Abstract: The invention is a method for preparing a finished part in a mold wherein the finished part includes n mold inputs, the method comprising the steps of (a) providing a mold having n mold stations, (b) simultaneously adding a mold input at each mold station to create a finished part and n?1 part portions, (c) removing the finished part and each part portion from each mold station, (d) transferring the finished part to a finished part holding area and transferring each part portion to a different mold station, and (e) repeating steps (b) through (d).

Abstract: A locking apparatus for a machine having multiple stems which axially reciprocate with respect to a stationary unit by linkage with a reciprocating common plate. The locking apparatus includes: (a) a first locking assembly capable of alternatively locking and unlocking one of the stems to the common plate; and (b) a second locking assembly capable of alternatively locking and unlocking one of the stems to the stationary unit. The second locking mechanism is configured so that, when the first locking assembly locks a stem to the common plate, the second locking mechanism automatically unlocks that stem from the stationary unit, and when the first locking assembly is unlocked from the common plate, the second locking mechanism automatically locks that stem to the stationary unit.

Abstract: A locking apparatus for a machine having multiple stems which axially reciprocate with respect to a stationary unit by linkage with a reciprocating common plate. The locking apparatus includes: (a) a first locking assembly capable of alternatively locking and unlocking one of the stems to the common plate; and (b) a second locking assembly capable of alternatively locking and unlocking one of the stems to the stationary unit. The second locking mechanism is configured so that, when the first locking assembly locks a stem to the common plate, the second locking mechanism automatically unlocks that stem from the stationary unit, and when the first locking assembly is unlocked from the common plate, the second locking mechanism automatically locks that stem to the stationary unit.

Abstract: An injection mold apparatus has multiple injection zones, each zone having at least one heater and at least one temperature sensor generating a temperature indicating signal. A power source provides power to the heaters. A controller controls the temperature of at least some of the zones. For efficiency, the controller has two separate processors, a data-receiving processor for receiving temperature indicating signal from each sensor as well as power signals, and a control processor for receiving data from the data-receiving processor and for controlling the amount of power provided to the heaters. Preferably, the control is in a housing, with the housing mounted directly on the mold. Modified PID calculations are utilized. Power calculations for the amount of power to the heaters utilizes a modulo based algorithm.

Abstract: A mold apparatus for making multi-component products includes (i) a rotatable turret with a plurality of product connector pairs attached to opposite sides of the turret, (ii) a first mold disposed proximate to the turret and (iii) a second mold disposed on the opposite side of the turret. The first mold has a plurality of cavities for molding a first molded layer of the multi-component product, and the second mold has a plurality of cavities for molding a second layer onto the first molded layer. Each product connector is rotatable about its longitudinal axis to allow the mold apparatus to make multi-component products having first molded layers and second molded layers with indentations and/or protuberances disposed in a variety of orientations.

Abstract: An injection mold apparatus for the injection molding of plastic articles. The mold apparatus has a plurality of take-off plates. Each of the take-off plates comprises a plurality of article acceptors. The take-off plates are movable between positions wherein the article acceptors can accept molded articles from the mold and positions wherein the molded articles are moved away from the mold. In a preferred embodiment, each of the article acceptors consists of opposed half-cylinders which can be separated to accept and discharge the molded articles. Also in preferred embodiments, each of the article acceptors is internally cooled so as to be able to cool each article acceptor after it has been moved away from the mold.

Abstract: A mold apparatus useful for making molded foam articles has a pair of independently operated mold modules, both fed by a single hot melt injection unit. In a preferred, but not necessary, embodiment, each of the opposed mold portions of each mold module is retained in its respective closed position by a simple mechanical latch. In such a preferred embodiment, it is further preferred that, in the closed position, the two mold portions of each mold module are separated by a narrow air gap to allow air to escape from each mold module during operation.

Abstract: An injection mold apparatus has multiple injection zones, each zone having at least one heater and at least one temperature sensor generating a temperature indicating signal. A power source provides power to the heaters. A controller controls the temperature of at least some of the zones. For efficiency, the controller has two separate processors, a data-receiving processor for receiving temperature indicating signal from each sensor as well as power signals, and a control processor for receiving data from the data-receiving processor and for controlling the amount of power provided to the heaters. Preferably, the control is in a housing, with the housing mounted directly on the mold. Modified PID calculations are utilized. Power calculations for the amount of power to the heaters utilizes a modulo based algorithm.

Abstract: The invention is a mold apparatus for making multi-component products. The apparatus includes an elongate turret, a plurality of product connection pairs attached on opposite sides of the turret, a first mold disposed proximate to the turret and a second mold disposed on the opposite side of the turret. The first mold has a plurality of cavities for molding a first molded layer of the multi-component product, and the second mold has cavities for molding a second layer onto the first molded layer. The turret is rotatable between the first mold and the second mold by rotation about its longitudinal axis of the turret.

Abstract: A unitized heat conductive assembly 32 formed of a one piece heat conductive conduit 40 which permits shaping the heat conductive assembly as a continuous unit. The heat conductive assembly 32 is press fit into the heater block 12 configured so that it provides a predetermined flow path 14 for the flowable molten plastic materials to be delivered to the injector nozzles. There is provided a heat flow path 28 that follows the flow path 14. The heat conductive carrying conduit 40 is formed with an opening 42. The conductive conduit 40 is formed from a tubular piece of conductive metal such as copper or brass by a swaging process which forms a tubular structure 40 in a continuous length. The outer contour of the tubular structure 40 can be round or oral and the preferred shape is either square or rectangular.

Abstract: This invention provides an improved heating apparatus for controlling the temperatures of the resin melt that is pressure fed to a molding cavity comprising a heating jacket 30 comprising the concentric tubular elements; a copper sheath 32 having an inside surface 34 and an outer surface 36, a retainer sleeve 40 and coiled heating element 42 sandwiched between the sheath 32 and the retainer sleeve 40. The inside surface of the sheath 32 is formed with at least one circumferential groove 38 which provides an insulating air gap so that a lesser amount of heat is conducted to the central portion of the heating jacket 30 thereby creating three distinct temperature zones. The sheath 32 is provided with a channel 46 extending longitudinally down its inside surface 36 between the heating coil 42 and the outside surface of the housing 22 for the hot runner conduit 24.

Abstract: A hot tip nozzle assembly for injection molding plastic components comprises a nozzle housing defining a hot runner passage and a nozzle tip section which is received in the hot runner passage. The nozzle tip section defines a hot runner tip passage in flow communication with the hot runner passage. The nozzle tip section slides freely within the hot runner passage during injection molding. A stop is provided on the nozzle tip section to limit downward movement relative to the cavity gate and automatically position the nozzle tip relative to the injection gate of the mold. In addition, axial thermal expansion of the nozzle housing is not imparted to the nozzle tip section. The nozzle tip section also has a restricted length that can axially thermally expand. Accordingly, the position of the nozzle tip is only minutely affected by even larger temperature changes in the nozzle assembly.

Abstract: A nozzle body is provided that is equipped with a runner, passages and orifices all communicating with one another to provide a fluid delivery system to mold cavities. The nozzle body is provided with a heat insulating cap equipped with peripheral projections at spaced positions around the outside wall of the cap so that the fluid injected into the mold at the gatewell will shear with a smooth cleavage after solidifying to provide a smooth separation surface on the molded part. Each gatewell is disposed in a peripheral projection in the cap and the peripheral projection is spaced of few thousandths from the mold. The cap serves to minimize the loss of heat from the nozzle body by aligning and centering the cap and the nozzle body relative to the gatewells leading to the mold.

Abstract: A nozzle has a runner for passing fluid through the nozzle. The fluid is heated as it passes through the runner. The temperature of the fluid may be regulated. The fluid flows from the runner into a well formed in a nozzle well insert which is disposed on the nozzle. A gate is disposed in the nozzle well insert in communication with the well. A tip having a raised portion and a reduced portion, each extending in a helical pattern, is disposed in the runner with the raised portion abutting the surface of the runner. The outlet end of the tip is disposed relative to the well in the nozzle well insert so that the fluid in the reduced portion of the tip flows in a swirling motion through the well to wipe the surface of the well and remove the fluid previously in the well. The surfaces of the raised and reduced portions of the tip may be coated with a material to prevent such surfaces from becoming deformed by the fluid flowing through the tip and the gate into the mold. In this way, a fluid of one color (e.g.

Abstract: A heating block made from a heat conductive material has a passage through which a fluid heated by the heater can flow. A groove preferably having a looped configuration extends into the block from a peripheral surface in the block. A heater made from an electrically conductive and heat conductive material is disposed in the groove, preferably in a looped configuration corresponding to the looped configuration of the groove. A heat conductive member disposed in the groove is provided with a hole to receive the heater in an enveloping relationship. The member may be defined by a pair of separable portions. The member is preferably disposed in the looped relationship in the groove. Localized deformation of the heating block holds the member and the heater in a fixed relationship with the block. The heater may deteriorate or become defective with extended usage and may have to be replaced. To accomplish this, the heater and the member may be removed as a unit from the block after removing the deformation.

Abstract: A nozzle has a runner for passing fluid through the nozzle. The fluid is heated as it passes through the runner. The temperature of the fluid may be regulated. The fluid flows from the runner into a well formed in a nozzle well insert which is disposed on the nozzle. A gate is disposed in the nozzle well insert in communication with the well. A tip having a raised portion and a reduced portion, each extending in a helical pattern, is disposed in the runner with the raised portion abutting the surface of the runner. The outlet end of the tip is disposed relative to the well in the nozzle well insert so that the fluid in the reduced portion of the tip flows in a swirling motion through the well to wipe the surface of the well and remove the fluid previously in the well. The surfaces of the raised and reduced portions of the tip may be coated with a material to prevent such surfaces from becoming deformed by the fluid flowing through the tip and the gate into the mold. In this way, a fluid of one color (e.g.

Abstract: A manifold is disposed within a pair of abutting pre-load mold plates in a pre-load relationship. Fluid flowing through the manifold is heated by a first heater. The fluid is then divided into a plurality of passages in the manifold. Pairs of passages have a back-to-back in-line relationship. A cylinder between each pair of the in-line passages holds a pair of pistons in the in-line relationship. Each piston in the pair has piston units in an interdigitated relationship with piston units on the other piston in the pair. Each pair of pistons is movable by pressurized fluid (e.g. air) between first and second positions. In the first position, each piston provides for the fluid (e.g. resin melt) flow through one of the passages to a pair of runners in the manifold. In the second position, each piston prevents the resin melt flow through the passages. A first heater heats the resin melt flowing through the passages. A second heater heats the resin melt flowing through the runners.

Abstract: A nozzle body has a runner, a passage and an orifice, all communicating with one another to provide for fluid flow into and through the body. The fluid is heated during its flow through the nozzle body by an electrical heater on such body and by a heat conductive plug (e.g. copper) extending through the nozzle. A cap made from a heat insulating material (e.g. titanium) and disposed in a tight fit on the nozzle body has a gate well for receiving the fluid in the orifice and for injecting such fluid into a mold. The cap is constructed so that fluid cannot leak into the area around the cap when heated fluid flows through the gate well. The cap is also constructed so that the article formed in the mold from the fluid injected into the article will shear to provide a smooth peripheral surface when the article is ejected from the mold after solidifying.