Title of Invention	A COOLING DEVICE FOR USE WITH AN INDEX MOLDING MACHINE
Abstract	A cooling device (62) for use with an index molding machine (10) comprises : frame means (64) attached to rotary turret block (16) support means (18) of the molding machine ; means (70, 74) for receiving and cooling at least one molded part (50), and mounted to a first surface of a carrier plate (72) connected to the frame means ; and means (68) for moving said carrier plate between a first orientation where the receiving and cooling means is aligned with at least one molded part (50) and a second orientation where at least one molded part is cooled within the receiving and cooling means.

Title of Invention

A COOLING DEVICE FOR USE WITH AN INDEX MOLDING MACHINE

Abstract

A cooling device (62) for use with an index molding machine (10) comprises : frame means (64) attached to rotary turret block (16) support means (18) of the molding machine ; means (70, 74) for receiving and cooling at least one molded part (50), and mounted to a first surface of a carrier plate (72) connected to the frame means ; and means (68) for moving said carrier plate between a first orientation where the receiving and cooling means is aligned with at least one molded part (50) and a second orientation where at least one molded part is cooled within the receiving and cooling means.

Full Text	BACKGROUND OF THE INVENTION The present invention relates to a cooling device for use with an index molding machine, an injection molding machine and a process for forming cooled molded parts, and in particular to a two faced index molding machine, having improved part cooling and part removal. Index molding machines are known in the art. U.S. Patent No. 5,728,409, assigned to the assignee of the instant application, shows a four faced turret block with a temperature conditioning station mounted to the turret for directing cooling air onto newly molded articles and a tubular part removal system using an air conveyor. Currently, there is a need for a lower cost molding machine which employs only a two faced turret block and correspondingly half the number of core sets of tooling. Co-pending allowed U.S. Patent Application Serial No. 08/847, 895 to Arnott et al., entitled Injection Molding Machine Having a High Speed Turret, filed on April 28, 1997, also assigned to the assignee of the instant application, shows an index molding machine with a two faced turret block. This application however, does not discuss the problems of part cooling and controlled part removal. Co-pending U.S. Patent Application Serial No. 09/070, 598 to Gait et al., filed on April 30, 1998, entitled Tiebar Structure for Injection Molding Machine, also assigned to the assignee of the instant application, shows a two tiebar index molding machine. Here again, there is no discussion of part cooling or part removal. U.S. Patent No. 4,729,732 and U.S. Reissue Patent No. 33,237, both assigned to the assignee of the instant application, show a multi-position tooling plate with water cooled tubes used to remove and cool preforms from a conventional preform molding machine. The tooling plate design shown in these patents has two disadvantages. First, the robot mechanism occupies a substantial floor area adjacent the machine. Second, the preforms are cooled inside their tubes in a horizontal orientation. This has been found to be detrimental in that the weight of the preform causes it to press more firmly against the lower portion of the cooling tube while its upper surface tends to separate from the upper portion of the cooling tube. This unequal contact force with the cooling surface tends to promote unequal cooling of the preform from one side to the other. A vertical orientation during cooling provides a symmetrical weight distribution with a balanced heat removal result. Conventional index molding machines eject parts at the lowermost station, i.e., when the molded parts to be ejected are under the turret block. There is a need to accommodate part ejection/removal at a station opposite to the molding station to permit two faced turret operation in a molding cycle where the turret rotates 180° each time the mold opens instead of rotating 90° at each mold opening. SUMMARY OF THE INVENTION Accordingly, it is an object of the present invention to provide a two faced turret molding machine having improved part cooling and improved part removal. It is a further object of the present invention to provide a molding machine as above which is less expensive to produce. It is yet a further object of the present invention to provide a molding machine as above which allows cooling of the molded part in a vertical orientation. The foregoing objects are achieved by the molding machine, the cooling device, and the process of the present invention. Accordingly, the present invention provides a cooling device for use with an index molding machine having a rotary turret block mounted within support means and at least one mold core on each of at least two faces of said rotary turret block, said cooling device comprising frame means attached to said rotary turret block support means, means for receiving and cooling at least one molded part, said receiving and cooling means being mounted to a first surface of a carrier plate connected to said frame means ; and means for moving said carrier plate between a first orientation where said receiving and cooling means is aligned with said at least one molded part and a second orientation where said at least one molded part is being cooled within said receiving and cooling means. The invention also provides an injection molding machine comprising : a first platen carrying a first mold half having at least one mold cavity ; a second platen in association with said first platen, said second platen comprising rotatable turret block means rotatable on a central axis of rotation for rotating at least two movable mold halves into alignment with said first mold half ; each of said movable mold halves having at least one mold core and being movable between a first molding position where it is aligned with said first mold half and a second cooling position where it is not aligned with said first mold half ; means for moving said rotatable turret block means to bring a first one of said movable mold halves into a mold closed position ; means for injecting plastic material into said at least one mold cavity while said first one of said movable mold halves is in said mold closed position and forming at least one molded part ; said moving means comprising means for moving said rotatable turret block means and said first one of said movable mold halves to a mold open position where said at least one molded part resides on said at least one mold core on said first one of said movable mold halves ; means for rotating said rotatable turret block means to cause said first one of said movable mold halves to rotate from said mold open position to said second cooling position and to cause a second one of said movable mold halves to move to said first molding position ; and means attached to said rotatable turret block means for cooling exterior surfaces of said at least one molded part on said at least one mold core while said first one of said movable mold halves is in said second cooling position. The invention also provides a process for forming cooled molded parts comprising the steps of : providing an index molding machine having a first platen carrying a first mold half having at least one mold cavity and a second platen comprising rotatable turret block means rotatable on a central axis of rotation for rotating at least two movable mold halves into alignment with said first mold half, each of said movable mold halves having at least one mold core ; moving said rotatable turret block means to bring a first one of said movable mold halves into a mold closed position with said first mold half and clamping said first one of said movable mold halves and said first mold half ; injecting molten material into said at least one mold cavity to form a first molded part set of at least one molded part ; holding said first one of said movable mold halves in said mold closed and clamped position while cooling said first molded part set ; moving said rotatable turret block means to a mold open position where said first molded part set is positioned on said at least one mold core on said first one of said movable mold halves ; rotating said turret block means to bring said first molded part set to a cooling position ; providing a cooling device on a carrier plate adjacent said cooling position, said cooling device having at least one cooling tube for receiving said at least one molded part forming said first set ; ejecting each said molded part forming said first set into said at least one cooling tube ; rotating said at least one cooling tube to a position where each said molded part in said first set is in a desired orientation ; and cooling each said molded part in said first set while it is in said desired orientation. The desired orientation is preferably a vertical orientation. The process may further comprises forming a second set of molded part (s) on mold core(s) on a second one of the movable mold halves while the molded part(s) in the first set is being cooled and thereafter rotating the rotatable turret block so that said second set of molded part(s) is in said cooling position and subjecting the second set of molded part(s) to cooling. Other details of the molding machine, cooling device, and the process of the present invention, as well as other objects and advantages attendant thereto, are set forth in the following detailed description and the accompanying drawings wherein like reference numerals depict like elements. BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS FIG. 1a is a side view of a two tiebar index molding machine ; FIG. 1b is an end view of the molding machine of FIG. 1A ; FIG. 2a is a side view of a first embodiment of a cooling device in accordance with the present invention ; FIG. 2b is a side view of the cooling device of FIG. 2a showing the cooling tubes in a part removing position; FIG. 2c illustrates an alternative actuation system for moving the cooling device of FIG. 2a between positions; FIG. 3 is a partial sectional view of the molding machine of FIG. la; FIG. 4 is a partial sectional view of the molding machine of FIG. 1a; FIG. 5 is a partial sectional view of the molding machine of FIG. la in a part transferring mode; FIG. 6 is a partial sectional view of the molding machine of FIG. la with the cooling device ejecting cooled molded parts; FIG. 7 is a chart showing the sequence of operation of the molding machine of FIG. la; FIGS. 8a and 8b illustrate an alternative embodiment of a cooling device having multi-position cooling tubes for use with an index molding machine; FIGS. 9a - 9c illustrate an alternative actuation system for the cooling device of FIGS. 8a and 8b; and FIGS. 10a and 10b illustrate another alternative actuation system for the cooling device of FIGS. 8a and 8b. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S) Referring now to the drawings, FIGS. 1a and 1b illustrate a two tiebar index molding machine 10 of the type shown in co- pending U.S. patent application no. 09/070,598, to Galt et al., entitled Tiebar Structure for Injection Molding Machine, filed April 30, 1998, which is incorporated by reference herein. The index molding machine 10 includes a base 12, a fixed platen 14, and a movable platen 16 which is movable with respect to the fixed platen 14. The movable platen 16 is a two-faced rotary turret block, which is positioned within the movable platen, with pinions in bearings mounted in carriers 18 that slide on the base 12. The turret block 16 is rotated or indexed on a central axis 20 so that the faces thereof represent two positions in an injection molding cycle. Thus, the rotatable turret block 16 is rotatable on a central axis of rotation 20 for rotating a plurality of movable mold halves 36 attached thereto into alignment with a first mold half 32 carried by the fixed platen 14. Each movable mold half 36 includes at least one mold core 38 and is matable with the first mold half 32 for forming a mold for forming at least one molded article, with the mold halves being clamped together as will be described hereinafter. The first mold half 32 may be joined to the fixed platen 14 in any suitable manner known in the art and may contain one or more mold cavities 34 which together with the mold core(s) 38 form one or more mold cavity spaces 40. Parts 50, such as preforms, are molded by injecting plastic material through the mold half 32 from an injection unit (not shown) into the cavity space(s) 40 formed by the closed mold. Two tiebars 24 are provided and bolted to the carriers 18, each of which includes an inside stroke cylinder 22, the rod 23 of which is fixed to housing 25 which in turn is bolted to fixed platen 14. Each tiebar 24 includes external teeth 26 of a rotating clamp piston 30 with the clamp piston contained in fixed platen 14. The clamp piston 30 includes a row of teeth 28 and an adjacent row free from teeth so that on rotation of the clamp piston, the clamp piston teeth 28 alternately engage and disengage the tiebar teeth 26. Clamp piston 30 may be rotated by any desired and convenient means (not shown), such as a cylinder means acting on a pin via a slot in housing 25, such as a cylinder bolted to the fixed platen 14 with linkage means connecting the pins together and causing rotation of the pistons 30. In operation, a pin (not shown) rotates clamp piston 30 so that clamp piston teeth 28 are disengaged from teeth 2 6 on tiebars 24. High pressure oil is then supplied to the piston end 42 of stroke cylinder 22 via a line (not shown) causing stroke cylinder rod 23 to extend and move carriers 18 and turret block 16 away from the fixed platen 14, thereby opening the mold. In order to close the mold, oil is supplied to the rod side 44 of stroke cylinder 22 via a line (not shown), thereby retracting stroke cylinder rod 23 and closing the clamp until the mold is closed. The aforementioned pin (not shown) is then activated by a cylinder (not shown) and linkage means (not shown) to engage clamp piston teeth 28 with tiebar teeth 26.. High pressure oil is then provided to the clamp piston cylinder 4 6 causing the clamp pistons to clamp the mold. After molding, high pressure oil is provided to the mold break cylinder 48 causing clamp piston 30 to act on the back side of tiebar teeth 26 and urge the mold open. After a short stroke, clamp piston 30 is de-energized and the pin actuated by the aforementioned cylinder and linkage means causes the clamp piston to rotate to disengage clamp piston teeth 28 from tiebar teeth 2 6 so that stroke cylinder 22 can open the mold. As shown in FIG. la, the turret block 16 has two faces, each with a mold core plate 36 mounted to it. Each mold core plate 36 may be mounted to a respective face of the turret block 16 using any suitable conventional means known in the art. In a preferred embodiment, each mold core plate 36 has a plurality of core pins 38, equal in number to the number of mold cavities 34 in the first mold half 32. As can be seen in FIG. la, a first set A of core pins 38 is aligned with the mold cavities 34 in a molding position, while a second set B of core pins 38 are in a cooling position located 180 degrees from the molding position. After plastic material has been injected into the mold cavity spaces 40 and the molded parts 50 have been formed, the parts 50 are partially cooled in a customary manner by cooling circuits (not shown), such as water cooling circuits, in the mold cavity plate 32 and in the core pins 38. After partial cooling has occurred and the parts 50 have been sufficiently solidified to avoid part deformation, the mold is opened in the manner previously discussed and the molded parts 50 on the first set A of core pins 38 are withdrawn from the mold cavities 34. The turret block 16 is then rotated 180 degrees to present the second set B of core pins 38 for molding while the first set A of core pins 38, complete with the molded parts 50 thereon, are presented at the opposite side of the turret block for further cooling. 1 In accordance with a first embodiment of the present invention, a device 62 is provided to cool the molded parts and remove them from the core pins 38 when the molded parts are in the cooling position. The device 62 includes a frame 64 attached to the carrier 18 or its support. A cross beam 66 is attached to the frame 64 so as to be capable of rotation through a 90 degree angle. The end of the cross beam 66 remote from the frame 64 is connected to a drive means 68 for rotating the cross beam 66 through said 90 degree rotation. The drive means 68 may comprise any suitable drive means known in the art. A set of blowing tubes 7 0 is mounted to a first surface of a head or carrier plate 72 attached to the cross beam 66. The blowing tubes 70 are used to direct a cooling fluid, typically air, toward an end of the molded parts 50, while the parts 50 are on the core pins 38. This blowing position is shown in FIG. 2b. Cooling fluid may be supplied to the blowing tubes 70 in suitable manner known in the art. A set of cooling tubes 74 is mounted to a second surface of the head 72. As can be seen from FIG. la, the cooling tubes 74 are offset 90 degrees from the blowing tubes 70. The set of cooling tubes 74 are used to facilitate removal of the molded parts 50 from the core pins 38. The cooing tubes 74 assist the removal of the molded parts 50 through the application of a vacuum inside the tubes 7 4 in a known fashion. For example, a port (not shown) in the bottom of each tube 74 may be connected to a vacuum source (not shown). The tubes 74 may be cooled by a fluid, such as chilled water, and remove heat from the parts 50 positioned therein either by convection or conduction. For example, cooling may be achieved by intimate contact between exterior surface of the part and the inside surface of the tube as taught by U.S. Patent No. 4,729,732, which is incorporated by reference herein. FIG. 3-6 illustrate the sequence of operation of a molding machine in accordance with the present invention. FIG. 3 shows the clamp closed and the parts 50 being molded on the first core set A. FIG. 4 shows the clamp closed for molding on the second core set B while cooling air is being directed from tubes 70 onto the ends of the molded parts 50 on the first core set A. FIG. 5 shows the cross beam 66 rotated 90 degrees to align the cooling tubes 74 with the parts 50 on the first core set A as the parts are ejected into the tubes 74. Ejection of the molded parts 50 from the core pins 38 into tubes 74 is carried out by the provision of ejection means, such as ejection pins/sleeves or an ejection plate, on each mold face 36. FIG. 6 shows cross beam 66 rotated 90 degrees in the reverse direction to once again align the blowing tubes 70 with the next set of molded parts while the previous set of parts are ejected from cooling tubes 74. Ejection of the cooled parts 50 from the cooling tubes 74 may be effected by discontinuing the vacuum and allowing gravity to cause the parts to drop out of the tubes 74 or by blowing the parts 50 out of the tubes 74 or by mechanical ejection means such as those shown in U.S. Patent No. 5,447,426, which is incorporated by reference herein. FIG. 7 shows the sequence of operation for making the molded parts 50. The top half of the chart shows the molding process and indicates two identical sequences spaced in time, the first for the first core set A, and the second for the second core set B. Each of the sequences starts with the mold closed, as shown in FIG. 1a. The injection molding sequence of clamp, inject, hold/cool, and open then follows. During the mold opening stroke, the index turret block 16 simultaneously begins to rotate 180 degrees to align the second core set for molding while the first core set, with the molded parts 50 on the core pins 38, is aligned to the cooling and removal device 62. The rotation is completed during the closing stroke of the turret block 16. The bottom half of the chart shows the cooling process and indicates a sequence that overlaps the two molding processes shown in the top half of the chart. The ejection and cooling sequence begins as the first core set A with molded parts 50 thereon is aligned to the cooling and removal device 62. Cooling fluid, typically compressed air, is blown from tubes 70 directly onto the ends of the molded parts 50, as they remain cooling on the core pins 38. Thus, during this portion of the sequence, parts 50 are cooled both internally and externally. Then the head 72 is rotated 90 degrees to align the cooling tubes 74 with the molded parts 50 on the core pins 38. Next the ejection system of the mold in combination with the vacuum circuit in the cooling tubes 74 transfers the parts from the core pins 38 to the tubes 74 wherein the parts are immediately cooled on their outer surfaces by their contact with the water cooled tubes, in a known fashion. The device 62 is immediately rotated again so that the tubes 74 point downward and the molded parts 50 continue cooling in a vertical orientation to ensure symmetrical cooling and gravitational effects maintaining a distortion-free part. The molded parts 50 are held in the tubes 74 by the applied vacuum and continue to cool until just before it is time to rotate the device 62 back to receive the next set of molded parts from the second core set B. Thus, the cooling time for the complete process optimizes the time the molded parts 50 are cooled, first while in the mold and on the cores and secondly while in the cooling tubes 74. Additional cooling is provided by the air blowing from tubes 70 onto the parts 50 during the shaded portion shown on the chart. By maximizing the cooling time of the molded parts 50 as described hereinabove, it has been found that only two core sets are required for an optimum molding cycle. Thus the tooling cost for equipping a four faced turret block can be significantly reduced by using only a two faced turret block. The cost of the core sets is halved. As can be seen from the foregoing discussion, there has been provided in accordance with the present invention a lightweight cooling and part removal device mounted on the moving index carrier that first cools the outside of the part 50 by blowing air and subsequently continues to cool the part 50 inside a cooled tube 74 that also removes the part 50 from the mold. Still further, cooling of the part 50 is performed in a vertical orientation inside a cooled tube 74. As a result, the part 50 has improved properties which are beneficial. Using the device of the present invention, time in this vertical orientation is optimized. Referring now to FIG. 2c, an alternative mechanism can be used to rotate a head 72 containing only cooling tubes 72. As shown in this figure, the head 72 may be attached to a frame 64 mounted to one of the carriers 18- by pin connection 76. Further, a piston-cylinder type of actuation unit 78 may be connected to the frame 64. The arm 80 of the actuation unit may be connected to a rear portion 82 of the head 72. As shown in FIG. 2c, the cooling tubes 74 are aligned with core pins 38 and are removing molded articles therefrom. To rotate the head 72 and move the cooling tubes 74 to a vertical orientation, the actuation unit 78 retracts arm 80 and assumes the substantially vertical position shown in dotted lines in the figure. Referring now to FIGS. 8a and 8b, a second embodiment of the cooling device of the present invention is illustrated. In this embodiment, blowing tubes 7 0 have been omitted. Instead, the cooling device 62' has additional cooling tubes 74 so that multi- position cooling can be effected in a manner similar to that illustrated in U.S. Reissue Patent No. 33,237, which is incorporated by reference herein. As shown in FIG. 8a, the device 62' is mounted in position III on the index machine turret carriage 18. The device 62' has a single side frame 84 mounted to one of the carriers 18 which contains a cam track profile 86. The profile 86 is followed by a cam follower 88 mounted to a movable carrier plate 90 on which are mounted multiple cooling tubes 74. In a preferred embodiment, the number of cooling tubes 7 4 on the carrier plate 90 is twice the number of core pins 38 on each face of the turret block 16. By providing this number of cooling tubes 74, the molded parts can be held within the cooling tubes 74 for successive molding cycles, thus extending the cooling times which can be achieved. An actuator 92 is mounted to the side frame 84 and has a journaled connection 94 with the carrier plate 90 such that when the actuator=s rod 96 is extended the carrier plate 90, following the cam track profile 86, is first translated to move the carrier plate 90 in a vertical direction and then moved from the vertical plane orientation shown in FIG. 8a to the horizontal plane orientation shown in FIG. 8b. During translation, a first set of cooling tubes 74 holding molded parts is moved out of alignment with the core pins 38 and a fresh set of cooling tubes 74 is presented to receive the next set of molded parts. When the carrier plate 90 is in the position shown in FIG. 8b, the parts 50 can be cooled in a vertical orientation and ejected when ready onto the conveyor 98 below. The actuator 92 may comprise any suitable actuator known in the art such as piston-cylinder unit. FIGS. 9a - 9c illustrate an alternative actuation system for moving the cooling device 62' of FIG. 8a so that the carrier plate 90 moves from a vertical orientation to a horizontal orientation. In this embodiment, the actuator 92 is centrally mounted on a bridge 100 connecting support frames 102 on both sides of the machine 10. The actuator 92, in this arrangement, only effects the vertical positioning of the carrier plate 90. To effect rotation of the carrier plate 90 from the vertical position to the horizontal position shown in FIG. 9c, a separate actuator 102, preferably in the form of a piston-cylinder unit, is provided. The actuator 102 moves vertically with the carrier plate and when it reaches the end of its vertical travel, the actuator arm 103 is moved to rotate the carrier plate 90 about the pivot point 105 so that the parts 50 in the cooling tubes 74 is vertically oriented. FIGS. 10a and 10b illustrate yet another embodiment of an actuation system for the cooling device 62'. In this arrangement, two cylinders 104 and 106 are used to translate and rotate the carrier plate. As shown in the figure, the carrier plate 72 containing the cooling tubes 7 4 is pivotally connected at pivot 108 to the frame 64 which is connected to a support structure on the machine 10. The actuator or cylinder 104 may be attached to carrier plate 72 in any suitable manner known in the art and is used to translate the carrier plate 72 with tubes 74 in a vertical direction. This translation may be carried out in any suitable manner known in the art. The actuator or cylinder 106 is connected to the carrier plate 72 and is used to rotate the carrier plate 72 about pivot point 108 so that tubes 74 assume a vertical orientation. As can be seen from the foregoing discussion, there has been provided in the embodiments of FIGS. 8 - 10, a lightweight, multi-position cooling carrier plate arrangement for attachment to an index carrier that removes parts horizontally from the mold and cools and ejects them in a vertical orientation, while extending cooling time with multiple tubes. WE CLAIM : 1. A cooling device for use with an index molding machine having a rotary turret block mounted within support means and at least one mold core on each of at least two faces of said rotary turret block, said cooling device comprising : frame means attached to said rotary turret block support means ; means for receiving and cooling at least one molded part, said receiving and cooling, means being mounted to a first surface of a carrier plate connected to said frame means ; and means for moving said carrier plate between a first orientation where said receiving and cooling means is aligned with said at least one molded part and a second orientation where said at least one molded part is being cooled within said receiving and cooling means. 2. The cooling device as claimed in claim 1, wherein said at least one molded part is vertically oriented while being cooled within said receiving and cooling means. 3. The cooling device as claimed in claim 1, wherein said receiving and cooling means comprises at least one cooling tube for receiving said at least one molded part and for cooling same by placing an external surface of said at least one molded part in contact with an interior surface of said at least one cooling tube. 4. The cooling device as claimed in claim 3, wherein each said cooling tube has vacuum means for facilitating removal of a respective molded part from at least one mold core pin and for holding said respective molded part within said cooling tube. 5. The cooling device as claimed in claim 1, wherein said carrier plate has two surfaces at right angles to each other; and means are provided for blowing cooling air onto exterior surfaces of said at least one molded part, said blowing means being mounted to a second one of said two surfaces. 6. The cooling device as claimed in claim 5, wherein said receiving and cooling means comprises at least one cooling tube mounted to said first surface, said at least one cooling tube being oriented substantially perpendicular to said blowing means; and said carrier plate is connected to a cross beam attached to said frame means and said moving means comprises means for rotating said cross beam through a rotation of 90°. 7. The cooling device as claimed in claim 1, wherein said carrier plate is rotatably connected to said frame means, and said moving means comprises an actuation unit mounted to said frame means and to a rear surface of said carrier plate for moving said carrier plate between said first and second orientations. 8. The cooling device as claimed in claim 1, wherein each of said faces has a number of mold cores for carrying molded parts from a molding position to a cooling position, and said receiving and cooling means comprises a number of cooling tubes for receiving and cooling said molded parts, the number of cooling tubes being at least twice the number of mold cores. 9. The cooling device as claimed in claim 1, wherein - said frame means contains a cam track profile, said carrier plate having a cam follower which engages with said cam track profile; and said moving means comprises an actuator unit attached to said carrier plate for causing said carrier plate to move along said cam track profile and move from said first orientation to said second orientation. 10. The cooling device as claimed in claim 1, wherein- said cooling and receiving means comprise a plurality of cooling tubes; and means are provided for extending the cooling of said at least one molded part, said extending means comprising first actuation means for translating said carrier plate while said carrier plate is in said first orientation between a first position where a first one of said cooling tubes is aligned with a first molded part on a first mold core on a first of said two faces in order to receive same for cooling and a second position where said first one of said cooling tubes is not aligned with any mold core and a second one of said cooling tubes is aligned with a mold core on a second one of said two faces for receiving a second molded part. 11. The cooling device as claimed in claim 10, wherein said moving means comprises a second actuation means for rotating said carrier plate between said first orientation and said second orientation, and said first and second actuation means are connected to said frame means. 12. The cooling device as claimed in claim 1, wherein said index molding machine comprises: a first platen carrying a first mold half having at least one mold cavity; a second platen in association with said first platen, said second platen comprising rotatable turret block means rotatable on a central axis of rotation for rotating at least two movable mold halves into alignment with said first mold half ; each of said movable mold halves having at least one mold core and being movable between a first molding position where it is aligned with said first mold half and a second cooling position where it is not aligned with said first mold half ; means for moving said rotatable turret block means to bring a first one of said movable mold halves into a mold closed position means for injecting plastic material into said at least one mold cavity while said first one of said movable mold halves is in said mold closed position and forming at least one molded part ; said moving means comprising means for moving said rotatable turret block means and said first one of said movable mold halves to a mold open position where said at least one molded part resides on said at least one mold core on said first one of said movable mold halves ; means for rotating said rotatable turret block means to cause said first one of said movable mold halves to rotate from said mold open position to said second cooling position and to cause a second one of said movable mold halves to move to said first molding position ; and means attached to said rotatable turret block means for cooling exterior surfaces of said at least one molded part on said at least one mold core while said first one of said movable mold halves is in said second cooling position. 13. The injection molding machine as claimed in claim 12, wherein said cooling means comprises : at least one cooling tube mounted to a first surface of a carrier plate attached to said molding machine ; and means for rotating said carrier plate between a first position where said at least one cooling tube is aligned with said at least one molded part on said first one of said movable mold halves and a second position wherein said at least one molded part is resident in said at least one cooling tube and is oriented vertically. 14. The injection molding machine as claimed in claim 13, wherein each said cooling tube cools a respective molded part by contact between exterior surfaces of said molded part and interior surfaces of said cooling tube and has vacuum means for holding said respective molded part within said cooling tube ; said movable mold half is provided with means for ejecting said at least one molded part into said at least one cooling tube ; said cooling device is provided with means for blowing a cooling fluid onto exterior surfaces of said at least one molded part ; and said blowing means are mounted to a second surface of said carrier plate, said second surface being substantially perpendicular to said first surface. 15. The injection molding machine as claimed in claim 14, wherein said carrier plate is mounted to a rotatable cross beam connected to said injection molding machine, and said rotating means comprises means for rotating said cross beam through a 90° angle of rotation ; and said cooling device comprises at least twice as many cooling tubes as molded parts. 16. The injection molding machine as claimed in claim 13, wherein said cooling device comprises : a frame having a cam track profile attached to said machine ; and a cam follower on said carrier plate for cooperating with said cam track profile ; and said rotating means comprises an actuation unit attached to said carrier plate for causing said carrier plate to move along said cam track profile. 17. The injection molding machine as claimed in claim 16, wherein said actuation unit translates said carrier plate between a first position where a first cooling tube receives a first molded part from said first one of said movable mold halves and a second position where a second cooling tube receives a second molded part from the second one of said movable mold halves while said first molded part is being cooled within said first cooling tube. 18. The injection molding machine as claimed in claim 13, wherein said cooling device comprises means for translating said carrier plate between a first position where a first cooling tube receives a first molded part from said first one of said movable mold halves and a second position where a second cooling tube receives a second molded part from the second one of said movable mold halves while said first molded part is being cooled within said first cooling tube. 19. The injection molding machine as claimed in claim 18, wherein said translating means comprises a first actuation unit connected to a support structure attached to said machine, and said rotating means comprises a second actuation unit attached to said support structure. 20. A process for forming cooled molded parts using the cooling device as claimed in claim 1, said process comprising the steps of: providing an index molding machine having a first platen carrying a first mold half having at least one mold cavity and a second platen comprising rotatable turret block means rotatable on a central axis of rotation for rotation for rotating at least two movable mold halves into alignment with said first mold half, each of said movable mold halves having at least one mold core; moving said rotatable turret block means to bring a first one of said movable mold halves into a mold closed position with said first mold half and clamping said first one of said movable mold halves and said first mold half; injecting molten material into said at least one mold cavity to form a first molded part set of at least one molded part; holding said first one of said movable mold halves in said mold closed and clamped position while cooling said first molded part set; moving said rotatable turret block means to a mold open position where said first moulded part set is positioned on said at least one mold core on said first one of said movable mold halves; rotating said turret block means to bring said first molded part set to a cooling position; providing a cooling device on a carrier plate adjacent said cooling position, said cooling device having at least one cooling tube for receiving said at least one molded part forming said first set ; ejecting each said molded part forming said first set into said at least one cooling tube ; rotating said at least one cooling tube to a position where each said molded part in said first set is in a desired orientation ; and cooling each said molded part in said first set while it is in said desired orientation. 21. The process as claimed in claim 20, comprising : moving said rotatable turret block means to bring a second one of said movable mold halves into said mold closed position and clamping said second one of said movable mold halves to said first mold half ; injecting molten material into said at least one mold cavity to form a second molded part set comprising at least one molded part while said first molded part set is being cooled ; holding said second one of said movable mold halves in said mold closed and clamped position while cooling said second molded part set ; moving said rotatable turret block means to a mold open position where said second molded part set is positioned on said at least one mold core on said second one of said movable mold halves ; rotating said turret block means to bring said second molded part set to said cooling position ; ejecting said second molded part set into said at least one cooling tube ; rotating said at least one cooling tube to a position where each molded part in said second set is in said desired orientation ; and cooling each said molded part in said second set while it is in said desired orientation. 22. The process as claimed in claim 21, wherein said cooling device is provided with means for blowing air onto exterior surfaces of said molded parts ; and prior to each said ejecting step, air is blown onto each respective set of molded parts while said molded parts are on said mold cores on a respective one of said movable mold halves and thereafter said carrier plate is rotated to bring said at least one cooling tube into alignment with said respective set of molded parts. 23. The process as claimed in claim 22, wherein said carrier plate rotating step comprises rotating said carrier plate 90°, and said step of rotating said at least one cooling tube to bring said molded parts being cooled into said desired orientation also causes said blowing means to be aligned with the next set of molded parts to be cooled. 24. The process as claimed in claim 21, comprising : translating said carrier plate after said first molded part set ejection step to bring a second set of cooling tubes into alignment with said second set of molded parts to be cooled. 25. The process as claimed in claim 21, wherein said desired orientation is a vertical orientation. 26. A cooling device for use with an index molding machine, substantially as herein described, particularly with reference to and as illustrated in the accompanying drawings. 27. A process for forming cooled molded parts, substantially as herein described, particularly with reference to and as illustrated in the accompanying drawings. A cooling device (62) for use with an index molding machine (10) comprises : frame means (64) attached to rotary turret block (16) support means (18) of the molding machine ; means (70, 74) for receiving and cooling at least one molded part (50), and mounted to a first surface of a carrier plate (72) connected to the frame means ; and means (68) for moving said carrier plate between a first orientation where the receiving and cooling means is aligned with at least one molded part (50) and a second orientation where at least one molded part is cooled within the receiving and cooling means.

Full Text

BACKGROUND OF THE INVENTION
The present invention relates to a cooling device for use with
an index molding machine, an injection molding machine and a
process for forming cooled molded parts, and in particular to a two
faced index molding machine, having improved part cooling and part
removal.
Index molding machines are known in the art. U.S. Patent No.
5,728,409, assigned to the assignee of the instant application, shows
a four faced turret block with a temperature conditioning station
mounted to the turret for directing cooling air onto newly molded
articles and a tubular part removal system using an air conveyor.
Currently, there is a need for a lower cost molding machine which
employs only a two faced turret block and correspondingly half the
number of core sets of tooling.
Co-pending allowed U.S. Patent Application Serial No. 08/847,
895 to Arnott et al., entitled Injection Molding Machine Having a High
Speed Turret, filed on April 28, 1997, also assigned to the assignee of
the instant application, shows an index molding machine with a two
faced turret block. This application however, does not discuss the
problems of part cooling and controlled part removal.
Co-pending U.S. Patent Application Serial No. 09/070, 598 to
Gait et al., filed on April 30, 1998, entitled Tiebar Structure for
Injection Molding Machine, also assigned to the assignee of the
instant application, shows a two tiebar index molding machine.
Here again, there is no discussion of part cooling or part
removal.
U.S. Patent No. 4,729,732 and U.S. Reissue Patent No.
33,237, both assigned to the assignee of the instant application,
show a multi-position tooling plate with water cooled tubes used
to remove and cool preforms from a conventional preform molding
machine. The tooling plate design shown in these patents has two
disadvantages. First, the robot mechanism occupies a substantial
floor area adjacent the machine. Second, the preforms are cooled
inside their tubes in a horizontal orientation. This has been
found to be detrimental in that the weight of the preform causes
it to press more firmly against the lower portion of the cooling
tube while its upper surface tends to separate from the upper
portion of the cooling tube. This unequal contact force with the
cooling surface tends to promote unequal cooling of the preform
from one side to the other. A vertical orientation during
cooling provides a symmetrical weight distribution with a
balanced heat removal result.
Conventional index molding machines eject parts at the
lowermost station, i.e., when the molded parts to be ejected are
under the turret block. There is a need to accommodate part
ejection/removal at a station opposite to the molding station to
permit two faced turret operation in a molding cycle where the
turret rotates 180° each time the mold opens instead of rotating 90°
at each mold opening.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide
a two faced turret molding machine having improved part cooling and
improved part removal.
It is a further object of the present invention to provide a
molding machine as above which is less expensive to produce.
It is yet a further object of the present invention to provide a
molding machine as above which allows cooling of the molded part in
a vertical orientation.
The foregoing objects are achieved by the molding machine,
the cooling device, and the process of the present invention.
Accordingly, the present invention provides a cooling device for
use with an index molding machine having a rotary turret block
mounted within support means and at least one mold core on each of
at least two faces of said rotary turret block, said cooling device
comprising frame means attached to said rotary turret block support
means, means for receiving and cooling at least one molded part,
said receiving and cooling means being mounted to a first surface of
a carrier plate connected to said frame means ; and means for moving
said carrier plate between a first orientation where said receiving and
cooling means is aligned with said at least one molded part and a
second orientation where said at least one molded part is being
cooled within said receiving and cooling means.
The invention also provides an injection molding machine
comprising : a first platen carrying a first mold half having at least one
mold cavity ; a second platen in association with said first platen, said
second platen comprising rotatable

turret block means rotatable on a central axis of rotation for rotating
at least two movable mold halves into alignment with said first mold
half ; each of said movable mold halves having at least one mold
core and being movable between a first molding position where it is
aligned with said first mold half and a second cooling position where it
is not aligned with said first mold half ; means for moving said
rotatable turret block means to bring a first one of said movable mold
halves into a mold closed position ; means for injecting plastic
material into said at least one mold cavity while said first one of said
movable mold halves is in said mold closed position and forming at
least one molded part ; said moving means comprising means for
moving said rotatable turret block means and said first one of said
movable mold halves to a mold open position where said at least one
molded part resides on said at least one mold core on said first one
of said movable mold halves ; means for rotating said rotatable turret
block means to cause said first one of said movable mold halves to
rotate from said mold open position to said second cooling position
and to cause a second one of said movable mold halves to move to
said first molding position ; and means attached to said rotatable
turret block means for cooling exterior surfaces of said at least one
molded part on said at least one mold core while said first one of said
movable mold halves is in said second cooling position.
The invention also provides a process for forming cooled
molded parts comprising the steps of : providing an index molding
machine having a first platen carrying a first mold half having at least
one mold cavity and a second platen comprising rotatable turret
block means rotatable on a central axis of rotation for rotating at least
two movable mold halves into alignment with said first mold half,
each of said movable mold halves having at least one mold core ;
moving said rotatable turret block means to bring a first one of said
movable mold halves into a mold closed position with said first mold
half and clamping said first one of said movable mold halves and said
first mold half ; injecting molten material into said at least one mold
cavity to form a first molded part set of at least one molded part ;
holding said first one of said movable mold halves in said mold closed
and clamped position while cooling said first molded part set ; moving
said rotatable turret block means to a mold open position where said
first molded part set is positioned on said at least one mold core on
said first one of said movable mold halves ; rotating said turret block
means to bring said first molded part set to a cooling position ;
providing a cooling device on a carrier plate adjacent said cooling
position, said cooling device having at least one cooling tube for
receiving said at least one molded part forming said first set ; ejecting
each said molded part forming said first set into said at least one
cooling tube ; rotating said at least one cooling tube to a position
where each said molded part in said first set is in a desired
orientation ; and cooling each said molded part in said first set while
it is in said desired orientation.
The desired orientation is preferably a vertical orientation. The
process may further comprises forming a second set of molded part
(s) on mold core(s) on a second one of the movable mold halves while
the molded part(s) in the first set is being cooled and thereafter
rotating the rotatable turret block so that said second set of molded
part(s) is in said cooling position and subjecting the second set of
molded part(s) to cooling.
Other details of the molding machine, cooling device, and the
process of the present invention, as well as other objects and
advantages attendant thereto, are set forth in the following detailed
description and the accompanying drawings wherein like reference
numerals depict like elements.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
FIG. 1a is a side view of a two tiebar index molding machine ;
FIG. 1b is an end view of the molding machine of FIG. 1A ;
FIG. 2a is a side view of a first embodiment of a cooling device
in accordance with the present invention ;
FIG. 2b is a side view of the cooling device of FIG. 2a
showing the cooling tubes in a part removing position;
FIG. 2c illustrates an alternative actuation system for
moving the cooling device of FIG. 2a between positions;
FIG. 3 is a partial sectional view of the molding machine of
FIG. la;
FIG. 4 is a partial sectional view of the molding machine of
FIG. 1a;
FIG. 5 is a partial sectional view of the molding machine of
FIG. la in a part transferring mode;
FIG. 6 is a partial sectional view of the molding machine of
FIG. la with the cooling device ejecting cooled molded parts;
FIG. 7 is a chart showing the sequence of operation of the
molding machine of FIG. la;
FIGS. 8a and 8b illustrate an alternative embodiment of a
cooling device having multi-position cooling tubes for use with
an index molding machine;
FIGS. 9a - 9c illustrate an alternative actuation system for
the cooling device of FIGS. 8a and 8b; and
FIGS. 10a and 10b illustrate another alternative actuation
system for the cooling device of FIGS. 8a and 8b.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)
Referring now to the drawings, FIGS. 1a and 1b illustrate a
two tiebar index molding machine 10 of the type shown in co-
pending U.S. patent application no. 09/070,598, to Galt et al.,
entitled Tiebar Structure for Injection Molding Machine, filed
April 30, 1998, which is incorporated by reference herein. The
index molding machine 10 includes a base 12, a fixed platen 14,
and a movable platen 16 which is movable with respect to the
fixed platen 14. The movable platen 16 is a two-faced rotary
turret block, which is positioned within the movable platen, with
pinions in bearings mounted in carriers 18 that slide on the base
12. The turret block 16 is rotated or indexed on a central axis
20 so that the faces thereof represent two positions in an
injection molding cycle. Thus, the rotatable turret block 16 is
rotatable on a central axis of rotation 20 for rotating a
plurality of movable mold halves 36 attached thereto into
alignment with a first mold half 32 carried by the fixed platen
14. Each movable mold half 36 includes at least one mold core 38
and is matable with the first mold half 32 for forming a mold for
forming at least one molded article, with the mold halves being
clamped together as will be described hereinafter.
The first mold half 32 may be joined to the fixed platen 14
in any suitable manner known in the art and may contain one or
more mold cavities 34 which together with the mold core(s) 38
form one or more mold cavity spaces 40. Parts 50, such as
preforms, are molded by injecting plastic material through the
mold half 32 from an injection unit (not shown) into the cavity
space(s) 40 formed by the closed mold.
Two tiebars 24 are provided and bolted to the carriers 18,
each of which includes an inside stroke cylinder 22, the rod 23
of which is fixed to housing 25 which in turn is bolted to fixed
platen 14. Each tiebar 24 includes external teeth 26 of a
rotating clamp piston 30 with the clamp piston contained in fixed
platen 14. The clamp piston 30 includes a row of teeth 28 and an
adjacent row free from teeth so that on rotation of the clamp
piston, the clamp piston teeth 28 alternately engage and
disengage the tiebar teeth 26. Clamp piston 30 may be rotated by
any desired and convenient means (not shown), such as a cylinder
means acting on a pin via a slot in housing 25, such as a
cylinder bolted to the fixed platen 14 with linkage means
connecting the pins together and causing rotation of the pistons
30.
In operation, a pin (not shown) rotates clamp piston 30 so
that clamp piston teeth 28 are disengaged from teeth 2 6 on
tiebars 24. High pressure oil is then supplied to the piston end
42 of stroke cylinder 22 via a line (not shown) causing stroke
cylinder rod 23 to extend and move carriers 18 and turret block
16 away from the fixed platen 14, thereby opening the mold. In
order to close the mold, oil is supplied to the rod side 44 of
stroke cylinder 22 via a line (not shown), thereby retracting
stroke cylinder rod 23 and closing the clamp until the mold is
closed. The aforementioned pin (not shown) is then activated by
a cylinder (not shown) and linkage means (not shown) to engage
clamp piston teeth 28 with tiebar teeth 26.. High pressure oil is
then provided to the clamp piston cylinder 4 6 causing the clamp
pistons to clamp the mold. After molding, high pressure oil is
provided to the mold break cylinder 48 causing clamp piston 30 to
act on the back side of tiebar teeth 26 and urge the mold open.
After a short stroke, clamp piston 30 is de-energized and the pin
actuated by the aforementioned cylinder and linkage means causes
the clamp piston to rotate to disengage clamp piston teeth 28
from tiebar teeth 2 6 so that stroke cylinder 22 can open the
mold.
As shown in FIG. la, the turret block 16 has two faces, each
with a mold core plate 36 mounted to it. Each mold core plate 36
may be mounted to a respective face of the turret block 16 using
any suitable conventional means known in the art. In a preferred
embodiment, each mold core plate 36 has a plurality of core pins
38, equal in number to the number of mold cavities 34 in the
first mold half 32. As can be seen in FIG. la, a first set A of
core pins 38 is aligned with the mold cavities 34 in a molding
position, while a second set B of core pins 38 are in a cooling
position located 180 degrees from the molding position.
After plastic material has been injected into the mold
cavity spaces 40 and the molded parts 50 have been formed, the
parts 50 are partially cooled in a customary manner by cooling
circuits (not shown), such as water cooling circuits, in the mold
cavity plate 32 and in the core pins 38. After partial cooling
has occurred and the parts 50 have been sufficiently solidified
to avoid part deformation, the mold is opened in the manner
previously discussed and the molded parts 50 on the first set A
of core pins 38 are withdrawn from the mold cavities 34. The
turret block 16 is then rotated 180 degrees to present the second
set B of core pins 38 for molding while the first set A of core
pins 38, complete with the molded parts 50 thereon, are presented
at the opposite side of the turret block for further cooling.
1 In accordance with a first embodiment of the present
invention, a device 62 is provided to cool the molded parts and
remove them from the core pins 38 when the molded parts are in
the cooling position. The device 62 includes a frame 64 attached
to the carrier 18 or its support. A cross beam 66 is attached to
the frame 64 so as to be capable of rotation through a 90 degree
angle. The end of the cross beam 66 remote from the frame 64 is
connected to a drive means 68 for rotating the cross beam 66
through said 90 degree rotation. The drive means 68 may comprise
any suitable drive means known in the art.
A set of blowing tubes 7 0 is mounted to a first surface of a
head or carrier plate 72 attached to the cross beam 66. The
blowing tubes 70 are used to direct a cooling fluid, typically
air, toward an end of the molded parts 50, while the parts 50 are
on the core pins 38. This blowing position is shown in FIG. 2b.
Cooling fluid may be supplied to the blowing tubes 70 in
suitable manner known in the art.
A set of cooling tubes 74 is mounted to a second surface of
the head 72. As can be seen from FIG. la, the cooling tubes 74
are offset 90 degrees from the blowing tubes 70. The set of
cooling tubes 74 are used to facilitate removal of the molded
parts 50 from the core pins 38. The cooing tubes 74 assist the
removal of the molded parts 50 through the application of a
vacuum inside the tubes 7 4 in a known fashion. For example, a
port (not shown) in the bottom of each tube 74 may be connected
to a vacuum source (not shown). The tubes 74 may be cooled by a
fluid, such as chilled water, and remove heat from the parts 50
positioned therein either by convection or conduction. For
example, cooling may be achieved by intimate contact between
exterior surface of the part and the inside surface of the tube
as taught by U.S. Patent No. 4,729,732, which is incorporated by
reference herein.
FIG. 3-6 illustrate the sequence of operation of a molding
machine in accordance with the present invention. FIG. 3 shows
the clamp closed and the parts 50 being molded on the first core
set A. FIG. 4 shows the clamp closed for molding on the second
core set B while cooling air is being directed from tubes 70 onto
the ends of the molded parts 50 on the first core set A. FIG. 5
shows the cross beam 66 rotated 90 degrees to align the cooling
tubes 74 with the parts 50 on the first core set A as the parts
are ejected into the tubes 74. Ejection of the molded parts 50
from the core pins 38 into tubes 74 is carried out by the
provision of ejection means, such as ejection pins/sleeves or an
ejection plate, on each mold face 36. FIG. 6 shows cross beam 66
rotated 90 degrees in the reverse direction to once again align
the blowing tubes 70 with the next set of molded parts while the
previous set of parts are ejected from cooling tubes 74.
Ejection of the cooled parts 50 from the cooling tubes 74 may be
effected by discontinuing the vacuum and allowing gravity to
cause the parts to drop out of the tubes 74 or by blowing the
parts 50 out of the tubes 74 or by mechanical ejection means such
as those shown in U.S. Patent No. 5,447,426, which is
incorporated by reference herein.
FIG. 7 shows the sequence of operation for making the molded
parts 50. The top half of the chart shows the molding process
and indicates two identical sequences spaced in time, the first
for the first core set A, and the second for the second core set
B. Each of the sequences starts with the mold closed, as shown
in FIG. 1a. The injection molding sequence of clamp, inject,
hold/cool, and open then follows. During the mold opening
stroke, the index turret block 16 simultaneously begins to rotate
180 degrees to align the second core set for molding while the
first core set, with the molded parts 50 on the core pins 38, is
aligned to the cooling and removal device 62. The rotation is
completed during the closing stroke of the turret block 16.
The bottom half of the chart shows the cooling process and
indicates a sequence that overlaps the two molding processes
shown in the top half of the chart. The ejection and cooling
sequence begins as the first core set A with molded parts 50
thereon is aligned to the cooling and removal device 62. Cooling
fluid, typically compressed air, is blown from tubes 70 directly
onto the ends of the molded parts 50, as they remain cooling on
the core pins 38. Thus, during this portion of the sequence,
parts 50 are cooled both internally and externally. Then the
head 72 is rotated 90 degrees to align the cooling tubes 74 with
the molded parts 50 on the core pins 38. Next the ejection
system of the mold in combination with the vacuum circuit in the
cooling tubes 74 transfers the parts from the core pins 38 to the
tubes 74 wherein the parts are immediately cooled on their outer
surfaces by their contact with the water cooled tubes, in a known
fashion. The device 62 is immediately rotated again so that the
tubes 74 point downward and the molded parts 50 continue cooling
in a vertical orientation to ensure symmetrical cooling and
gravitational effects maintaining a distortion-free part. The
molded parts 50 are held in the tubes 74 by the applied vacuum
and continue to cool until just before it is time to rotate the
device 62 back to receive the next set of molded parts from the
second core set B. Thus, the cooling time for the complete
process optimizes the time the molded parts 50 are cooled, first
while in the mold and on the cores and secondly while in the
cooling tubes 74. Additional cooling is provided by the air
blowing from tubes 70 onto the parts 50 during the shaded portion
shown on the chart.
By maximizing the cooling time of the molded parts 50 as
described hereinabove, it has been found that only two core sets
are required for an optimum molding cycle. Thus the tooling cost
for equipping a four faced turret block can be significantly
reduced by using only a two faced turret block. The cost of the
core sets is halved.
As can be seen from the foregoing discussion, there has been
provided in accordance with the present invention a lightweight
cooling and part removal device mounted on the moving index
carrier that first cools the outside of the part 50 by blowing
air and subsequently continues to cool the part 50 inside a
cooled tube 74 that also removes the part 50 from the mold.
Still further, cooling of the part 50 is performed in a vertical
orientation inside a cooled tube 74. As a result, the part 50
has improved properties which are beneficial. Using the device
of the present invention, time in this vertical orientation is
optimized.
Referring now to FIG. 2c, an alternative mechanism can be
used to rotate a head 72 containing only cooling tubes 72. As
shown in this figure, the head 72 may be attached to a frame 64
mounted to one of the carriers 18- by pin connection 76. Further,
a piston-cylinder type of actuation unit 78 may be connected to
the frame 64. The arm 80 of the actuation unit may be connected
to a rear portion 82 of the head 72. As shown in FIG. 2c, the
cooling tubes 74 are aligned with core pins 38 and are removing
molded articles therefrom. To rotate the head 72 and move the
cooling tubes 74 to a vertical orientation, the actuation unit 78
retracts arm 80 and assumes the substantially vertical position
shown in dotted lines in the figure.
Referring now to FIGS. 8a and 8b, a second embodiment of the
cooling device of the present invention is illustrated. In this
embodiment, blowing tubes 7 0 have been omitted. Instead, the
cooling device 62' has additional cooling tubes 74 so that multi-
position cooling can be effected in a manner similar to that
illustrated in U.S. Reissue Patent No. 33,237, which is
incorporated by reference herein.
As shown in FIG. 8a, the device 62' is mounted in position
III on the index machine turret carriage 18. The device 62' has
a single side frame 84 mounted to one of the carriers 18 which
contains a cam track profile 86. The profile 86 is followed by a
cam follower 88 mounted to a movable carrier plate 90 on which
are mounted multiple cooling tubes 74. In a preferred
embodiment, the number of cooling tubes 7 4 on the carrier plate
90 is twice the number of core pins 38 on each face of the turret
block 16. By providing this number of cooling tubes 74, the
molded parts can be held within the cooling tubes 74 for
successive molding cycles, thus extending the cooling times which
can be achieved.
An actuator 92 is mounted to the side frame 84 and has a
journaled connection 94 with the carrier plate 90 such that when
the actuator=s rod 96 is extended the carrier plate 90, following
the cam track profile 86, is first translated to move the carrier
plate 90 in a vertical direction and then moved from the vertical
plane orientation shown in FIG. 8a to the horizontal plane
orientation shown in FIG. 8b. During translation, a first set of
cooling tubes 74 holding molded parts is moved out of alignment
with the core pins 38 and a fresh set of cooling tubes 74 is
presented to receive the next set of molded parts. When the
carrier plate 90 is in the position shown in FIG. 8b, the parts
50 can be cooled in a vertical orientation and ejected when ready
onto the conveyor 98 below. The actuator 92 may comprise any
suitable actuator known in the art such as piston-cylinder unit. FIGS. 9a - 9c illustrate an alternative actuation system for
moving the cooling device 62' of FIG. 8a so that the carrier
plate 90 moves from a vertical orientation to a horizontal
orientation. In this embodiment, the actuator 92 is centrally
mounted on a bridge 100 connecting support frames 102 on both
sides of the machine 10. The actuator 92, in this arrangement,
only effects the vertical positioning of the carrier plate 90.
To effect rotation of the carrier plate 90 from the vertical
position to the horizontal position shown in FIG. 9c, a separate
actuator 102, preferably in the form of a piston-cylinder unit,
is provided. The actuator 102 moves vertically with the carrier
plate and when it reaches the end of its vertical travel, the
actuator arm 103 is moved to rotate the carrier plate 90 about
the pivot point 105 so that the parts 50 in the cooling tubes 74
is vertically oriented.
FIGS. 10a and 10b illustrate yet another embodiment of an
actuation system for the cooling device 62'. In this
arrangement, two cylinders 104 and 106 are used to translate and
rotate the carrier plate. As shown in the figure, the carrier
plate 72 containing the cooling tubes 7 4 is pivotally connected
at pivot 108 to the frame 64 which is connected to a support
structure on the machine 10. The actuator or cylinder 104 may be
attached to carrier plate 72 in any suitable manner known in the
art and is used to translate the carrier plate 72 with tubes 74
in a vertical direction. This translation may be carried out in
any suitable manner known in the art. The actuator or cylinder
106 is connected to the carrier plate 72 and is used to rotate
the carrier plate 72 about pivot point 108 so that tubes 74
assume a vertical orientation.
As can be seen from the foregoing discussion, there has been
provided in the embodiments of FIGS. 8 - 10, a lightweight,
multi-position cooling carrier plate arrangement for attachment
to an index carrier that removes parts horizontally from the mold
and cools and ejects them in a vertical orientation, while
extending cooling time with multiple tubes.
WE CLAIM :
1. A cooling device for use with an index molding machine
having a rotary turret block mounted within support means and at
least one mold core on each of at least two faces of said rotary
turret block, said cooling device comprising :
frame means attached to said rotary turret block support
means ;
means for receiving and cooling at least one molded part,
said receiving and cooling, means being mounted to a first
surface of a carrier plate connected to said frame means ; and
means for moving said carrier plate between a first
orientation where said receiving and cooling means is aligned with
said at least one molded part and a second orientation where said
at least one molded part is being cooled within said receiving and
cooling means.
2. The cooling device as claimed in claim 1, wherein said at
least one molded part is vertically oriented while being cooled
within said receiving and cooling means.
3. The cooling device as claimed in claim 1, wherein said
receiving and cooling means comprises at least one cooling tube
for receiving said at least one molded part and for cooling same
by placing an external surface of said at least one molded part in
contact with an interior surface of said at least one cooling tube.
4. The cooling device as claimed in claim 3, wherein each said
cooling tube has vacuum means for facilitating removal of a
respective molded part from at least one mold core pin and for
holding said respective molded part within said cooling tube.

5. The cooling device as claimed in claim 1, wherein said carrier plate has two
surfaces at right angles to each other; and means are provided for blowing cooling air onto
exterior surfaces of said at least one molded part, said blowing means being mounted to a
second one of said two surfaces.
6. The cooling device as claimed in claim 5, wherein said receiving and cooling
means comprises at least one cooling tube mounted to said first surface, said at least one
cooling tube being oriented substantially perpendicular to said blowing means; and said
carrier plate is connected to a cross beam attached to said frame means and said moving
means comprises means for rotating said cross beam through a rotation of 90°.
7. The cooling device as claimed in claim 1, wherein said carrier plate is rotatably
connected to said frame means, and said moving means comprises an actuation unit
mounted to said frame means and to a rear surface of said carrier plate for moving said
carrier plate between said first and second orientations.
8. The cooling device as claimed in claim 1, wherein each of said faces has a
number of mold cores for carrying molded parts from a molding position to a cooling
position, and said receiving and cooling means comprises a number of cooling tubes for
receiving and cooling said molded parts, the number of cooling tubes being at least twice
the number of mold cores.
9. The cooling device as claimed in claim 1, wherein -
said frame means contains a cam track profile, said carrier
plate having a cam follower which engages with said cam track profile; and
said moving means comprises an actuator unit attached to said carrier plate for
causing said carrier plate to move along said cam track profile and move from said first
orientation to said second orientation.
10. The cooling device as claimed in claim 1, wherein-
said cooling and receiving means comprise a plurality of cooling tubes; and
means are provided for extending the cooling of said at least one molded part, said
extending means comprising first actuation means for translating said carrier plate while
said carrier plate is in said first orientation between a first position where a first one of said
cooling tubes is aligned with a first molded part on a first mold core on a first of said two
faces in order to receive same for cooling and a second position where said first one of
said cooling tubes is not aligned with any mold core and a second one of said cooling
tubes is aligned with a mold core on a second one of said two faces for receiving a
second molded part.
11. The cooling device as claimed in claim 10, wherein said moving means comprises
a second actuation means for rotating said carrier plate between said first orientation and
said second orientation, and said first and second actuation means are connected to said
frame means.
12. The cooling device as claimed in claim 1, wherein said index molding machine
comprises:
a first platen carrying a first mold half having at least one mold cavity;

a second platen in association with said first platen, said
second platen comprising rotatable turret block means rotatable
on a central axis of rotation for rotating at least two movable mold
halves into alignment with said first mold half ;
each of said movable mold halves having at least one mold
core and being movable between a first molding position where it
is aligned with said first mold half and a second cooling position
where it is not aligned with said first mold half ;
means for moving said rotatable turret block means to bring
a first one of said movable mold halves into a mold closed position
means for injecting plastic material into said at least one
mold cavity while said first one of said movable mold halves is in
said mold closed position and forming at least one molded part ;
said moving means comprising means for moving said
rotatable turret block means and said first one of said movable
mold halves to a mold open position where said at least one
molded part resides on said at least one mold core on said first
one of said movable mold halves ;
means for rotating said rotatable turret block means to
cause said first one of said movable mold halves to rotate from
said mold open position to said second cooling position and to
cause a second one of said movable mold halves to move to said
first molding position ; and
means attached to said rotatable turret block means for
cooling exterior surfaces of said at least one molded part on said
at least one mold core while said first one of said movable mold
halves is in said second cooling position.
13. The injection molding machine as claimed in claim 12,
wherein said cooling means comprises :
at least one cooling tube mounted to a first surface of a
carrier plate attached to said molding machine ; and
means for rotating said carrier plate between a first position
where said at least one cooling tube is aligned with said at least
one molded part on said first one of said movable mold halves and
a second position wherein said at least one molded part is
resident in said at least one cooling tube and is oriented
vertically.
14. The injection molding machine as claimed in claim 13,
wherein each said cooling tube cools a respective molded part
by contact between exterior surfaces of said molded part and
interior surfaces of said cooling tube and has vacuum means for
holding said respective molded part within said cooling tube ;
said movable mold half is provided with means for
ejecting said at least one molded part into said at least one
cooling tube ;
said cooling device is provided with means for blowing
a cooling fluid onto exterior surfaces of said at least one molded
part ; and
said blowing means are mounted to a second surface
of said carrier plate, said second surface being substantially
perpendicular to said first surface.
15. The injection molding machine as claimed in claim 14,
wherein said carrier plate is mounted to a rotatable cross beam
connected to said injection molding machine, and said rotating
means comprises means for rotating said cross beam through a
90° angle of rotation ; and said cooling device comprises at least
twice as many cooling tubes as molded parts.
16. The injection molding machine as claimed in claim 13,
wherein said cooling device comprises : a frame having a cam
track profile attached to said machine ; and a cam follower on said
carrier plate for cooperating with said cam track profile ; and said
rotating means comprises an actuation unit attached to said
carrier plate for causing said carrier plate to move along said cam
track profile.
17. The injection molding machine as claimed in claim 16,
wherein said actuation unit translates said carrier plate between a
first position where a first cooling tube receives a first molded part
from said first one of said movable mold halves and a second
position where a second cooling tube receives a second molded
part from the second one of said movable mold halves while said
first molded part is being cooled within said first cooling tube.
18. The injection molding machine as claimed in claim 13,
wherein said cooling device comprises means for translating said
carrier plate between a first position where a first cooling tube
receives a first molded part from said first one of said movable
mold halves and a second position where a second cooling tube
receives a second molded part from the second one of said
movable mold halves while said first molded part is being cooled
within said first cooling tube.
19. The injection molding machine as claimed in claim 18, wherein said
translating means comprises a first actuation unit connected to a support structure
attached to said machine, and said rotating means comprises a second actuation
unit attached to said support structure.
20. A process for forming cooled molded parts using the cooling device as
claimed in claim 1, said process comprising the steps of:
providing an index molding machine having a first platen carrying a first
mold half having at least one mold cavity and a second platen comprising rotatable
turret block means rotatable on a central axis of rotation for rotation for rotating at
least two movable mold halves into alignment with said first mold half, each of said
movable mold halves having at least one mold core;
moving said rotatable turret block means to bring a first one of said movable
mold halves into a mold closed position with said first mold half and clamping said
first one of said movable mold halves and said first mold half;
injecting molten material into said at least one mold cavity to form a first
molded part set of at least one molded part;
holding said first one of said movable mold halves in said mold closed and
clamped position while cooling said first molded part set;
moving said rotatable turret block means to a mold open position where said
first moulded part set is positioned on said at least one mold core on said first one
of said movable mold halves;
rotating said turret block means to bring said first molded part set to a
cooling position;
providing a cooling device on a carrier plate adjacent said
cooling position, said cooling device having at least one cooling
tube for receiving said at least one molded part forming said first
set ;
ejecting each said molded part forming said first set into said
at least one cooling tube ;
rotating said at least one cooling tube to a position where
each said molded part in said first set is in a desired orientation ;
and
cooling each said molded part in said first set while it is in
said desired orientation.
21. The process as claimed in claim 20, comprising :
moving said rotatable turret block means to bring a second
one of said movable mold halves into said mold closed position
and clamping said second one of said movable mold halves to said
first mold half ;
injecting molten material into said at least one mold cavity to
form a second molded part set comprising at least one molded part
while said first molded part set is being cooled ;
holding said second one of said movable mold halves in said
mold closed and clamped position while cooling said second
molded part set ;
moving said rotatable turret block means to a mold open
position where said second molded part set is positioned on said
at least one mold core on said second one of said movable mold
halves ;
rotating said turret block means to bring said second molded
part set to said cooling position ;
ejecting said second molded part set into said at least one
cooling tube ;
rotating said at least one cooling tube to a position where
each molded part in said second set is in said desired orientation ;
and
cooling each said molded part in said second set while it is
in said desired orientation.
22. The process as claimed in claim 21, wherein
said cooling device is provided with means for blowing air
onto exterior surfaces of said molded parts ; and
prior to each said ejecting step, air is blown onto each
respective set of molded parts while said molded parts are on said
mold cores on a respective one of said movable mold halves and
thereafter said carrier plate is rotated to bring said at least one
cooling tube into alignment with said respective set of molded
parts.
23. The process as claimed in claim 22, wherein said carrier
plate rotating step comprises rotating said carrier plate 90°, and
said step of rotating said at least one cooling tube to bring said
molded parts being cooled into said desired orientation also
causes said blowing means to be aligned with the next set of
molded parts to be cooled.
24. The process as claimed in claim 21, comprising :
translating said carrier plate after said first molded part set
ejection step to bring a second set of cooling tubes into alignment
with said second set of molded parts to be cooled.
25. The process as claimed in claim 21, wherein said desired orientation is a
vertical orientation.
26. A cooling device for use with an index molding machine, substantially as
herein described, particularly with reference to and as illustrated in the
accompanying drawings.
27. A process for forming cooled molded parts, substantially as herein
described, particularly with reference to and as illustrated in the accompanying
drawings.

A cooling device (62) for use with an index molding machine (10)
comprises :
frame means (64) attached to rotary turret block (16) support means
(18) of the molding machine ;
means (70, 74) for receiving and cooling at least one molded part (50),
and mounted to a first surface of a carrier plate (72) connected to the frame
means ; and
means (68) for moving said carrier plate between a first orientation
where the receiving and cooling means is aligned with at least one molded
part (50) and a second orientation where at least one molded part is cooled
within the receiving and cooling means.

Documents:

826-cal-1999-abstract.pdf

826-cal-1999-assignment.pdf

826-cal-1999-claims.pdf

826-cal-1999-correspondence.pdf

826-cal-1999-description (complete).pdf

826-cal-1999-drawings.pdf

826-cal-1999-examination report.pdf

826-cal-1999-form 1.pdf

826-cal-1999-form 18.pdf

826-cal-1999-form 2.pdf

826-cal-1999-form 3.pdf

826-cal-1999-form 5.pdf

826-cal-1999-gpa.pdf

826-cal-1999-granted-abstract.pdf

826-cal-1999-granted-assignment.pdf

826-cal-1999-granted-claims.pdf

826-cal-1999-granted-correspondence.pdf

826-cal-1999-granted-description (complete).pdf

826-cal-1999-granted-drawings.pdf

826-cal-1999-granted-examination report.pdf

826-cal-1999-granted-form 1.pdf

826-cal-1999-granted-form 18.pdf

826-cal-1999-granted-form 2.pdf

826-cal-1999-granted-form 3.pdf

826-cal-1999-granted-form 5.pdf

826-cal-1999-granted-gpa.pdf

826-cal-1999-granted-reply to examination report.pdf

826-cal-1999-granted-specification.pdf

826-cal-1999-granted-translated copy of priority document.pdf

826-cal-1999-reply to examination report.pdf

826-cal-1999-specification.pdf

826-cal-1999-translated copy of priority document.pdf

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Patent Number

242749

Indian Patent Application Number

826/CAL/1999

PG Journal Number

37/2010

Publication Date

10-Sep-2010

Grant Date

09-Sep-2010

Date of Filing

06-Oct-1999

Name of Patentee

HUSKY INJECTION MOLDING SYSTEMS LTD

Applicant Address

500, QUEEN STREET SOUTH, BOLTON, ONTARIO, CANADA L7E 5S5

Inventors:

#	Inventor's Name	Inventor's Address
1	ILMONEN ROBERT TAYLOR	40, FOUNTAIN HEAD ROAD, NORTH YORK ONTRIO, CANADA M3J 2V1
2	ING RONALD	909, ROYAL YORK ROAD, ETOBICOKE, ONTARIO, CANADA M8Y 2V8
3	GALT JOHN	GENERAL DELIVERY, 68, MACTAGGART DR., NOBLETON, ONTARIO, CANADA L0G 1N0
4	BOURQUE JACQUES P.	79, GRAY AVENUE, ALLISTON, ONTARIO, CANADA L9R 1P5
5	JACOVICH WILLIAM J.	793, HOLLANDER ROAD, NEWMARKET, ONTARIO CANADA L3Y 8H4

PCT International Classification Number

B29C 45/73

PCT International Application Number

N/A

PCT International Filing date

PCT Conventions:

#	PCT Application Number	Date of Convention	Priority Country
1	09/167,699	1998-10-07	U.S.A.