Abstract: System and method for assembling blow molded parts without the use of separate fasteners, including a tab-and-slot or dovetail mortise and tenon joint that includes a slide-and-lock tab feature. A retention barb on the tab slides along a ramp to engage with a receptacle within the slot. Tabs and slots can have varying widths to create mutual incompatibility with other joint components that are otherwise similarly constructed. An optional stopper on the tab and corresponding notch within the slot can add an additional axis of incompatibility with other joints throughout the assembly. These features prevent incorrect assembly and allow convenient redesigns.

Abstract: An apparatus for creating a blow molded article is provided, including a mold having first and second mold portions that, when located adjacent each other along a seam, at least partially enclose a mold cavity, wherein the mold cavity at least partially defines a molding surface against which a wall of the blow molded article is blown during blow molding, a first cutting device moveably disposed in the first mold portion, and a second cutting device moveably disposed in the second mold portion, wherein the first and second cutting devices, when in an activated position, each have a cutting surface that extends into the mold cavity by an amount substantially equal to a desired wall thickness of the blow molded article.

Abstract: An insert for protecting articles to be stored in a protective case. The insert is generally hollow and formed of a flexible thermoplastic material. The insert may be formed by a blow-molding process. The insert is shaped to fit within a protective case, which is also often formed by a blow-molded process. The material used to form the insert is less dense than that of the material used to form the protective case, and therefore the insert material is less stiff, softer, and more flexible.

Abstract: A modular support assembly generally comprising vertical support members and a horizontal support member, such as a shelf, for supporting objects. The horizontal support member includes a main panel portion and flange portions connected along the sides of the panel for fortifying same. The vertical support members have cavities on their inner surfaces, and the horizontal support members have protrusions at their ends corresponding to the cavities. In some embodiments, the flanges are hingedly connected to the panel such that they pivot between a flat position and a supporting position perpendicular to the panel. In certain embodiments, the protrusions are integrally formed with extend out from the flanges. In some embodiments, the assembly is blow-molded article.

Abstract: A system for making blow molded receptacles is disclosed generally comprising two mold portions that, when positioned adjacent each other, at least partially enclose a cavity defined by a molding surface, against which the walls of a blow molded receptacle are blown. One of the portions is a mold core, which has a base surface and a raised portion extending out from the base surface into the cavity. The raised portion has an outer surface and a side surface, which results in a corresponding, inner sidewall on the blow-molded receptacle. The raised portion houses a punch partly disposed in an opening in the side surface for punching a hole in the sidewall. In some embodiments, the side surface is substantially perpendicular to the seal between the two mold portions, and an actuator displaces the punch in a direction substantially parallel to the seam.

Abstract: A blow-molded carrying chest which includes an integrally molded frame with a top frame member slideably engaged with the left and right frame members. The frame includes a base frame member, and right and left frame members integrally molded to the base frame member. A top frame member is slideably engaged with the right and left frame members to secure the top frame member and assemble the carrying chest without requiring any fasteners. Below the top frame member is a plurality of drawers which are locked by hinged doors on the right and left frame members that prevent the plurality of drawers from sliding when the carrying chest is in transport.

Abstract: A method and apparatus for facilitating the creation of holes in a blow molded container is disclosed generally comprising first and second mold portions mounted adjacent each other along a seam and a mechanism for creating holes at the seam. In some embodiments, first and second punches are used to create one hole underneath the container's handle. In some embodiments, a third mold portion is used to create a rose surface and create a plurality of holes therein.

Abstract: A method and apparatus for blow molding a case for housing an object, such as a tool, is disclosed generally comprising first and second mold portions located adjacent each other to create separate cavities for forming base and lid portions of a case and a punch for each portion corresponding to the outline of an object. In certain embodiments, the punch protrudes into the cavity during blow molding to create a sidewall to facilitate a press fit. In some embodiments, additional punches and/or recesses are provided to produce additional apertures or flanges in the walls of the tool case.

Abstract: A blow molded case is disclosed generally comprising a double wall, blow molded base portion having inner and outer case walls, and a lid portion connected to the base portion such that the lid, when in a closed position, at least partly covers the inner case wall of the base portion, which accommodates a first object. The outer wall of the base portion has a hole for receiving a second object, such as a drawer or other receptacle. In certain embodiments, the hole is a punched hole, created by extending a punch through a sidewall of the base portion substantially perpendicular to the parting line thereof. In certain embodiments, the sidewall is non-planar, and in some embodiments, the sidewall includes a recess adjacent the hole for easily gripping the second object.

Abstract: Methods and apparatuses for creating blow-molded components are disclosed. More particularly, the present invention concerns methods and apparatuses for creating double-wall blow-molded components with one or more protuberances not abutting a parting line of a mold. Generally, the protuberances are created by a method comprising the steps of blowing blow-molding material against a molding surface with a cavity of a predetermined shape, so that the blow-molding material enters the cavity at a first end, and urging the blow-molding back toward the first end of the cavity by moving a piston of a predetermined shape. The invention also concerns apparatuses to employ such methods, and the resulting blow-molded objects.

Abstract: An apparatus for forming a blow-molded article including a mold assembly at least partially defining a mold surface against which a blow-molded article is conformed during blow molding, and at least one dynamic device including an insert at least partially defining the mold surface, the insert movable from an extended position to a retracted position, wherein the insert is maintained in the extended position during the blow molding and the insert is moved to the retracted position following the blow molding to enable extraction of the article.

Abstract: A method and apparatus for facilitating the creation of holes in a blow molded container is disclosed generally comprising first and second mold portions mounted adjacent each other along a seam and a mechanism for creating holes at the seam. In some embodiments, first and second punches are used to create one hole underneath the container's handle. In some embodiments, a third mold portion is used to create a rose surface and create a plurality of holes therein.

Abstract: A blow molded article includes an outer wall and an article retaining feature projecting outwardly therefrom. The article retaining feature includes a distal wall and a side wall connecting the distal wall and the outer wall of the blow molded article. The side wall is generally orthogonal to the outer wall of the blow molded article, and an inner surface is defined at least partially by inner edges of the side wall, the distal wall and the outer wall of the blow molded article. The side wall has a hole integrally molded therein.

Abstract: A method for blow molding bottles having a hole formed in a molded interior recess extending from a top face of a bottle neck includes the steps of: (i) providing a mold having a neck forming cavity with an end flange surface therein; (ii) disposing a parison of molten material within the mold; (iii) introducing pressurized fluid into the parison to expand it against the mold walls, thereby forming a final shape of the bottle; (iv) forming the interior recess in the bottle by advancing a recess forming rod through a hole in the end flange surface and into the neck forming cavity; and (v) creating a dispensing hole in the interior recess by advancing a punch through a hole in an end face of the recess forming rod.

Abstract: An apparatus for blow molding bottles having a hole formed in a molded interior recess is provided. The apparatus includes a mold having a neck forming cavity having an end flange surface. A recess forming rod is slideable within a hole in the end flange surface from an initial position wherein a face of the rod is withdrawn into the hole in the mold to an extended position wherein the face of the rod protrudes into the neck forming cavity so as to create the molded interior recess. A punch is slideable within a hole in the rod from an initial position wherein a face of the punch is withdrawn into the hole in the mold to an extended position wherein the face of the punch protrudes beyond the face of the rod into the neck forming cavity so as to create the hole in the interior recess.

Abstract: A blow molded article includes an outer wall and an article retaining feature projecting outwardly therefrom. The article retaining feature includes a distal wall and a side wall connecting the distal wall and the outer wall of the blow molded article. The side wall is generally orthogonal to the outer wall of the blow molded article, and an inner surface is defined at least partially by inner edges of the side wall, the distal wall and the outer wall of the blow molded article. The side wall has a hole integrally molded therein.

Abstract: A chainsaw case for a chainsaw having a bar is provided. The case includes a base having a lower, a rear, and two end walls, one of the end walls having a slot therein. A front member is pivotally connected to the base and is pivotable from a closed position toward a position in which the front member is substantially coplanar with the lower wall. A top member is pivotally connected to the base about a pivot axis which is substantially parallel to the pivot axis of the front member, and is pivotable from a closed position toward a position in which the top member is substantially coplanar with the rear wall. The case also includes a scabbard for being applied to the bar of the chainsaw, the scabbard having an end portion adapted to be received within the slot when the chainsaw is disposed within the base.