Abstract: A cooling plate for an injection molding machine includes a plate body, a plurality of sockets in the plate body for receiving respective spigot portions of a plurality of cooling tubes, and a cooling fluid conduit system in the plate body for cooling the cooling tubes. The cooling plate further includes an air conduit system in the plate body for providing air flow communication with the cooling tubes. Each socket forms a blockable flow passage between the cooling fluid conduit system and the air conduit system.

Abstract: A method for injection molding a preform includes: a) loading a barrier membrane into a first mold cavity; b) injecting melt into the first mold cavity to undermold the barrier membrane and form a preform inner layer on an inside of the barrier membrane; c) moving the preform inner layer and the barrier membrane from the first mold cavity into a second mold cavity; and d) injecting melt into the second mold cavity to overmold the barrier membrane and form a preform outer layer on an outside of the barrier membrane. Preforms formed by the method and an injection molding machine to carry out the method are also disclosed.

Abstract: An injection molding machine includes a machine base extending along a horizontal machine axis; a stationary platen fixed to the base; a moving platen supported by the base; a center section supported by the base axially intermediate the stationary and moving platens; at least one mold stroke actuator for translating the moving platen and the center section along the machine axis between a mold-open position and a mold-closed position; a two-stage first injection unit supported by the base behind the stationary platen for injecting a first resin through the stationary platen; and a two-stage second injection unit supported by the base behind the moving platen for injecting a second resin through the moving platen. The second injection unit is translatable along the machine axis to accommodate translation of the moving platen during movement between the mold-open and mold-closed positions.

Abstract: An injection molding machine includes a machine base extending along a horizontal machine axis; a stationary platen fixed to the base; a moving platen supported by the base; a center section supported by the base axially intermediate the stationary and moving platens; at least one mold stroke actuator for translating the moving platen and the center section along the machine axis between a mold-open position and a mold-closed position; a two-stage first injection unit supported by the base behind the stationary platen for injecting a first resin through the stationary platen; and a two-stage second injection unit supported by the base behind the moving platen for injecting a second resin through the moving platen. The second injection unit is translatable along the machine axis to accommodate translation of the moving platen during movement between the mold-open and mold-closed positions.

Abstract: A method for receiving and ejecting molded articles includes: (a) drawing air from a cooling tube cavity into an air channel through a plate bore to draw at least a portion of a molded article into the cavity; (b) moving a valve within the plate bore from a first position for conducting air from the cavity to the air channel to a second position for reducing air flow through the plate bore relative to the first position; and (c) when the valve is in the second position, urging pressurized air from the air channel to the cavity through the plate bore to assist ejection of the molded article from the cavity.

Abstract: A shooting pot assembly for a two-stage injection unit includes: (a) a housing; (b) a plunger chamber in the housing; (c) an injection plunger in the plunger chamber; and (d) a conduit network including (i) a feed conduit, (ii) an outlet conduit, and (iii) a transfer conduit. The shooting pot assembly further includes (e) a purge valve assembly having a purge conduit open to the plunger chamber and in fluid communication with the transfer conduit via the plunger chamber when the plunger is in the advanced position. The purge valve assembly further includes a purge valve closure member movable between a closed position, in which the purge conduit is blocked, and an open position, in which the purge conduit is open for flushing stale melt from the transfer conduit through the purge conduit via supply of fresh melt into the transfer conduit from the feed conduit.

Abstract: An injection molding machine includes a machine base extending along a horizontal machine axis; a stationary platen fixed to the base; a moving platen supported by the base; a center section supported by the base axially intermediate the stationary and moving platens; at least one mold stroke actuator for translating the moving platen and the center section along the machine axis between a mold-open position and a mold-closed position; a two-stage first injection unit supported by the base behind the stationary platen for injecting a first resin through the stationary platen; and a two-stage second injection unit supported by the base behind the moving platen for injecting a second resin through the moving platen. The second injection unit is translatable along the machine axis to accommodate translation of the moving platen during movement between the mold-open and mold-closed positions.

Abstract: A method for receiving and ejecting molded articles includes: (a) drawing air from a cooling tube cavity into an air channel through a plate bore to draw at least a portion of a molded article into the cavity; (b) moving a valve within the plate bore from a first position for conducting air from the cavity to the air channel to a second position for reducing air flow through the plate bore relative to the first position; and (c) when the valve is in the second position, urging pressurized air from the air channel to the cavity through the plate bore to assist ejection of the molded article from the cavity.

Abstract: A cooling plate assembly includes (a) a cooling plate having a plate front surface; (b) an air channel extending within a thickness of the cooling plate; (c) a plate bore extending into the cooling plate from the plate front surface for providing fluid communication between the air channel and a cavity of a cooling tube mountable to the cooling plate; and (d) a valve within the plate bore. The valve is movable between a first position in which a first air flow passage extending within the plate bore is open for conducting air from the cavity to the air channel, and a second position in which the first air flow passage is obstructed to reduce air flow between the cavity and the air channel, and in which a second air flow passage extending within the plate bore is open for conducting air from the air channel to the cavity.

Abstract: A cooling plate for an injection molding machine includes a plate body, a plurality of sockets in the plate body for receiving respective spigot portions of a plurality of cooling tubes, and a cooling fluid conduit system in the plate body for cooling the cooling tubes. The cooling plate further includes an air conduit system in the plate body for providing air flow communication with the cooling tubes. Each socket forms a blockable flow passage between the cooling fluid conduit system and the air conduit system.

Abstract: A cooling plate assembly for an injection molding machine includes a cooling plate and a cooling fluid conduit system in the cooling plate. The cooling fluid conduit system includes a cooling fluid line extending between a cooling fluid inlet and a cooling fluid outlet. A socket is open to a front face of the cooling plate and intersects the first cooling fluid line. A cooling tube is mounted to the cooling plate, and includes a molded-article-receiving nest for receiving and cooling an injection molded article, a spigot received in the socket and blocking the first cooling fluid line, and a cooling tube conduit adjacent the molded-article-receiving nest. The cooling tube conduit extends between a cooling tube fluid inlet connected to the first cooling fluid line upstream of the socket, and a cooling tube fluid outlet connected to the first cooling fluid line downstream of the socket.

Abstract: A cooling plate assembly includes (a) a cooling plate having a plate front surface; (b) an air channel extending within a thickness of the cooling plate; (c) a plate bore extending into the cooling plate from the plate front surface for providing fluid communication between the air channel and a cavity of a cooling tube mountable to the cooling plate; and (d) a valve within the plate bore. The valve is movable between a first position in which a first air flow passage extending within the plate bore is open for conducting air from the cavity to the air channel, and a second position in which the first air flow passage is obstructed to reduce air flow between the cavity and the air channel, and in which a second air flow passage extending within the plate bore is open for conducting air from the air channel to the cavity.

Abstract: A cooling plate assembly for an injection molding machine includes a cooling plate and a cooling fluid conduit system in the cooling plate. The cooling fluid conduit system includes a cooling fluid line extending between a cooling fluid inlet and a cooling fluid outlet. A socket is open to a front face of the cooling plate and intersects the first cooling fluid line. A cooling tube is mounted to the cooling plate, and includes a molded-article-receiving nest for receiving and cooling an injection molded article, a spigot received in the socket and blocking the first cooling fluid line, and a cooling tube conduit adjacent the molded-article-receiving nest. The cooling tube conduit extends between a cooling tube fluid inlet connected to the first cooling fluid line upstream of the socket, and a cooling tube fluid outlet connected to the first cooling fluid line downstream of the socket.

Abstract: A hot runner apparatus for a mold assembly of an injection molding machine includes a hot runner plate assembly having a first end portion and a second end portion and a machine axis extending therebetween. At least one insert coupling having an axial bore is secured to the first end portion of the hot runner plate assembly, for separable sealed engagement with a gate insert affixed to a cold half of the mold assembly. The insert coupling includes a coupling interface for contacting a mating interface of the gate insert in sealed contact during an injection cycle of the injection molding machine. The coupling interface includes a primary side surface that is inclined relative to the machine axis.

Abstract: A hot runner apparatus for a mold assembly of an injection molding machine includes a hot runner plate assembly having a first end portion and a second end portion and a machine axis extending therebetween. At least one insert coupling having an axial bore is secured to the first end portion of the hot runner plate assembly, for separable sealed engagement with a gate insert affixed to a cold half of the mold assembly. The insert coupling includes a coupling interface for contacting a mating interface of the gate insert in sealed contact during an injection cycle of the injection molding machine. The coupling interface includes a primary side surface that is inclined relative to the machine axis.

Abstract: An injection molding machine and a mold are used to form batches of hallow parts, such as PET preforms. An end of arm tool transfers the molded preforms from the mold to a temperature conditioning station having a conveyor. The batch of molded preforms is received and retained on the end of arm tool by an array of cooling tubes that are attached to a number of identical cooling tubes carrier devices. The conveyor is adapted to receive the carrier devices and the cooling tubes loaded with molded preforms from the end of arm tool. The conveyor is also adapted to transfer rapidly the carrier devices and the empty cooling tubes into the end of arm tool before the end of arm tool is moved back into the molding area to receive subsequent batches of molded preforms.

Abstract: An injection molding machine and a mold are used to form batches of hallow parts, such as PET preforms. An end of arm tool transfers the molded preforms from the mold to a temperature conditioning station having a conveyor. The batch of molded preforms is received and retained on the end of arm tool by an array of cooling tubes that are attached to a number of identical cooling tubes carrier devices. The conveyor is adapted to receive the carrier devices and the cooling tubes loaded with molded preforms from the end of arm tool. The conveyor is also adapted to transfer rapidly the carrier devices and the empty cooling tubes into the end of arm tool before the end of arm tool is moved back into the molding area to receive subsequent batches of molded preforms.

Abstract: An injection molding shooting pot shot size control apparatus is configured to be installed in a coinjection hot runner with a coinjection nozzle, the coinjection nozzle having at least two melt channels ending at the same gate includes a valve inlet and a valve outlet. An adjustable melt control mechanism, preferably in the form of a hydraulically actuated wedge, is configured to (i) be disposed in a cavity plate adjacent to a hot runner assembly, and allow the shot size position to be set while the mold is open, and (ii) permit the charged shooting pot cylinder to decompress the melt when the wedge is pulled away from the shooting pot piston.

Abstract: Apparatus and method whereby coinjection molding shooting pot actuation structure is configured to be installed in a coinjection hot runner with a coinjection nozzle, the coinjection nozzle having at least two melt channels ending at the same gate. The shooting pot is preferably disposed in one of a mold cavity half and a mold core half. A shooting pot piston is configured to discharge a melt from the shooting pot. A transmission structure is configured to (i) extend through one of the mold cavity half and the mold core half, and (ii) to transmit a force to the shooting pot piston. Actuation structure is disposed on the opposite side of the mold cavity half from the coinjection hot runner, and is configured to provide the force to the transmission structure. This configuration conserves space in the mold.

Abstract: Coinjection molding system control apparatus and method preferably includes flow control structure and/or steps configured to reduce pressure on a second melt, preferably causing a relatively small portion of a first melt to flow from a distal portion of a first melt channel in the coinjection nozzle into a distal end of a second melt channel in the coinjection nozzle. This prevents substantial amounts of the second melt from being dragged into the mold cavity when the next shot of the first melt is injected.