect and disconnect the first plate and a services block; a second quick connection mechanism operable to connect and disconnect the second plate and the services block; the method comprising interchanging the first plate with the second plate on the services block by operating the first and second quick connection mechanisms.

In some embodiments, the mold assembly further comprises: a first services channel, the first services channel being located within the first plate; a second services channel, the second services channel being located within the second plate; a third services channel located within the services plate;

a first services connecting mechanism operable to connect and disconnect the first services channel and the third services channel; a second services connecting mechanism operable to connect and disconnect the second services channel and the third services channel; wherein when the first plate is connected to the services block and the first service channel is in communication with the third services channel a service is delivered from the services block to the first plate; wherein when the

second plate is connected to the services block and the second service channel is in communication with the third services channel a service is delivered from the services block to the second plate; the method further comprises when the first plate and the second cplate are interchanged by operating the first and second quick connection mechanisms, the first services connecting mechanism disconnects the first services channel and the third services channel; and thereafter the second services connecting mechanism connects the second services channel and the third services channel.

In some embodiments, the first and second services connecting mechanisms both comprise a quick connection mechanism.

In some embodiments, each of the first and second quick connection mechanisms comprise a pneumatically biased mechanism.

In some embodiments, the method comprises releasing the pneumatically biased mechanism of the first quick connection mechanism or the second quick connection mechanism by providing a pressurized air supply by way of the services block.

In some embodiments, the method comprises defining a mold for blow molding.

An example method of forming a mold system comprises: forming a first base block; forming a second base block that is configured substantially the same as the first base block; forming a first and a second mold cavity blocks, each having a base block facing surface operable to be secured to the first and second respective base blocks and a cavity side with a mold cavity surface topography that comprises a contact surface area and a mold cavity wall surface, wherein the configuration of the mold cavity wall surface of the first mold cavity block is different from the configuration of the mold cavity wall surface of the second mold cavity block, but where the size of the contact surface area of the first mold cavity block is substantially similar to the size of the contact surface area of the second mold cavity block connecting the first base block to the first mold cavity block; connecting the second base block to the second mold cavity block.

In some embodiments, the contact surface area of the first mold cavity block is shaped differently than the contact surface area of the second mold cavity block.

In some embodiments, the size of the contact surface area of the first and second mold cavity blocks is selected based on the known size of the clamping force of the mold assembly to be applied to the contact surface area.

In some embodiments, the method further comprises: providing a quick connection device on each of the first and second base blocks, each quick connection device being operable to connect to and disconnect from a common quick connection device on a common services block.

An example method of manufacturing a cavity plate comprises: forming a base block with a quick connection device operable to connect with and disconnect from a quick connection device on a services block; forming a mold cavity block by depositing material on a surface of the base block with an additive manufacturing process to thereby form a mold cavity surface topography that comprises a contact surface area and a mold cavity wall surface.

An example method of forming a cavity plate comprises: forming a base block having a services channel; forming a mold cavity block the mold cavity block having a cavity surface side and a base block facing surface opposite to the cavity surface side, and wherein the mold cavity block has a trough area formed in the base block facing surface; inserting a services channel module into the trough area, the services channel module comprising at least one services channel operable to be interconnected to the services channel in the base block.

An example mold assembly comprises: a pair of mating mold sections cooperatively defining a mold cavity; a pair of services blocks, each for mounting a respective one of the mold blocks to a platen of a molding machine;a handling coupler projecting from an exterior surface of each mold section, for engagement by a handling device to hold the mold blocks together in a mating configuration and to remove the mold assembly from the mold machine.

In some embodiments, the handling coupler comprises a quick connection mechanism.

In some embodiments, the assembly comprises a mold quick connection mechanism operable to connect and disconnect each of the mold sections and sa respective one of the services blocks.

In some embodiments, the mold sections have curved outer surfaces, and the services blocks have corresponding curved inner surfaces to receive the mold blocks.

In some embodiments, the mold quick connection mechanism comprises a connector projecting from one of the curved surfaces.

In some embodiments, the mold assembly is a blow molding assembly.

In some embodiments, the mold assembly comprises a third mold section operable to cooperatively define the mold cavity with the mold blocks.

In some embodiments, the third mold section comprises a quick connection mechanism for coupling to an actuator.

In some embodiments, the services blocks comprise respective load limiting blocks, the load limiting blocks opposing one another with clearance therebetween in a molding configuration of the molding assembly, and operable to abut one another and bear a clamping force in response to compression of the mold blocks.

In some embodiments, the mold blocks are formed of an aluminum alloy.

BRIEF DESCRIPTION OF DRAWINGS

In the drawings, which depict example embodiments:

FIG. 1 is a schematic diagram of a molding system;

FIG. 2 is a schematic diagram of a molding system with process cells defining multiple paths through the system;

FIG. 3 is an isometric view of a molding system;

FIG. 4A-4B are isometric views of a dispensing station of the system of FIG. 3;

FIGS. 4C-4E are isometric views of sub-assemblies of the dispensing station of FIG. 4A;

FIGS. 4F-4G are enlarged partial isometric views of a barrel unit;

FIG. 4F1 is a schematic view of a coupling for holding the barrel unit of FIGS. 4F-4G to a drive unit;

FIGS. 4I-4J are enlarged partial isometric views of the barrel unit of FIG. 4F with a drive unit;

FIG. 4K is a schematic diagram of a removal tool for removing a barrel unit from a drive unit;

FIGS. 4L-40 are enlarged partial cutaway views showing a process of coupling a barrel unit to a drive unit;

FIGS. 4P-4R are enlarged partial cutaway views showing a process of removing a barrel unit from a drive unit;

FIG. 4S is a schematic view of the removal tool of FIG. 4K installing a barrel unit to a drive unit;

FIG. 5 is a longitudinal cross-sectional diagram of the dispensing station of FIG. 4;

FIGS. 6A-6B are isometric and isometric cutaway views, respectively, of a vessel for transporting molding material;

FIGS. 7A-7B are isometric views of the material vessel of FIGS. 6A-6B and a carrier;

FIGS. 8A, 8B, 8C, and 8D are side and cross sectional views showing stages of a dispensing operation at the dispensing station of FIG. 4;

FIG. 9 is an exploded view of a gate assembly;

FIGS. 10A-10B are enlarged cross-sectional views showing operation of the gate assembly of FIG. 9;

FIG. 11 is an isometric view of a shaping station of the system of FIG. 3;

FIGS. 12A-12D are cross-sectional and isometric views of the shaping station of FIG. 11;

FIGS. 13A-13B are isometric and side views, respectively, of a linkage for a clamping assembly;

FIG. 13C is a diagram of forces on the linkage of FIGS. 13A-13B;

FIGS. 14A-14B are isometric and side views, respectively, of another linkage for a clamping assembly;

FIGS. 15A-15B are isometric and side views, respectively, of another linkage for a clamping assembly;

FIG. 16 is a side view of another linkage for a clamping assembly;

FIG. 17 is an isometric view of a core actuation assembly of the shaping station of FIG. 11 ;

FIGS. 18A-18B are isometric and cross-sectional views, respectively, of a core positioning actuator of the core actuation assembly of FIG. 17;

FIG. 19 is an isometric view of a loading actuator of the core actuation assembly of FIG. 17;

FIG. 20 is a partial cutaway view of the loading actuator of FIG. 19;

FIG. 21 A is a schematic view showing interlocking between the core positioning actuator of FIGS. 18A-18B and the loading actuator of FIG. 17;

FIG. 21B is a partial cross-sectional view of the core positioning actuator of FIGS. 18A-18B and the loading actuator of FIG. 17, showing interlocking;

FIG. 22 is an isometric view of a secondary mold opening actuator of the core actuation assembly of FIG. 17;

FIGS. 23A-23D are side, isometric, enlarged top and enlarged perspective views, respectively, of a shaper module of the shaping station of FIG. 11 ;

FIG. 24A-24B are front isometric and top elevation views of another shaping station;

FIG. 24C is a rear isometric view of the shaping station of FIG. 24A;

FIG. 24D is front isometric view of support structures of the shaping station of FIG. 24A;

FIGS. 24E-24F are isometric views of the support structures of FIG. 24D, cutaway at lines E-E and F-F in FIG. 24B;

FIG. 24G is an isometric view of the shaping station of FIG. 24A, cutaway to show internal components;

FIG. 24F1 is an enlarged partial cross-sectional of the shaping station of FIG. 24A;

FIGS. 24I-24J are isometric and cross-sectional views of the shaping station of FIG. 24A in a mold-open state;

FIGS. 24K-24L are isometric and cross-sectional views of the shaping station of FIG. 24A in a mold-open state, with the mold core in a molding position;

FIGS. 24M-24N are isometric and cross-sectional views of the shaping station of FIG. 24A in a mold-closed state;

FIGS. 240-24P are isometric and cross-sectional views of the shaping station of FIG. 24A in a mold-closed state, with a preload force applied to the mold core;

FIGS. 24Q-24R are isometric and cross-sectional views of the shaping station of FIG. 24A in a mold-open state;

FIGS. 24S-24T are isometric and cross-sectional views of the shaping station of FIG. 24A during mold removal;

FIG. 25A is a side perspective view of a one embodiment of part of a mold assembly;

FIG. 25B is a front elevation view of a portion of the part of the mold assembly of FIG. 25 A;

FIG. 25C are side perspective views of the embodiment of portions of the part of the mold assembly of FIG. 25A;

FIGS. 25D, E and F are similar side perspective views as FIG. 25C, of portions of the part of the mold assembly of FIG. 25A;

FIG. 25G is top perspective view of an embodiment of a mold cavity block;

FIG. 25F1 is a is top perspective view of an embodiment of a cavity plate that includes the mold cavity block of FIG. 25G;

FIG. 251 is top perspective view of an alternate embodiment of a mold cavity block;

FIG. 25J is top plan view of the mold cavity block of FIG. 251

FIG. 25K is another top perspective view of the mold cavity block of FIG. 251;

FIG. 26A and 26B are side perspective views of an alternate embodiment of portions of a mold assembly;

FIG. 26C is a top plan section view at part marked 26C in FIG. 26A;

FIG. 26D is a side perspective view of part of the embodiment of the portions of the mold assembly of

FIGS. 26A and 26B;

FIG. 26E is a perspective view of a disconnected components of the part shown in FIG. 26D;

FIG. 26F is a perspective view of another disconnected components of the part shown in FIG. 26D;

FIG. 26G are rear elevation views of the disconnected component of the part shown in FIG. 26D;

FIG. 26F1 is top plan view of the mold cavity block used in the part of FIG. 26D;

FIG. 261 is a top perspective view of the mold cavity block of the part of FIG. 26D;

FIG. 26J is a top perspective view of an alternate mold cavity block that can be employed in the part of

FIG. 26D;

FIG. 27A is a top perspective view of a base block;

FIG. 27B is a rear perspective view of the base block of FIG. 27A;

FIG. 28A is an assembly diagram for part of a mold assembly; and

FIG. 28B is a schematic view of a cooling fluid circuit.

FIG. 29 is a cross-sectional view of a mold of the shaping station of FIG. 11 and a vessel;

FIG. 30 is a sequence of overhead and isometric views showing sealing of a vessel;

FIG. 31 is an isometric view showing sealing of another vessel;

FIG. 32 is an isometric view of the actuator assembly of the shaping station of FIG. 11 ;

FIGS. 33A, 33B and 33C are isometric, cutaway and cross-sectional views, respectively, of a vessel and an actuation assembly at the shaping station of FIG. 11 ;

FIGS. 34A-34K are cross-sectional and partial cross-sectional views showing stages of a shaping operation at the shaping station of FIG. 11 ;

FIGS. 35A-35F are cutaway views of the vessel and actuation assembly of FIGS. 17A-17C, showing operations of the vessel and actuation assembly;

FIG. 36 is an exploded view of a gate assembly;

FIGS. 37A-37B are enlarged cross-sectional views showing operation of the gate assembly of FIG. 36;

FIG. 38 is an isometric view of a conditioning station and a shaping station of the system of FIG. 3.

FIG. 39 is a side cross-sectional view of the conditioning station of FIG. 38;

FIGS. 40A, 40B and 40C are side and cross-sectional views showing stages of a conditioning operation at the conditioning station of FIG. 38;

FIG. 41A is an isometric view of a shaping station;

FIG. 41B is a side view of a press of the shaping station of FIG. 41;

FIG. 42 is a side view of another shaping station;

FIG. 43 is a top view of the shaping station of FIG. 42;

FIG. 44 is an exploded view of a mold and services plates of the shaping station of FIG. 42;

FIG. 45 is an exploded view of the mold of FIG. 44;

FIG. 46 is a cross-sectional view of the mold of FIG. 44;

FIGS. 47A-47B are top and side schematic views of the shaping station of FIG. 42 during mold removal;

FIGS. 48A-48B are top and side schematic views of the shaping station of FIG. 42 during mold removal;

FIGS. 49A-49B are top and side schematic views of the shaping station of FIG. 42 during mold removal;

FIG. 50 is a schematic view showing mold components at a shaping station;

FIGS. 51 A, 51B, 51C and 51D are schematic views showing stages of a shaping operation with the mold components of FIG. 50;

FIG. 52 is a top plan view of the molding system of FIG. 3, showing a transport subsystem;

FIG. 53 is a plan view of an injection molding system in accordance with another embodiment;

FIG. 54 is a cross-sectional view along the lines I-I of FIG. 53;

FIG. 55A is a side view of a track section;

FIG. 55B is a cross-sectional view along the lines II-II of FIG. 55A;

FIG. 55C is a perspective fragmentary view of a portion of the track of the system of FIG. 55A;

FIG. 56 is a side view of a portion of the system of FIG. 53;

FIG. 57 is a perspective fragmentary view of another portion of the system of FIG. 53;

FIG. 58 is a perspective fragmentary view of a further portion of the system of FIG. 53;

FIG. 59 is a perspective fragmentary view of a yet a further portion of the system of FIG. 53;

FIG. 60 is a perspective detail view of a portion of FIG. 58;

FIG. 61 is a top view of a conditioner and shaper station and associated transfer system;

FIG. 62 is a side view of the stations and transfer system of FIG. 61

FIGS. 63A-63B are isometric and side views, respectively, of a carriage of the transfer system of FIG. 61;

FIG. 64 is a block diagram;

FIG. 65 is a perspective fragmentary view of a portion of a modified system;

FIG. 66 is a perspective detail view of a portion of FIG. 63.

FIG. 67 is a flow chart showing a method of transporting molding material; and

FIG. 68 is a flow chart showing a method of producing plastic molded products.

DETAILED DESCRIPTION

FIG. 1 schematically depicts an example plastic molding system 100 for producing plastic molded articles. As described in further detail below, plastic molding system 100 is capable of carrying out molding processes comprising dispensing, conditioning and shaping operations.

Plastic molding system 100 includes a plurality of process cells, each including one or more process stations at which an operation of a molding process can be performed. Specifically, the depicted embodiment comprises a dispensing cell 102, shaping cells 104, 106 and a conditioning cell 108. Other embodiments may include more or fewer cells and carry out molding processes with more or fewer process steps. Alternatively or additionally, plastic molding system 100 may include cells for other operations. For example, plastic molding system 100 may include cells for post-molding operations such as container filling, labelling or capping.

The process cells of plastic molding system 100 are connected by a transport subsystem 110.

Any of process cells 102, 104, 106, 108 may have more than one station of a given type. Transport subsystem 110 selectively connects stations of the process cells to one another. Transport subsystem 110 is configurable to define multiple possible process paths through process cells of molding system 100. For example, transport subsystem 110 may be capable of transporting an article from a given station in one process cell 102, 104, 106, 108, to a selected one of a plurality of possible stations in a another process cell 102, 104, 106, 108.

FIG. 2 schematically depicts an example embodiment with a dispensing cell 102 having 4 dispensing stations 102-1, 102-2, 102-3, 102-4; a shaping cell 104 having 8 shaping stations 104-1, 104-2, 104-3, 104-4, 104-5, 104-6, 104-7, 104-8; a shaping cell 106 having 2 shaping stations 106-1, 106-2; and a conditioning cell 108 having 2 conditioning stations 108-1, 108-2.

In the embodiment of FIG. 2, transport subsystem 110 is capable of connecting any of dispensing stations 102-1, 102-2, 102-3, 102-4 to any of shaping stations 104-1, 104-2,...104-8; and of connecting any of shaping stations 104-1, 104-2,... 104-8 to any of conditioning stations 108-1, 108-2; and of connecting any of conditioning stations 108-1, 108-2 to any of shaping stations 106-1, 106-2. Thus, numerous possible paths are defined through molding system 100. As depicted, there exist 128 unique combinations of one dispensing station 102, one shaping station 104, one conditioning station 108 and one shaping station 106 and each unique combination corresponds to a possible path. In some embodiments, one or more of the process cells may be omitted from some paths, such that additional

paths are possible. For example, conditioning at conditioning cell 108 or shaping at shaping cell 106 may not be required in all instances.

In other embodiments, more or fewer stations may be present in each process cell, and more or fewer paths through the molding system may be possible.

In some embodiments, process cells or stations of process cells may be physically separated from one another. Transport subsystem 110 may include apparatus for moving molding material through space between process cells or stations thereof. The apparatus may include one or both of vessels 124 (FIGS. 6A-6B) for holding molding material and carriers 125 (FIG. 7) for moving the vessels through space, e.g. along a guide or track, between the process cells or stations. In the embodiment described in detail herein, the vessel is selectively coupled to the carrier such that the vessel may be coupled and decoupled to the carrier at one or more process stations. In another embodiment, not shown, the vessel could otherwise be fixed to the carrier and the process stations configured to accommodate the vessel that remains connected with the carrier. In either case, the vessel may be thermally insulated from the carrier.

In the depicted embodiment, shaping cell 104 contains injection molding stations and shaping cell 106 contains blow molding stations. Conditioning cell 108 contains stations for thermally conditioning articles to prepare for blow molding. For example, injection molded articles formed at shaping cell 104 may cool after molding and be subsequently warmed to a temperature suitable for blow molding. Alternatively or additionally, stations of conditioning cell 108 may be configured to create a specific desired thermal profile in an article. For example, some shaping operations may call for an input article having a non-uniform temperature distribution. Stations of conditioning cell 108 may generate such temperature distribution by selectively heating specific regions, with or without a net transfer of heat into or out of the article. In some embodiments, articles may experience a net loss of heat in conditioning cell 108, despite warming of specific regions. Thus, stations of conditioning cell 108 may achieve thermal profiles not easily achieved by heat input at the dispensing cell 102.

As explained in further detail below, each station may have identical or unique characteristics. For example, the dispensing stations of dispensing cell 102 may each be configured to dispense the same or a different feedstock (e.g. a different material and/or colour). The shaping stations of shaping cells 104,

106 may be configured to mold articles having identical or different shapes, features or the like. The conditioning stations of conditioning cell 108 may each be configured to condition parts in common or to a different state. Accordingly, molding system 100 may be configured so that it is simultaneously capable of producing up to 128 identical or unique parts at any time. Alternatively or additionally, molding system 100 may be configured so that identical parts may be produced on multiple paths. For example, a single dispensing station can produce shots of feedstock to feed multiple stations of shaping cells 104, 106. In some embodiments, cells can be rapidly reconfigured. Accordingly, the number of system resources being used to produce parts of a given type may vary.

Each unique path through molding system 100 includes a unique combination of selected stations of dispensing cell 102, shaping cells 104, 106 and possibly other process cells such as, for example, the conditioning cell 108. Likewise, each unique combination of stations may produce finished articles with identical or unique characteristics. For example, different stations of dispensing cell 102 may produce articles having different colour material type or weight. Different stations of shaping cells 104, 106 may produce articles having different shapes. Different stations of conditioning cell 108 may produce articles having different shapes or other characteristics.

FIG. 3 is a perspective view of molding system 100. In the depicted embodiment, molding system 100 is for forming hollow plastic articles such as bottles or other containers. Molding system 100 has two shaping cells. Specifically, shaping cell 104 is an injection molding cell for molding a dose of feedstock material into a molded preform shape. Shaping cell 106 is a blow-molding cell (specifically, a stretch blow-molding cell) for transforming a preform of a particular shape into a finished hollow container of another, (e.g. a further-expanded) shape. Conditioning cell 108 prepare in-progress articles for operations performed at a shaping cell. Transport subsystem 110 links stations of the respective cells 102, 104, 106, 108. Links between cells are flexible. For example, in some embodiments, transport subsystem 110 links every station of each cell to every station of the neighboring cells. In other examples, some or all stations in a given cell are each linked to a plurality of stations in a neighboring cell. In some examples, some stations may be linked to stations of neighboring cells in a 1:1 manner. For instance, in the embodiment of FIG. 3, each station of dispensing cell 102 is linked to a plurality of stations of shaping cell 104, and each station of shaping cell 104 is linked to a plurality of stations of conditioning cell 108. However, each station of conditioning cell 108 is linked to one corresponding station of shaping cell 106.

Feedstock Dispensing

With primary reference to FIGS. 4A-4S, details of an example dispensing cell 102 will now be described.

Each station 102-1, 102-2, 102-3, 102-4 of dispensing cell 102 comprises one or more devices for melting a feedstock such as a plastic feedstock and for transferring the feedstock. In the depicted embodiment, the dispensing devices output molding material in doses of a specific size. However, in other embodiments, the dispensing devices may simply perform bulk transfer of molding material, without precise metering of dose size.

In the depicted embodiment, each station of dispensing cell 102 comprises an extruder 112. However, other types of dispensing devices are possible. For example, melting and dispensing doses of feedstock may be accomplished by use of a conduction melter. In the depicted example, extruders 112 receive feedstock material in the form of polyethylene terephthalate (PET) pellets. However, other feedstock materials and other forms are possible. For example, feedstock may be provided as a filament (e.g. on a spool), or as bars or blocks.

Extruders 112 may dispense different feedstock materials. In some examples, extruders 112 may dispense feedstock materials in differing volume, colors, different material types or grades, or at different temperatures. In some embodiments, extruders may be capable of dosing or blending additives, such as dyes or oxygen scavenging agents, into the feedstock material. In some embodiments, extruders 112 may be of different sizes, or may be configured to dispense feedstock at different rates or in different dose sizes. For example, system 100 may be set up to form containers of different size, with each extruder 112 being configured to dispense feedstock in doses corresponding to a specific size.

FlGs. 4A-4B are isometric and exploded views, respectively of an extruder 112 showing components thereof in greater detail. As depicted, extruder 112 has a barrel 114, in which a screw 116 (FIG. 5) is housed, and a drive unit 115 for driving rotation of the screw 116. Rotation of the screw 116 is driven by a drivetrain 130 within drive unit 115, which may include an electric motor. Barrel 114 has an inlet opening for supply of feedstock and an outlet orifice 122 (FIG. 5) for dispensing of molten feedstock into a vessel 124.

Referring to FIG. 4B, in the depicted embodiment, extruders 112 are mounted to supports 162 within dispensing cell 102. A set of supports 162 may be provided for each dispensing station 102-1, 102-2, 102-3, 102-4. As depicted, barrel 114 and the screw 116 within barrel 114 (collectively referred to as barrel unit 117) are releasably coupled to drive unit 115. Specifically, a coupling 161 rotationally couples the screw 116 to drivetrain 130 and one or more locating features 163 are received in corresponding recesses of supports 162 to position and secure barrel 114 relative to the support 162. Alternatively, alignment features 163 may be part of supports 162 and may be received in corresponding recesses on barrel 114. Supports 162 may include actuators for selectively engaging or releasing locating features 163. Thus, barrel 114 and screw 116 may be released and removed as a unit and replaced by another barrel 114 and screw 116. Coupling 161 and locating features 163 are located on one or both of a coupling block 4010 of barrel unit 117 and a frame 4012 of drive unit 115. References herein to removal, replacement or installation of extruders 112 are intended to include removal, replacement or installation of a barrel 114 and screw 116 as an assembly. In this way, extruder characteristics or characteristics of a feedstock may be rapidly and easily changed.

In some embodiments, removal, replacement or installation of extruders 112 may be affected automatically. For example, extruders 112 may be gripped and removed from supports 162 and may be moved by one or more robots under computer control. The computer control may be part of an overall control system of system 100, and releasing or engaging of locating features such as locating features 163 on barrel 114 may be coordinated with operation of the robot, such that extruders 112 are securely retained upon installation by a robot, and until subsequent removal by a robot.

FIGS. 4C and 4D depict barrel unit 117 and drive unit 115 of an extruder 112 in greater detail. In the configuration of FIG. 4C, barrel unit 117 is coupled to drive unit 115. In the configuration of FIG. 4D, barrel unit 117 is released from drive unit 115.

As depicted, barrel unit 117 includes a barrel 4002 and a screw 116 within barrel 4002. A nozzle assembly 4006 is positioned at the distal end of barrel 4002, in which outlet orifice 122 is defined. Rotation of screw 116 within barrel 4002 causes heating and melting of molding material, and conveys the molding material towards outlet orifice 122 in nozzle assembly 4006. A shroud 4008 is positioned around barrel 4002. During operation, barrel 4002 may become very hot. Shroud 4008 serves as a barrier to guard against damage to surrounding components and to protect against injury to operators.

Barrel 4002 is mounted to coupling block 4010. For example, barrel 4002 may have a flange (not shown) which interfaces with block 4010 and is secured thereto by fasteners. As will be described in greater detail, screw 116 is received in and supported by barrel 4002.

Nozzle assembly 4006 includes a thermal conditioning element 4007 proximate outlet 122. Thermal conditioning element 4007 maintains nozzle assembly 4006 at a desired temperature, to in turn control the temperature of molding material in nozzle assembly 4006 and molding material exiting nozzle assembly 4006 through outlet 122. One or more temperature measurement devices such as thermocouples may be positioned at nozzle assembly 4006, and thermal conditioning element 4007 may be controlled based on measurements from such devices.

Drive unit 115 and barrel unit 117 are connected by way of a coupling system operated by one or more actuators. The one or more actuators are operable to couple and decouple the drive unit 115 and barrel unit 117 using the coupling system. That is, the coupling system is operable to physically fix barrel unit 117 in position relative to drive unit 115. The coupling system is further operable to connect screw 116 with the drive unit 115 for driving rotation of the screw 116. In the depicted embodiment, the coupling system includes a retaining mechanism 4014 and a drive mechanism 4016. Retaining mechanism 4014 is operable to physically hold barrel unit 117 in place against drive unit 115. Drive mechanism 4016 rotationally connects drive unit 115 to screw 116 for rotating the screw.

In the depicted embodiment, retaining mechanism 4014 and drive mechanism 4016 are operated by separate actuators. In other embodiments, a single actuator may operate both of retaining mechanism 4014 and drive mechanism 4016. In other embodiments, a single mechanism may provide both the retention and drive functions.

In the depicted embodiment, the actuators for retaining mechanism and drive mechanism 4016 are pneumatic. However, other types of actuators may be used, including electro-mechanical actuators such as solenoids, magnetic actuators, or hydraulic actuators.

Barrel unit 117 further includes one or more service ports 4018, each for connecting to a corresponding port of drive unit 115 or proximate drive unit 115. Service ports may include, for example, conduits for circulation of coolant such as water to and from barrel unit 117, conduits for supply of air, e.g. pressurized air for pneumatic actuation systems, and electrical connections. Electrical connections may, include, for example, any of power supplies, controls, and signal wiring. Drive unit 115 also includes a resin feed port 4076 (FIG. 41). Resin feed port 4076 receives a feed of molding material, e.g. pelletized molding material, and communicates with barrel unit 117 to supply molding material to the barrel. Service ports 4018 may be configured for quick connection to and disconnection from the corresponding ports of drive unit 115. In an example, service ports 4018 may couple using push-to-connect pneumatic or hydraulic connectors, magnetic connectors, barb fittings or the like. Thus, service ports 4018 may automatically connect or disconnect from the corresponding ports by application of force, e.g. due to movement of barrel unit 117, or in response to a control signal.

FIG. 4E depicts barrel unit 117, with coupling block 4010 and shroud 4008 removed to show internal features. Barrel unit 117 has a resin input port 4074 which communicates with the interior of barrel 4002 to deliver molding material to the interior of barrel 4002. Molding material is typically input to barrel 4002 in solid granular form and may be delivered, e.g. from a hopper (not shown). The hopper may be mounted to drive unit 115 or proximate drive unit 115 and deliver molding material to resin input port 4074 by way of a corresponding resin feed port 4076 on drive unit 115. In some embodiments, resin input port 4074 and resin feed port 4076 abut one another. In other embodiments, one of input port 4074 and feed port 4076 may be received within the other. In some embodiments, input port 4074 and feed port 4076 may be positively coupled to one another, for example, using quick connect fittings such as push-to-connect pneumatic or hydraulic connectors, magnetic connectors, barb fittings or the like. Connection and disconnection of such fittings may be automatically affected by application of force, e.g. due to movement of barrel unit 117, or in response to a control signal.

As best shown in FIG. 4F-4G, one or more locating devices may be provided to position drive unit 115 and barrel unit 117. The locating devices position barrel unit relative to drive unit 115 as the barrel unit is moved toward a coupling position. Specifically, the locating devices guide barrel unit 117 so that it seats against drive unit 115 in a coupling position, in which retention mechanism 4014 and drive mechanism 4016 can be engaged. That is, in the coupling position, components of the retaining mechanism 4014 and drive mechanism 4016 on barrel unit 117 align with the corresponding components on drive unit 115. The locating devices may progressively bias barrel unit 117 into its correct alignment as the barrel unit 117 is moved towards drive unit 115. In the depicted embodiment, the locating devices comprise leader pins 4020 and mating recesses 4022 (FIG. 4D). As shown, leader pins 4020 project from coupling block 4010 of barrel unit 117 and are received in recesses 4022 in frame member 4012 of drive unit 115.

Leader pins 4020 and recesses 4022 engage one another as barrel unit 117 is moved toward drive unit 115. Such engagement aligns barrel unit 117 relative to drive unit 115 such that the barrel unit 117 and drive unit 115 can be coupled by actuation of retaining mechanism 4014. In the depicted example, the alignment devices engage one another prior to engagement of the coupling system.

FIG. 4F1 depicts retaining mechanism 4014 in greater detail. In the depicted embodiment, retaining mechanism 4014 includes a stud 4024 and a socket 4026 which can selectively interlock with stud 4024. As shown, stud 4024 is part of barrel unit 117 and socket 4026 is part of drive unit 115. Stud

4024 may, for example, be threaded to coupling block 4010. Socket 4026 may be a recess cut into frame 4012 or an insert attached (e.g. threaded) to frame 4012. Flowever, socket 4026 may instead be part of barrel unit 117 and stud 4024 may instead be part of drive unit 115.

Stud 4024 has inner and outer flanges 4028, defining a channel 4032 therebetween. Socket 4026 has an opening 4034, sized to receive stud 4024, and a gripping device 4036. Gripping device 4036 is configured for reception in channel 4032, in interlocking engagement with flanges 4028.

Gripping device 4036 is movable between engaged and disengaged states. In the disengaged state, gripping device 4036 clears flanges 4028 of stud 4024 such that stud 4024 may be freely inserted in or withdrawn from socket 4026. In the engaged state, gripping device interlocks with stud 4024, preventing stud 4024 from being withdrawn from socket 4026.

In the depicted embodiment, gripping device 4036 comprises a series of balls 4038 and a movable locking collar 4040. In the engaged state, locking collar 4040 holds balls 4038 against channel 4032. Balls 4038 bear against the distal flange 4028 of stud 4024, urging stud 4024 (and barrel unit 117) against drive unit 115. In the disengaged state, locking collar 4040 is withdrawn, allowing balls 4038 to shift away from stud 4024.

As shown, locking collar 4040 is spring-biased to the engaged state. An actuator is provided to selectively overcome the spring bias and thereby release locking collar 4040 and balls 4038. In the depicted embodiment, the spring bias is overcome by pneumatic pressure provided by a retention control line 4044, which is controlled by a valve (not shown).

Drive mechanism 4016 is shown in detail in FIGS. 4I-4J. Drive mechanism 4016 includes a driveshaft 4050 driven by an electric motor (not shown). Driveshaft 4050 has an end with a toothed connector, e.g. spline 4052. The connector interfaces with a mating connector of screw 116, namely, spline 4054. As shown, spline 4052 of drive unit 115 and spline 4054 of screw 116 interface by way of a spline insert 4056.

Spline insert 4056 mates to both of splines 4052, 4054. Spline insert 4056 is movable along the axis of rotation of driveshaft 4050, between an engaged position and a retracted position.

In the engaged position, spline insert 4056 meshes with splines 4052, 4054 and rotationally couples driveshaft 4050 and screw 116. In the retracted position, spline insert 4056 is retracted along the axis of driveshaft 4050, to disengage from spline 4054 of screw 116. Thus, in the retracted position of spline insert 4056, driveshaft 4050 and screw 116 are de-coupled from one another. Retraction of spline insert 4056 may occur without any movement of driveshaft 4050. That is, spline insert may move along a longitudinal axis relative to both of driveshaft 4050 and spline 4054 of screw 116 to disengage.

The position of spline insert 4056 is controlled by an actuator, namely, drive actuation assembly 4060. As shown, drive actuation assembly 4060 includes a pneumatic cylinder 4062. The piston of pneumatic cylinder 4062 is connected to spline insert 4056 by way of a link 4064. Movement of the piston through its stroke in a first direction moves spline insert 4056 to its engaged position. Movement of the piston through its stroke in the opposite direction moves spline insert 4056 to its disengaged position.

A shroud is also coupled to link 4064 and moves along with link 4064 and spline insert 4056. In the engaged position, the shroud is positioned around the mating interface between spline insert 4056 and spline 4054 of screw 116. The shroud guards against ingress of objects or contaminants such as dust or other particulates, which may cause premature wear or reduced performance of the splines 4052, 4054.

Splines 4052, 4054 and spline insert 4056 define mating interfaces, namely interfaces between mating teeth at which torque can be transferred. The mating faces have relatively large axial length, such that the mating interfaces can accommodate some movement of driveshaft 4050 and screw 116 along their longitudinal axes. In other words, screw 116 and driveshaft 4050 can shift axially relative to one another without interfering with meshing of splines 4052, 4054 and spline insert 4056.

Screw 116 is rotationally supported by a bearing 4070 which is in turn supported on coupling block 4010 by a flange 4071. A support ring 4072 is secured to screw 116 above bearing 4070, by press-fit or other suitable technique.

In operation, screw 116 may be vertically supported at least in part by friction between spline insert 4056 and spline 4054 and by pressure of molding material within barrel 114. In this condition, there may be clearance between support ring 4072 and bearing 4070. When operation is terminated, screw 116 may fall until support ring 4072 abuts bearing 4070. Support ring 4072 is positioned such that, when screw 116 falls in this manner, a clearance gap opens between the ends of screw 116 and drive shaft 4050. In this state, drive unit 117 may be moved without rubbing and consequent wearing of drive shaft 4050 and screw 116 against one another.

Conveniently, in the depicted embodiment, engagement and disengagement of drive mechanism 4016 and retaining mechanism 4014 may occur independently of one another. That is, drive mechanism 4016 may be engaged or disengaged without changing the state of retaining mechanism 4014. Engagement of drive mechanism 4016 occurs by movement along the longitudinal axis of screw 116, and barrel unit 117 is physically located relative to drive unit 115 by movement in a perpendicular direction. Likewise, physical fixation of barrel unit 117 to drive unit 115 occurs by clamping in a direction perpendicular to the axis of screw 116, i.e. in a direction perpendicular to that in which engagement of drive mechanism 4016 occurs. Alignment of barrel unit 117 relative to drive unit 115 also occurs by movement along an axis perpendicular to that of screw 116. That is, leader pins 4020 extend in a direction perpendicular to the axis of screw 116. Independent operation of drive mechanism 4016 and retaining mechanism 4014 could also be achieved in other configurations. For example, the mechanisms could be configured to engage by movement along parallel axes, but the movements could be independent of one another.

Coupling block 4010 comprises at least one mating surface 4076. When barrel unit 117 is coupled to drive unit 115, mating surface 4076 abuts a corresponding face of drive unit 115 (i.e. a corresponding face of frame 4012). Mating surface 4076 may bear against frame 4012 to hold barrel unit 117 square to drive unit 115.

In some embodiments, mating surface 4076 may be located so as to limit stress on drive mechanism 4016. For example, as shown in FIG. 4F, mating surface 4076 is located at a central plane C of coupling block 4010. Longitudinal axis L of screw 116 lies within central plane C.

In operation, forces may be exerted on the tip of barrel 114. Such forces may include axial forces, i.e. forces parallel to longitudinal axis L, and transverse forces perpendicular to longitudinal axis L.

Transverse forces may for example be caused by misalignment. The length of barrel 114 may act as a moment arm, such that transverse forces exert torque on barrel 114.

Contact between mating surface 4076 and frame 4012 may resist torque on barrel 114. That is, frame 4012 may exert reaction forces on mating surface 4076 which resist movement or twisting of barrel unit 117.

Alignment of plane C and longitudinal axis L may limit stress on barrel 114 and on spline 4054. Conversely, if place C and longitudinal axis L were spaced apart, transverse forces could also act around a secondary moment arm, perpendicular to longitudinal axis L. Alignment of mating face 4076 and longitudinal axis L avoids such secondary moment arms and therefore limits the torque to which spline 4054 and barrel 114 may be subjected.

Coupling block 4010 has a rear surface 4078 opposite mating surface 4076. When barrel unit 117 is coupled to drive unit 115, rear surface 4078 faces outwardly, away from drive unit 115. At least one pull stud 4080 is fixedly attached (e.g. threaded) to coupling block 4010. Each pull stud 4080 protrudes from coupling block 4010 for engagement by a removal tool to remove barrel unit 117 from drive unit 115.

FIG. 4K shows an example removal tool 4082. Removal tool 4082 is an automated (e.g. robotic) transportation device. Removal tool 4082 has a base 4084 and a rack 4086 supported on the base. Rack 4086 has a plurality of nests 4088, each capable of engaging and retaining a barrel unit 117. Two nests 4088-1 and 4088-2 are shown in FIG. 4K. However, any number of nests may be present.

Each nest 4088 has one or more couplings 4090 operable to selectively engage pull studs 4080. In some embodiments, couplings 4090 may be identical to gripping devices 4036 of drive unit 115 and pull studs 4080 may be identical to studs 4024 of barrel unit 117. Couplings 4090 are controlled by actuators (not shown). The actuators may be, for example, electronic, pneumatic or hydraulic actuators.

Rack 4086 may be mounted to base 4084 with a movable arm 4092. Arm 4092 is operable to extend to engage a barrel unit 117 for removal from drive unit 115, and to retract for transportation once the barrel unit is secured in a nest 4088. Arm 4092 may, for example, be drive by an electric servomotor or by a hydraulic or pneumatic cylinder.

As noted, plastic molding system 100 may include a plurality of barrel units 117, which may be interchangeably mountable to one or more drive units 115. For example, each barrel unit 117 may contain a different type of molding material, such as a different resin type different colour of material or the like.

Interchangeability of barrel units 117 may allow for rapid setup of molding system 100 to produce a specific variety of molded part. Removal tool 4082 may allow for automated changing of barrel units 117 at a drive unit 115. That is, removal tool 4082 may be capable of automatically approaching a drive unit 115, engaging a barrel unit 117 installed at that drive unit 115, removing the barrel unit 117 and retaining it, and installing a new barrel unit 117. Removal tool 4082 may then be capable of automatically transporting the removed barrel unit to a storage or cleaning area.

FIGS. 4L-40 depict a process of installing a barrel unit 117 to a drive unit 115.

As shown in FIG. 4L, a barrel unit 117 is carried by removal tool 4082 to a position facing drive unit 115. In some embodiments, removal tool 4082 may be guided into position relative to drive unit 115. For example, a beacon, such as an infra-red or other light-based beacon, or a radio-frequency (RF) beacon may be installed at drive unit 115 or barrel unit 117 and corresponding sensors may be installed at removal tool 4082. Removal tool 4082 may be programmed to detect signals from the beacon and move toward the detected signals. In other embodiments, removal tool 4082 may be programmed to monitor and record its position. For example, removal tool 4082 may initially be manually moved into position at a particular drive unit 115 and may record coordinates corresponding to that position. Thereafter, on receipt of a specific instruction, removal tool 4082 may automatically return to the recorded position. In some embodiments, removal tool 4082 may be programmed in this manner to retain a number of transfer positions, each for engaging with a respective drive unit 115.

With removal tool 4082 aligned with drive unit 115, arm 4092 is extended to move the barrel unit 117 towards drive unit 115.

As barrel unit 117 approaches drive unit 115, gripping devices 4036 of barrel unit 117 are opened. In the depicted embodiment, opening of gripping devices 4036 entails energizing the gripping device to overcome a spring bias towards the closed state. Energizing may be by providing a stream of pressurized air or water, or by an electrical signal.

Alignment devices on the barrel unit 117 and drive unit 115 engage one another to position barrel unit 117 relative to drive unit 115. Specifically, leader pins 4020 are received in recess 4022 and guide barrel unit 117 onto drive unit 115.

As shown in FIG. 4M, stud 4024 is received in socket 4026. The tapered leading end of stud 4024 may bear against walls of socket 4026 or against gripping device 4036 to provide fine alignment of stud 4024.

What barrel unit 117 is being installed, screw 116 is supported by support ring 4072 resting atop bearing 4070. In this condition, with barrel unit 117 positioned so that stud 4024 aligns with socket 4026 of drive unit 115, a clearance gap exists between the ends of screw 116 and drive shaft 4050. Thus, as barrel unit 117 is moved into position, screw 116 passes below drive shaft 4050 and spline insert 4056 without contacting either the drive shaft or the spline insert.

As shown in FIG. 4N, Barrel unit 117 is moved towards drive unit 115 until stud 4024 is fully received within socket 4026. The retaining actuator is activated to close gripping device 4036, thereby locking stud 4024 and barrel unit 117 in place relative to the drive unit 115. Engagement of stud 4024 by gripping device 4036 pulls stud 4024 and barrel unit 117 towards drive unit 115. With stud 4024 so engaged, mating surface 4076 of coupling block 4010 is clamped tightly against drive unit 115. In some embodiments, gripping device 4036 remains closed, engaging stud 4024 unless energy is applied to release it, for example, in the form of hydraulic or pneumatic pressure.

As shown in FIG. 40, with barrel unit 117 physically fixed to drive unit 115, drive mechanism 4016 may be activated to rotationally couple screw 116 to a motor by way of drive shaft 4050. A signal is provided to drive actuation assembly 4060, causing pneumatic cylinder 4062 to extend and move spline insert 4056 to its engaged position. Extension of spline insert 4056 causes spline insert 4056 to mesh with spline 4054, thereby rotationally coupling screw 116 to drive shaft 4050 and the motor driving drive shaft 4050.

WHAT IS CLAIMED IS:

1. A mold assembly comprising:

- a services block;

- a plate defining at least a portion of a molding cavity;

- a quick connection mechanism operable to connect and disconnect said plate and said services block;

wherein in operation of said mold assembly, said services block is connected to said plate with said quick connection mechanism.

2. A mold assembly as claimed in claim 1 wherein said plate comprises a base block and a mold cavity block; and wherein in operation of said mold assembly, said services block is connected to a platen and said services block is connected to said base block with said quick connection mechanism.

3. A mold assembly as claimed in claims 2 wherein said quick connection mechanism is operable to connect and disconnect said base block of said plate and said services block.

4. A mold assembly as claimed in claims 2 or 3 wherein said quick connection mechanism is a first connection mechanism and wherein said base block and said mold cavity block are two separate parts that are connected together with a second connection mechanism.

5. A mold assembly as claimed in claim 4, wherein said second connection mechanism is not a quick connection mechanism.

6. A mold assembly as claimed in claim 2 wherein said base block and said mold cavity block are formed as a unitary body and wherein said quick connection mechanism is operable to connect and disconnect said base block of said plate and said services block.

7. A mold assembly as claimed in any one of claims 1 to 6, wherein the quick connection mechanism is operable to be selectively engaged to hold said plate and the services block together.

8. A mold assembly as claimed in any one of claims 1 to 7, wherein the quick connection mechanism is operable to selectively interlock the plate and the services block.

9. A mold assembly as claimed in any one of claims 1 to 8, wherein the quick connection mechanism is operable to selectively provide a clamping action between the plate and the services block.

10. A mold assembly as claimed in any one of claims 1 to 9, wherein the quick connection mechanism is operable to switch between connected and disconnected states to connect and disconnect respectively the plate and the services block.

11. A rnold assembly as claimed in any one of claims 1 to 10, further comprising an actuator operable to actuate said quick connection mechanism.

12. A rnold assembly as claimed in any one of claims 1 to 11, wherein the quick connection mechanism comprises a spring device operable to selectively bias a part of the plate against the services block.

13. A mold assembly as claimed in any one of claims 1 to 12, wherein the quick connection mechanism is operable to selectively hold the services block and the plate together without the installation of a fastener.

14. A mold assembly as claimed in claim 1 wherein said quick connection mechanism comprises a releasable stud and a socket connector apparatus.

15. A mold assembly as claimed in claim 2, wherein said mold cavity block has a cavity side with a mold cavity surface topography that comprises a contact surface area and a mold cavity wall surface.

16. A mold assembly as claimed in claim 15 wherein the magnitude of the contact surface area is selected based on a clamping force of said mold assembly to be applied to said contact surface area.

17. A mold assembly as claimed in claims 15 or 16, wherein the cavity wall surface provides a longitudinal sectional surface profile of the item to be molded.

18. A mold assembly as claimed in claims 15, 16 or 17 wherein said mold cavity wall surface is configured to provide a surface for forming part of a mold cavity.

19. A mold assembly as claimed in any one of claims 15 to 18, wherein said mold cavity wall surface is configured to provide a surface for forming half of a mold cavity.

20. A mold assembly as claimed in claims 18 or 19, wherein said contact surface area of said mold cavity block is configured and operable to engage an opposed contact surface area of a corresponding mold cavity block of a corresponding engaged and mated plate.

21. A mold assembly as claimed in any one of claims 15 to 20, wherein said mold cavity surface topography is configured to provide at least part of a vent channel when said contact surface area of said mold cavity block is engaged with an opposed contact surface area of a corresponding mold cavity block of a corresponding engaged and mated plate.

22. A mold assembly as claimed in any one of claims 15 to 21 wherein said mold cavity surface topography is configured to provide at least part of a gate area when said contact surface area of said mold cavity block is engaged with an opposed contact surface area of a corresponding mold cavity block of a corresponding engaged and mated plate.

23. A mold assembly as claimed in any one of claims 15 to 22 wherein said mold cavity surface topography is configured to provide at least part of a core alignment surface located proximate to said mold cavity wall surface of said mold cavity block when said contact surface area of said mold cavity block is engaged with an opposed contact surface area of a corresponding mold cavity block of a corresponding engaged and mated plate.

24. A mold assembly as claimed in any one of claims 15 to 23, wherein said mold cavity surface topography further comprises a non-contact surface area and wherein said contact surface area and said non-contact surface area are generally parallel to each other.

25. A mold assembly as claimed in any one of claims 15 to 23, wherein said mold cavity surface topography further comprises a non-contact surface area that slopes inwardly toward said contact surface.

26. A mold assembly as claimed in claim 1, wherein said mold assembly further comprises

- a first services channel located within said plate;

- a second services channel located within said services block;

- wherein said first services channel is in communication with said second services channel such that a service may be delivered from said services block to said plate.

27. A mold assembly as claimed in claim 2, wherein said mold assembly further comprises

- a first services channel located within said base block;

- a second services channel located within said mold cavity block;

- a third services channel located within said services block;

- wherein said first services channel is in communication with said second services channel and said first services channel is in communication with said third services channel such that in operation a service is delivered from said services block to said base block to said mold cavity block.

28. A mold assembly as claimed in claim 27 wherein said service is cooling fluid operable to cool said mold cavity block.

29. A mold assembly as claimed in claims 27 or 28, wherein said mold cavity block has a cavity side with a mold cavity surface topography that comprises a contact surface area and a mold cavity wall surface and wherein said second services channel has a plurality of portions configured to conform at least in part to the mold cavity wall surface when extending through a body portion of said mold cavity block.

30. A mold assembly as claimed in claims 27, 28 or 29, further comprising a services connecting mechanism operable to connect said first services channel and said third services channel.

31. A mold assembly as claimed in claim 30 wherein said services connecting mechanism comprises a services quick connection mechanism.

32. A mold assembly as claimed in any one of claims 27 to 31, wherein said mold assembly further comprises

- a fourth services channel located within said base block;

- a fifth services channel located within said services block;

- wherein said fourth service channel is in communication with said second services channel and said fifth services channel is in communication with said second services channel such that in operation a service is delivered from said services block to said base block to said mold cavity block and then to said base block and then to said services block.

33. A mold assembly as claimed in any one of claims 1 to 32, wherein said quick connection mechanism comprises a pneumatically biased mechanism.

34. A mold assembly as claimed in claim 33, wherein said base block comprises pneumatic ports for operating said pneumatically biased mechanism by a mold handling device.

35. A mold assembly as claimed in any one of claims 1 to 34, wherein said base block and said cavity block have substantially cylindrical mating surfaces.

36. A mold assembly as claimed in any one of claims 1 to 35, wherein said mold assembly defines a mold for blow molding.

37. A mold assembly as claimed in any one of claims 1 to 36 wherein said mold assembly further comprises a third connection mechanism that is operable to connect said services block and said platen.

38. A mold assembly as claimed in any one of claims 1 to 37 wherein

- said services block comprises a first services block, said plate comprises a first plate, and said quick connection mechanism comprises a first quick connection mechanism ;

- and wherein said mold assembly further comprises

- a second services block;

- a second plate defining another portion of said molding cavity;

- a second quick connection mechanism operable to connect and disconnect said second plate and said second services block;

wherein in operation of said mold assembly, said second services block is connected to said second plate with said second quick connection mechanism.

39. A mold assembly as claimed in claim 38, wherein said first mold cavity block has a cavity side with a first mold cavity surface topography that comprises a first contact surface area and a first mold cavity wall surface and wherein said second mold cavity block has a cavity side with a second mold cavity surface topography that comprises a second contact surface area and a second mold cavity wall surface, such that in operation said first contact surface of said first mold cavity block matingly engages with said second contact surface of said second mold cavity block, said first mold cavity wall surface of said first mold cavity block co-operates with the second mold cavity wall surface of said second mold cavity block to form a mold cavity for an item to be molded.

40. A mold assembly as claimed in claims 38 or 39 wherein said first mold cavity surface topography further comprises a first non-contact surface area and wherein said first contact surface area and said first non-contact surface area are generally parallel to each other.

41. A mold assembly as claimed in claims 38, 39 or 40, wherein said second mold cavity surface topography further comprises a second non-contact surface area and wherein said second contact surface area and said second non-contact surface area are generally parallel to each other.

42. A mold assembly as claimed in claims 38 or 39, wherein said first mold cavity surface topography further comprises a first non-contact surface area and wherein said first non-contact surface area slopes inwardly toward said first contact surface, and wherein said second mold cavity surface topography further comprises a second non-contact surface area and wherein said second non-contact

surface area slopes inwardly toward said second contact surface.

43. A mold assembly as claimed in any one of claims 1 to 42, comprising a handling coupler projecting from an exterior surface of said plate for engagement by a handling device to remove said plate from said mold assembly.

44. The mold assembly of claim 43, wherein said handling coupler comprises a handling quick connection mechanism.

45. A plate defining at least a portion of a molding cavity for use in a mold assembly, said plate comprising:

- a base block;

- a mold cavity block connected to said base block;

a first quick connection device on said base block operable to selectively connect to and disconnect from a second quick connection device on a services block;

wherein in operation of said mold assembly, said base block is connected to said services block by operation of said first and second quick connection devices.

46. A plate as claimed in claim 45 wherein said base block and said mold cavity block are two separate parts that are connected together with a connection mechanism.

47. A plate as claimed in claim 45 wherein said base block and said mold cavity block are formed as a unitary body.

48. A plate as claimed in claim 45 wherein said base block further comprises:

- a first services channel located within said base block;

- a second services channel located within said mold cavity block;

- a third quick connection device operable to connect with a fourth quick connection device on said services block;

wherein in operation, said first services channel is in communication with a third services channel in said services block, and said first services channel is in communication with said second services channel located within said mold cavity block, when said third quick connection device is operably connected with said fourth quick connection device such that a service may be delivered from said services block to said base block and on to said mold cavity block through said first services channel, said second services channel and said third services channel.

49. A plate as claimed in claim 48, wherein said plate further comprises

- a fourth services channel located within said base block;

- wherein said fourth services channel is in communication with said second services channel, and said fourth services channel is in communication with a fifth services channel in said services block, such that in operation a service is delivered from said services block to said base block to said mold cavity block and then back to said base block and then back to said services block.

50. A plate as claimed in claim 48 wherein said first, second, third, fourth and fifth services channels comprise at least part of a fluid cooling circuit for supplying cooling fluid to cool said mold cavity block.

51. A plate as claimed in claim 50, wherein said first quick connection device comprises a

pneumatically biased mechanism.

52. A plate as claimed in any one of claims 45 to 51, wherein said base block and said cavity block have substantially cylindrical mating surfaces.

53. A plate as claimed in any one of claims 45 to 52, comprising a handling coupler projecting from an exterior surface of said plate for engagement by a handling device to remove said plate from a platen.

54. The plate of claim 53, wherein said handling coupler comprises a handling quick connection mechanism.

55. A molding system comprising:

- a services block ;

- a first plate defining at least a portion of a first molding cavity;

- a first quick connection mechanism operable to connect and disconnect said first plate and said services block;

- a second plate defining at least a portion of a second molding cavity;

- a second quick connection mechanism operable to connect and disconnect said second plate and said services block;

wherein said first cplate is operable to be connected to and disconnected from said services block with said first quick connection mechanism and said second plate is operable to be connected to and disconnected from said services block with said second quick connection mechanism whereby said first plate can be interchanged with said second plate to be operable to modify said molding system between having said first molding cavity and said second molding cavity .

56. A molding system as claimed in claim 55 wherein:

- said first plate comprises a base block and a first mold cavity block;

-said first quick connection mechanism is operable to connect and disconnect said base block of said first plate and said services block;

- said second plate comprises a base block and a second mold cavity block;

- said second quick connection mechanism is operable to connect and disconnect said base block of said second plate and said services block.

57. A system as claimed in claim 56 wherein said base block of said first plate and said first mold cavity block are two separate parts that are connected by a third connection mechanism.

58. A system as claimed in claim 57 wherein said base block of said second plate and said second mold cavity block are two separate parts that are connected by a fourth connection mechanism.

59. A system as claimed in claim 58, wherein said third and fourth connection mechanisms are not

quick connection mechanisms.

60. A system as claimed in claim 56 wherein said base block of said first plate and said first mold cavity block are formed as a unitary body and said base block of said second plate and said second mold cavity block are formed as a unitary body.

61. A molding system as claimed in any one of claims 55 to 60 wherein said first mold cavity block has a base block facing surface connected to said base block of said first plate and an opposed first cavity side with a first cavity surface topography that comprises a first contact surface area and a first cavity wall surface; and wherein said second mold cavity block has a base block facing surface connected to said base block of said second c plate and a second cavity side with a second cavity surface topography that comprises a second contact surface area and a second cavity wall surface, and wherein said first cavity surface topography is configured differently to said second cavity surface topography.

62. A molding system as claimed in claim 61 wherein said first cavity wall surface is configured differently to said second cavity wall surface.

63. A molding system as claimed in claim 61 or 62, wherein said first contact surface is shaped differently to said second contact surface.

64. A molding system as claimed in any one of claims 61 to 63, wherein said first contact surface and said second contact surface have substantially the same sized surface areas.

65. A mold assembly as claimed in any one of claims 61, 62 or 63, wherein said first cavity surface topography further comprises a first non-contact surface area and wherein said first contact surface area and said first non-contact surface area are generally parallel to each other; and wherein said second cavity surface topography further comprises a second non-contact surface area and wherein said second contact surface area and said second non-contact surface area are generally parallel to each other.

66. A molding system as claimed in any one of claims 55 to 63, comprising a handling coupler projecting from an exterior surface of each of said first and second plates for engagement by a handling device to remove said plates from said mold assembly.

67. The mold assembly of claim 66, wherein said handling coupler comprises a handling quick connection mechanism.

68. A molding system comprising:

- a services block;

- a base block;

- a first mold cavity block;

- a second mold cavity block

- a first connection mechanism operable to connect and disconnect said base block and said services block

- a second connection mechanism operable to connect and disconnect each of said first and

second mold cavity blocks with said base block;

wherein in operation said first and second mold cavity blocks can be interchangeably connected to said base block with said second connection mechanism, and wherein said base block can be connected to said services block with said first connection mechanism.

69. A molding system as claimed in claim 68 wherein said first connection mechanism is a quick connection mechanism.

70. A molding system comprising:

- a first plate defining at least a portion of a first molding cavity that is a separate part to a services block, said first plate having a first cavity wall surface;

- a first quick connection mechanism operable to connect and disconnect said first plate to a services block;

- a second plate defining at least a portion of a second molding cavity that is a separate part to the services block, said second plate having a second cavity wall surface;

- a second quick connection mechanism operable to connect and disconnect said second cavity block and said services block;

wherein said first cavity wall surface is configured differently to said second cavity wall surface.

71. A molding system as claimed in claim 70, wherein said first plate has a cavity side with a first cavity surface topography that comprises a first contact surface and the first cavity wall surface;

- said second plate has a cavity side with a second cavity surface topography that comprises a second contact surface and the second cavity wall surface, and wherein said first cavity surface topography is configured differently to said second cavity surface topography.

72. A molding system as claimed in claim 71 , wherein said first contact surface is shaped differently to said second contact surface.

73. A molding system as claimed in claims 71 or 72, wherein said first contact surface and said second contact surface have substantially the same sized surface areas.

74. A mold assembly as claimed in any one of claims 71 to 73, wherein said first cavity surface topography further comprises a first non-contact surface and wherein said first contact surface and said first non-contact surface are generally parallel to each other; and wherein said second cavity surface topography further comprises a second non-contact surface and wherein said second contact surface and said second non-contact surface are generally parallel to each other.

75. A mold assembly as claimed in any one of claims 71 to 74 wherein said first cavity surface topography further comprises a first non-contact surface; and wherein said second cavity surface topography further comprises a second non-contact surface and wherein the sum of the first contact surface area and the first non-contact area is substantially of the same magnitude as the sum of the second contact area and the second non-contact area.

76. A mold assembly comprising:

- a support frame;

- a first platen supported by said support frame;

- a first services plate connected to said first platen;

- a first plate defining a first portion of a molding cavity;

- a first quick connection mechanism operable to connect and disconnect said first plate and said first services block;

- a second platen supported by said support frame;

- a second services plate connected to said second platen;

- a second plate defining a second portion of said molding cavity;

- a second quick connection mechanism operable to connect and disconnect said second plate and said second services block:

wherein in operation:

- said first plate is connected to said first services block with said first quick connection mechanism, and said first services block is connected to said first platen; and

- said second plate is connected to said second services block with said second quick connection mechanism, and said second services block is connected to said second platen.

77. A mold assembly as claimed in claim 76 wherein said first platen is a stationary platen such that in operation, said stationary platen does not move relative to said support frame; and wherein said second platen is a moving platen such that in operation said moving platen moves relative to said support frame and said stationary platen.

78. A mold assembly as claimed in claims 76 or 77, wherein:

- said first plate comprises a first base block and a first mold cavity block; and wherein in operation of said mold assembly, said first services block is connected to a first platen and said first services block is connected to said first base block with a third quick connection mechanism; and

- said second plate comprises as second base block and a second mold cavity block;

and wherein in operation of said mold assembly, said second services block is connected to a second platen and said second services block is connected to said second base block with a fourth quick connection mechanism.

79. A mold assembly as claimed in claim 78 wherein said first mold cavity block has a base block facing surface operable to be secured to said first base block and a cavity side with a first cavity surface topography that comprises a first contact surface area and a first cavity wall surface and wherein said second mold cavity block has a base block facing surface operable to be secured to said second base block and a cavity side with a cavity surface topography that comprises a contact surface area and a second cavity wall surface.

80. A mold assembly as claimed in claim 79 wherein said mold assembly further comprises a core assembly having a core device, in operation said core device being received with a cavity formed by

said cavity wall surfaces of said first and second mold cavity blocks to thereby form a mold cavity for an item to be molded.

81. An apparatus comprising :

- a plate defining at least a portion of a molding cavity, said plate comprising a base block and a mold cavity block, said base block having a services channel therein;

- a connection mechanism operable to connect said mold cavity block to said base block;

wherein in operation, said mold cavity block is connected to said base block with said connection mechanism;

wherein said mold cavity block has a cavity surface side and a base block facing surface opposite to said cavity surface side, and said mold cavity block has a trough area formed in said base block facing surface;

said apparatus further comprising a services channel module received into said trough area, said services channel module comprising at least one services channel operable to be interconnected to said services channel in said base block.

82. An apparatus as claimed in claim 81 wherein said plate is made at least in part from a metal material and said services channel module is made at least in part from a plastic material.

83. An apparatus as claimed in claims 81 or 82 wherein said cavity surface side has a mold cavity wall surface, and wherein said services channel module is a channel for supplying cooling fluid which is operable to cool said mold cavity block, and wherein said services channel module comprises a cooling fluid channel having a plurality of portions configured to conform at least in part of said mold cavity wall surface when extending from an input port to an output port.

84. A method of operating a mold assembly, said mold assembly comprising:

- a platen;

- a services block connected to said platen;

- a first plate defining at least a portion of a first molding cavity;

- a second plate defining at least a portion of a second molding cavity;

- a first quick connection mechanism operable to connect and disconnect said first plate and a services block;

- a second quick connection mechanism operable to connect and disconnect said second plate and said servicesblock;

said method comprising interchanging said first plate with said second plate on said services block by operating said first and second quick connection mechanisms.

85. A method as claimed in claim 84, wherein said mold assembly further comprises:

- a first services channel, said first services channel being located within said first plate;

- a second services channel, said second services channel being located within said second plate;

- a third services channel located within said services plate;

- a first services connecting mechanism operable to connect and disconnect said first services channel and said third services channel;

- a second services connecting mechanism operable to connect and disconnect said second services channel and said third services channel;

- wherein when said first plate is connected to said services block and said first service channel is in communication with said third services channel a service is delivered from said services block to said first plate;

- wherein when said second plate is connected to said services block and said second service channel is in communication with said third services channel a service is delivered from said services block to said second plate;

said method further comprises when said first plate and said second cplate are interchanged by operating said first and second quick connection mechanisms, said first services connecting mechanism disconnects said first services channel and said third services channel; and thereafter said second services connecting mechanism connects said second services channel and said third services channel.

86. A method as claimed in claim 85 wherein said first and second services connecting

mechanisms both comprise a quick connection mechanism.

87. A method as claimed in any one of claims claim 84 to 86, wherein each of said first and second quick connection mechanisms comprises a pneumatically biased mechanism.

88. A method as claimed in claim 87, comprising releasing said pneumatically biased mechanism of said first quick connection mechanism or said second quick connection mechanism by providing a pressurized air supply by way of said services block.

89. A method as claimed in any one of claims 84 to 87, wherein said method comprises defining a mold for blow molding.

90. A method of forming a mold system comprising:

- forming a first base block;

- forming a second base block that is configured substantially the same as the first base block;

- forming a first and a second mold cavity blocks, each having a base block facing surface operable to be secured to said first and second respective base blocks and a cavity side with a mold cavity surface topography that comprises a contact surface area and a mold cavity wall surface, wherein the configuration of the mold cavity wall surface of the first mold cavity block is different from the configurationof the mold cavity wall surface of the second mold cavity block, but where the size of the contact surface area of the first mold cavity block is substantially similar to the size of the contact surface area of the second mold cavity block;

- connecting said first base block to said first mold cavity block;

- connecting said second base block to said second mold cavity block.

91. A method as claimed in claim 90 wherein said contact surface area of said first mold cavity

block is shaped differently than the contact surface area of the second mold cavity block.

92. A method as claimed in claim 90 wherein the size of the contact surface area of said first and second mold cavity blocks is selected based on the known size of the clamping force of said mold assembly to be applied to said contact surface area.

93. A method as claimed in any one of claims 90, 91 or 92 further comprising:

- providing a quick connection device on each of said first and second base blocks, each quick connection device being operable to connect to and disconnect from a common quick connection device on a common services block.

94. A method of manufacturing a cavity plate comprising:

- forming a base block with a quick connection device operable to connect with and disconnect from a quick connection device on a services block;

- forming a mold cavity block by depositing material on a surface of said base block with an additive manufacturing process to thereby form a mold cavity surface topography that comprises a contact surface area and a mold cavity wall surface.

95. A method of forming a cavity plate comprising:

- forming a base block having a services channel;

- forming a mold cavity block said mold cavity block having a cavity surface side and a base block facing surface opposite to said cavity surface side, and wherein said mold cavity block has a trough area formed in said base block facing surface;

- inserting a services channel module into said trough area, said services channel module comprising at least one services channel operable to be interconnected to said services channel in said base block.

96. A mold assembly, comprising:

a pair of mating mold sections cooperatively defining a mold cavity;

a pair of services blocks, each for mounting a respective one of said mold blocks to a platen of a molding machine;

a handling coupler projecting from an exterior surface of each mold section, for engagement by a handling device to hold said mold blocks together in a mating configuration and to remove said mold assembly from said mold machine.

97. The mold assembly of claim 96, wherein said handling coupler comprises a quick connection mechanism.

98. The mold assembly of claim 96 or claim 97, comprising a mold quick connection mechanism operable to connect and disconnect each of said mold sections and sa respective one of said services blocks.

99. The mold assembly of claim 98, wherein said mold sections have curved outer surfaces, and said services blocks have corresponding curved inner surfaces to receive said mold blocks.

100. The mold assembly of claim 99, wherein said mold quick connection mechanism comprises a

connector projecting from one of said curved surfaces.

101. The mold assembly of any one of claims 96 to 100, wherein said mold assembly is a blow molding assembly.

102. The mold assembly of any one of claims 96 to 101, comprising a third mold section operable to cooperatively define said mold cavity with said mold blocks.

103. The mold assembly of claim 102, wherein said third mold section comprises a quick connection mechanism for coupling to an actuator.

104. The mold assembly of any one of claims 96 to 103, wherein said services blocks comprise respective load limiting blocks, said load limiting blocks opposing one another with clearance therebetween in a molding configuration of said molding assembly, and operable to abut one another and bear a clamping force in response to compression of said mold blocks.

105. The mold assembly of any one of claims 96 to 104, wherein said mold blocks are formed of an aluminum alloy.