PLASTIC MOLDING APPARATUS AND METHOD WITH SHAPER MODULE

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. 62/866,059, 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 operation of molds.

BACKGROUND

Typical plastic molding machines, such as injection molding and blow molding machines, are large and heavy and are installed permanently at a production facility. Mold components are fixed to platens, which are operated by a fixed press, which may be mechanically or hydraulically actuated. Set up of a machine to produce molded articles with a specific mold is complex and both time and labour-intensive.

In an injection molding machine, a mold typically comprises two halves, with one half, referred to as the cavity, defining the outer surface of an article to be molded, and the other half, referred to as the core, defining the inner surface of the article to be molded. To remove articles, molds must be opened through a long stroke to provide clearance between the mold and cavity, and a separate moving structure referred to as a stripper plate is extended to push articles off the core.

SUMMARY

An example apparatus for operating a mold having a cavity assembly and a core that cooperatively define a mold for molding of plastic articles comprises: a clamping assembly operable to move cavity plates of the cavity assembly relative to each other along a cavity clamping axis, between a closed position in which the cavity plates abut in clamped contact, and an open position in which the cavity plates are separated for removal of a molded article; a core clamping assembly comprising an actuator operable to move the nioiu core reiauve iu me cavity assembly along a core clamp axis between a closed position in which the core is interposed between the cavity plates to define the mold, and a removal position in which the core is retracted for removal of a molded article.

In some embodiments, the core clamp axis is perpendicular to the cavity clamp axis.

In some embodiments, the actuator is operable to apply a force along the core clamping axis to urge the mold core towards the cavity plates during molding.

In some embodiments, the force is a preload force for resisting pressure from molding material in the mold.

In some embodiments, the actuator is operable to withdraw the mold core from a molded article along the core clamping axis.

In some embodiments, the core clamping assembly comprises a retainer for holding a molded article while the core is withdrawn.

In some embodiments, the actuator comprises a rotary crank and a link assembly for causing a reciprocating motion.

In some embodiments, the crank assembly comprises an eccentric rotor.

In some embodiments, the apparatus is for injection molding.

In some embodiments, the apparatus comprises an injection orifice for receiving a flow of molding material along the core axis.

In some embodiments, the core clamping axis is vertical.

In some embodiments, the injection orifice mates to a vessel for receiving molding material from the vessel.

In some embodiments, the clamping assembly is operable to move both of the first and second cavity plates towards and away from one another.

An example apparatus for operating a mold having a cavity assembly and a core that cooperatively define a mold for molding of plastic articles, comprising: a carriage comprising a support plate;

a clamping assembly mounted to the support plate; first and second mold support plates mounted to the clamping assembly, and movable by the clamping assembly between a closed position in which cavity plates of the cavity assembly abut one another in clamped contact to define a surface of an article to be molded, and an open position for removal of molded articles; the clamping assembly operable to exert a clamp force on the first and second mold support plates to hold the cavity plates in the closed position during molding of an article, wherein the clamp force is applied through a central axis of the mold support plates.

In some embodiments, exerting the clamp force causes tensile loading of the support plate along a longitudinal axis thereof.

In some embodiments, the clamp force is applied along the longitudinal axis of the support plate.

In some embodiments, the clamping assembly comprises a crank connected to a linkage to move the clamping assembly through a reciprocating stroke.

In some embodiments, the linkage comprises a link pivotably mounted to the support plate.

In some embodiments, the clamping assembly is mounted to the support plate such that exerting the clamp force creates substantially no bending moment in the support plate.

In some embodiments, the mold support plates are slidably supported by the support plate.

In some embodiments, the support plate comprises guides for maintaining square orientation of the mold plates relative to one another.

In some embodiments, the clamping assembly is operable to move both of the first and second mold support plates towards and away from one another.

An example apparatus for injection molding comprises: a support base; a moiu earner assem y removably mountable to the support base, comprising: a mounting plate having attachment features for engaging corresponding attachment features on the support base; a mold comprising first and second mold plates slidably supported on the mounting plate; a clamp mounted to the mounting plate, the clamp operable to move the mold between a closed state in which the mold plates abut one another, and an open state in which the mold plates are spaced apart for removing molded articles.

In some embodiments, the mold carrier assembly comprises a motor coupled to the clamp.

In some embodiments, the mold carrier assembly comprises an adjustment mechanism for moving the mold carrier assembly relative to the support base.

In some embodiments, the support base has an opening for removal of the mold carrier assembly, and wherein the adjustment mechanism is operable to align the mold carrier assembly with the opening.

In some embodiments, the attachment features comprise locking pins operable to selectively engage corresponding guide blocks on the support base.

In some embodiments, the mold carrier assembly comprises couplings for engagement of the mold carrier assembly with a lifting tool.

In some embodiments, the couplings comprise hooks for lifting by a crane.

An example molding assembly for injection molding comprises: a mold carrier assembly removably mountable to a support base, comprising: a mounting plate having attachment features for engaging corresponding attachment features on the support base; a mold comprising first and second mold plates slidably supported on the mounting plate; a clamp mounted to the mounting plate, the clamp operable to move the mold between a closed state in which the mold plates abut one another, and an open state in which the mold plates are spaced apart for removing molded articles.

In some embodiments, the mold carrier assembly comprises a motor coupled to the clamp.

In some embodiments, the mold carrier assembly comprises an aqjusimem mecnamsm ror moving the mold carrier assembly relative to the support base.

In some embodiments, the adjustment mechanism is operable to align the mold carrier assembly with an opening in the support base.

In some embodiments, the attachment features comprise locking pins operable to selectively engage corresponding guide blocks on the support base.

In some embodiments, the mold carrier assembly comprises couplings for engagement of the mold carrier assembly with a lifting tool.

In some embodiments, the couplings comprise hooks for lifting by a crane.

An apparatus for injection molding, comprising: a clamping assembly mounted to a support; a mold comprising first and second mold plates mounted to the clamping assembly, the mold movable by the clamping assembly between a closed position in which the cavity plates abut one another to define a surface of an article to be molded, and an open position for removal of molded articles; the clamping assembly driven by a crankshaft and comprising a connecting link causing reciprocating motion of the mold during each rotation of the crankshaft.

In some embodiments, reciprocating motion of the first mold plate is driven by a single connecting link coupled to the crankshaft.

In some embodiments, the single connecting link is coupled to the mold plate by a multi-bar linkage.

In some embodiments, the clamping assembly comprises first and second connecting links coupled to a common crankshaft, wherein the first connecting link drives reciprocating motion of the first mold plate and the second connecting link drives reciprocating motion of the second mold plate.

An example apparatus for operating a mold having a cavity and a core that cooperatively define a mold for molding of plastic articles comprises: a clamping assembly operable to move mold plates relative to each other between a closed position in which the plates abut in clamped contact, and an open position in which the plates are separated; a core aciuaior operame iu move the mold core relative to the plates along a core axis between a closed position in which the core is interposed between the plates, a preload position, in which the core is compressed from the closed position towards the plates, and a removal position in which the core is retracted for removal of a molded article.

In some embodiments, the apparatus comprises a spring load assembly for supporting the mold against the plates, wherein movement of the core from the closed position to the preload position compresses the spring load assembly.

In some embodiments, the mold core comprises an inner core and an outer core positioned around the outer core, wherein the actuator is operable to move one of the inner core and the outer core relative to the other of the inner core and the outer core along the core axis.

In some embodiments, the actuator is operable to withdraw the inner core relative to the outer core in the removal position, to dislodge a molded part from the inner core.

In some embodiments, the actuator is connected to the mold core with releasable couplings.

In some embodiments, the actuator is mounted to a platen of the clamp assembly.

In some embodiments, the apparatus comprises a slotted link connecting the actuator to the mold core.

In some embodiments, the core axis is perpendicular to a clamping axis of the clamp assembly.

In some embodiments, the core clamping axis is vertical.

In some embodiments, the apparatus is for injection molding.

An example clamping apparatus for injection molding of plastic articles, comprising:

a support frame; first and second platens suspended from the support frame, each the platen for mounting a respective mold plate; a linkage comprising a plurality of pivotably-connected members, the linkage operable by pivoting the links around a vertical axis to move the platens between a mold-closed position in which mold plates abut one anoiner, anu a moiu-open position in which mold plates are spaced apart from one another.

In some embodiments, the apparatus comprises mounts for attaching the first and second platens to the support frame, wherein the mounts lie in a vertical plane.

In some embodiments, the mounts are attached to a vertical plate.

In some embodiments, the platens defines a mold bounding envelope in which mold plates are mountable to the platens, the mold bounding envelope comprising ends defined by the platens, top and bottom sides, and opposing lateral sides perpendicular to the platens, and wherein the support frame and the linkage are adjacent one of the lateral sides.

In some embodiments, a lateral side of the mold bounding envelope opposite the support frame and the linkage is an access side through which a material handling device may be inserted.

In some embodiments, the bottom side of the mold bounding envelope is an access side.

In some embodiments, in the mold-open position, mold plates can be removed through a side of the mold bounding envelope.

In some embodiments, the platens are movable along a horizontal axis.

In some embodiments, the apparatus comprises a rotor driving the linkage.

In some embodiments, the support frame is mounted to a tower structure.

Embodiments may include the above-described features in any suitable combination.

Additional embodiments and features will be apparent to skilled persons in view of the disclosure herein.

BRIEF DESCRIPTION OF DRAWING»

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. 21A 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 snaping siaiion;

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. 25A;

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 DIOCK;

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. 51A, 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 or me iransrer system or 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 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 eaen process cen, ana 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, iuo. in some eiiiDouimems, 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 uoses oi a speciuc 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 Darrei r m anu screw no. 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 sysiem operaieu Dy 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.

WHAT IS CLAIMED IS:

1. An apparatus for operating a mold having a cavity assembly and a core that cooperatively define a mold for molding of plastic articles, comprising:

a clamping assembly operable to move cavity plates of the cavity assembly relative to each other along a cavity clamping axis, between a closed position in which said cavity plates abut in clamped contact, and an open position in which the cavity plates are separated for removal of a molded article;

a core clamping assembly comprising an actuator operable to move said mold core relative to the cavity assembly along a core clamp axis between a closed position in which said core is interposed between said cavity plates to define said mold, and a removal position in which said core is retracted for removal of a molded article.

2. The apparatus of claim 1, wherein said core clamp axis is perpendicular to said cavity clamp axis.

3. The apparatus of claim 1, wherein said actuator is operable to apply a force along said core clamping axis to urge said mold core towards said cavity plates during molding.

4. The apparatus of claim 3, wherein said force is a preload force for resisting pressure from molding material in said mold.

5. The apparatus of any one of claims 1 to 4, wherein said actuator is operable to withdraw said mold core from a molded article along said core clamping axis.

6. The apparatus of claim 5, wherein said core clamping assembly comprises a retainer for holding a molded article while said core is withdrawn.

7. The apparatus of any one of claims 1 to 6, wherein said actuator comprises a rotary crank and a link assembly for causing a reciprocating motion.

8. The apparatus of claim 6, wherein said crank assembly comprises an eccentric rotor.

9. The apparatus of any one of claims 1 to 8, wherein said apparatus is for injection

molding.

10. The apparatus of any one of claims 1 to 8, comprising an injection orifice for receiving a flow of molding material along said core axis.

11. The apparatus of claim 10, wherein said core clamping axis is vertical.

12. The apparatus of claim 10 or claim 11, wherein said injection orince maies iu a vessel ror receiving molding material from said vessel.

13. The apparatus of any one of claims 1 to 12, wherein said clamping assembly is operable to move both of said first and second cavity plates towards and away from one another.

14. An apparatus for operating a mold having a cavity assembly and a core that cooperatively define a mold for molding of plastic articles, comprising:

a carriage comprising a support plate;

a clamping assembly mounted to said support plate;

first and second mold support plates mounted to said clamping assembly, and movable by said clamping assembly between a closed position in which cavity plates of the cavity assembly abut one another in clamped contact to define a surface of an article to be molded, and an open position for removal of molded articles;

said clamping assembly operable to exert a clamp force on said first and second mold support plates to hold the cavity plates in said closed position during molding of an article, wherein said clamp force is applied through a central axis of said mold support plates.

15. The apparatus of claim 14, wherein exerting said clamp force causes tensile loading of said support plate along a longitudinal axis thereof.

16. The apparatus of claim 15, wherein said clamp force is applied along said longitudinal axis of said support plate.

17. The apparatus of any one of claims 14 to 16, wherein said clamping assembly comprises a crank connected to a linkage to move said clamping assembly through a reciprocating stroke.

18. The apparatus of claim 17, wherein said linkage comprises a link pivotably mounted to said support plate.

19. The apparatus of any one of claims 14 to 18, wherein said clamping assembly is mounted to said support plate such that exerting said clamp force creates substantially no bending moment in said support plate.

20. The apparatus of any one of claims 14 to 19, wherein said mold support plates are

slidably supported by said support plate.

21. The apparatus of any one of claims 14 to 20, wherein said suppori piaie comprises guiues for maintaining square orientation of said mold plates relative to one another.

22. The apparatus of any one of claims 14 to 21, wherein said clamping assembly is operable to move both of said first and second mold support plates towards and away from one another.

23. An apparatus for injection molding, comprising:

a support base;

a mold carrier assembly removably mountable to said support base, comprising:

a mounting plate having attachment features for engaging corresponding attachment features on said support base;

a mold comprising first and second mold plates slidably supported on said mounting plate;

a clamp mounted to said mounting plate, said clamp operable to move said mold between a closed state in which said mold plates abut one another, and an open state in which said mold plates are spaced apart for removing molded articles.

24. The apparatus of claim 23, wherein said mold carrier assembly comprises a motor

coupled to said clamp.

25. The apparatus of claim 23 or claim 24, wherein said mold carrier assembly comprises an adjustment mechanism for moving the mold carrier assembly relative to the support base.

26. The apparatus of claim 25, wherein said support base has an opening for removal of said mold carrier assembly, and wherein said adjustment mechanism is operable to align said mold carrier assembly with said opening.

27. The apparatus of any one of claims 23 to 26, wherein said attachment features comprise locking pins operable to selectively engage corresponding guide blocks on said support base.

28. The apparatus of any one of claims 23 to 27, wherein said mold carrier assembly

comprises couplings for engagement of said mold carrier assembly with a lifting tool.

29. The apparatus of claim 28, wherein said couplings comprise hooks for lifting by a crane.

30. A molding assembly for injection molding, comprising:

a mold carrier assembly removably mountable to a support base, comprising:

a mounting plate having attachment features for engaging corresponding attachment features on said support base;

a mold comprising first and second mold plates slidably supported on said mounting plate;

a clamp mounted to said mounting plate, said clamp operable to move said mold between a closed state in which said mold plates abut one another, and an open state in which said mold plates are spaced apart for removing molded articles.

31. The apparatus of claim 30, wherein said mold carrier assembly comprises a motor

coupled to said clamp.

32. The apparatus of claim 30 or claim 31, wherein said mold carrier assembly comprises an adjustment mechanism for moving the mold carrier assembly relative to the support base.

33. The apparatus of claim 30, wherein said adjustment mechanism is operable to align said mold carrier assembly with an opening in the support base.

34. The apparatus of any one of claims 30 to 33, wherein said attachment features comprise locking pins operable to selectively engage corresponding guide blocks on the support base.

35. The apparatus of any one of claims 30 to 34, wherein said mold carrier assembly

comprises couplings for engagement of said mold carrier assembly with a lifting tool.

36. The apparatus of claim 35, wherein said couplings comprise hooks for lifting by a crane.

37. An apparatus for injection molding, comprising:

a clamping assembly mounted to a support;

a mold comprising first and second mold plates mounted to said clamping assembly, said mold movable by said clamping assembly between a closed position in which said cavity plates abut one another to define a surface of an article to be molded, and an open position for removal of molded articles;

said clamping assembly driven by a crankshaft and comprising a connecting link causing reciprocating motion of said mold during each rotation of said crankshaft.

38. The apparatus of claim 37, wherein said clamping assembly, wnerein reciprocaung motion of said first mold plate is driven by a single connecting link coupled to said crankshaft.

39. The apparatus of claim 38, wherein said single connecting link is coupled to said mold plate by a multi-bar linkage.

40. The apparatus of any one of claims 37 to 39, wherein said clamping assembly comprises first and second connecting links coupled to a common crankshaft, wherein said first connecting link drives reciprocating motion of said first mold plate and said second connecting link drives reciprocating motion of said second mold plate.

41. An apparatus for operating a mold having a cavity and a core that cooperatively define a mold for molding of plastic articles, comprising:

a clamping assembly operable to move mold plates relative to each other between a closed position in which said plates abut in clamped contact, and an open position in which the plates are separated;

a core actuator operable to move said mold core relative to said plates along a core axis between a closed position in which said core is interposed between said plates, a preload position, in which said core is compressed from said closed position towards said plates, and a removal position in which said core is retracted for removal of a molded article.

42. The apparatus of claim 41, comprising a spring load assembly for supporting said mold against said plates, wherein movement of said core from said closed position to said preload position compresses said spring load assembly.

43. The apparatus of claim 41 or claim 42, wherein said mold core comprises an inner core and an outer core positioned around said outer core, wherein said actuator is operable to move one of said inner core and said outer core relative to the other of said inner core and said outer core along said core axis.

44. The apparatus of claim 43, wherein said actuator is operable to withdraw said inner core relative to said outer core in said removal position, to dislodge a molded part from said inner core.

45. The apparatus of any one of claims 41 to 44, wherein said actuator is connected to said mold core with releasable couplings.

46. The apparatus of any one of claims 41 to 45, wherein said aciuaior is mounieu LO a praien of said clamp assembly.

47. The apparatus of claim 46, comprising a slotted link connecting said actuator to said mold core.

48. The apparatus of any one of claims 41 to 47, wherein said core axis is perpendicular to a clamping axis of said clamp assembly.

49. The apparatus of any one of claims 41 to 48, wherein said core clamping axis is vertical.

50. The apparatus of any one of claims 41 to 49, wherein said apparatus is for injection

molding.

51. A clamping apparatus for injection molding of plastic articles, comprising:

a support frame;

first and second platens suspended from said support frame, each said platen for mounting a respective mold plate;

a linkage comprising a plurality of pivotably-connected members, said linkage operable by pivoting said links around a vertical axis to move said platens between a mold-closed position in which mold plates abut one another, and a mold-open position in which mold plates are spaced apart from one another

52. The clamping apparatus of claim 51, comprising mounts for attaching said first and

second platens to said support frame, wherein said mounts lie in a vertical plane.

53. The clamping apparatus of claim 52, wherein said mounts are attached to a vertical plate.

54. The clamping apparatus of any one of claims 51 to 53, wherein said platens defines a mold bounding envelope in which mold plates are mountable to said platens, said mold bounding envelope comprising ends defined by said platens, top and bottom sides, and opposing lateral sides perpendicular to said platens, and wherein said support frame and said linkage are adjacent one of said lateral sides.

55. The clamping apparatus of claim 54, wherein a lateral side of said mold bounding

envelope opposite said support frame and said linkage is an access side through which a material handling device may be inserted.

56. The clamping apparatus of claim 55, wherein the bottom side of said mold bounding envelope is an access side.

57. The clamping apparatus of claim 55, wherein, in said mold-open posiuon, nioiu piaies can be removed through a side of said mold bounding envelope.

58. The clamping apparatus of any one of claims 51 to 57, wherein said platens are movable along a horizontal axis.

59. The clamping apparatus of any one of claims 51 to 58, comprising a rotor driving said linkage.

60. The clamping apparatus of any one of claims 51 to 59, wherein said support frame is mounted to a tower structure.