CA2219235C - Five layer injection molding apparatus having four position valve member actuating mechanism - Google Patents
Five layer injection molding apparatus having four position valve member actuating mechanism Download PDFInfo
- Publication number
- CA2219235C CA2219235C CA002219235A CA2219235A CA2219235C CA 2219235 C CA2219235 C CA 2219235C CA 002219235 A CA002219235 A CA 002219235A CA 2219235 A CA2219235 A CA 2219235A CA 2219235 C CA2219235 C CA 2219235C
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- Canada
- Prior art keywords
- melt
- valve member
- channel
- source
- distribution manifold
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- 238000001746 injection moulding Methods 0.000 title claims abstract description 39
- 230000007246 mechanism Effects 0.000 title claims abstract description 27
- 239000000463 material Substances 0.000 claims abstract description 37
- 238000000465 moulding Methods 0.000 claims abstract description 10
- 239000012530 fluid Substances 0.000 claims description 58
- 239000000155 melt Substances 0.000 claims description 41
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 24
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 24
- 238000002347 injection Methods 0.000 claims description 17
- 239000007924 injection Substances 0.000 claims description 17
- 229920000219 Ethylene vinyl alcohol Polymers 0.000 claims description 10
- 238000000034 method Methods 0.000 claims description 10
- 239000004677 Nylon Substances 0.000 claims description 7
- 229920001778 nylon Polymers 0.000 claims description 7
- 239000004715 ethylene vinyl alcohol Substances 0.000 claims description 6
- -1 polyethylene terephthalate Polymers 0.000 claims description 6
- 239000012768 molten material Substances 0.000 claims 11
- 238000004519 manufacturing process Methods 0.000 claims 4
- 230000004888 barrier function Effects 0.000 abstract description 12
- 238000010438 heat treatment Methods 0.000 description 6
- 125000006850 spacer group Chemical group 0.000 description 5
- 229910000831 Steel Inorganic materials 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 238000001816 cooling Methods 0.000 description 3
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 2
- 239000005977 Ethylene Substances 0.000 description 2
- 235000013361 beverage Nutrition 0.000 description 2
- 238000000926 separation method Methods 0.000 description 2
- 239000000161 steel melt Substances 0.000 description 2
- 229920006163 vinyl copolymer Polymers 0.000 description 2
- 241000349731 Afzelia bipindensis Species 0.000 description 1
- 206010026749 Mania Diseases 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000000498 cooling water Substances 0.000 description 1
- KVFIJIWMDBAGDP-UHFFFAOYSA-N ethylpyrazine Chemical compound CCC1=CN=CC=N1 KVFIJIWMDBAGDP-UHFFFAOYSA-N 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- MYWUZJCMWCOHBA-VIFPVBQESA-N methamphetamine Chemical compound CN[C@@H](C)CC1=CC=CC=C1 MYWUZJCMWCOHBA-VIFPVBQESA-N 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1603—Multi-way nozzles specially adapted therefor
- B29C45/1607—Multi-way nozzles specially adapted therefor having at least three different ways
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1603—Multi-way nozzles specially adapted therefor
- B29C2045/1612—Multi-way nozzles specially adapted therefor using needle valves with at least four positions
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/16—Making multilayered or multicoloured articles
- B29C45/1642—Making multilayered or multicoloured articles having a "sandwich" structure
- B29C45/1646—Injecting parison-like articles
- B29C2045/1648—Injecting parison-like articles the parison core layer being a barrier material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
- B29C45/27—Sprue channels ; Runner channels or runner nozzles
- B29C45/2725—Manifolds
- B29C2045/273—Manifolds stacked manifolds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/26—Moulds
- B29C45/27—Sprue channels ; Runner channels or runner nozzles
- B29C45/28—Closure devices therefor
- B29C45/2806—Closure devices therefor consisting of needle valve systems
- B29C2045/2872—Closure devices therefor consisting of needle valve systems with at least three positions, e.g. two different open positions to control the melt flow
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/25—Solid
- B29K2105/253—Preform
Abstract
Valve gated multi-cavity injection molding apparatus for five layer molding having actuating mechanisms for reciprocating elongated valve members between four different positions. Each actuating mechanism has a front and a rear aligned cylinders, a first piston connected to the head of one of the valve members in the front cylinder and second and third pistons in the rear cylinder. The third piston has a stem portion which extends forwardly through the second piston into the front cylinder. Hydraulic pressure from four hydraulic lines connected to each actuating mechanism reciprocates each elongated valve member between the different positions. In the first closed position, the front end of the valve member is seated in the gate. In the second position, the front end of the valve member is retracted sufficiently to allow an initial amount of PET to flow from an outer annular melt channel through the gate. Then the valve member is retracted further to a third position to allow simultaneous flow of the PET and a barrier material from an inner annular melt channel. Then the valve member is retracted to a fully open position which allows the simultaneous flow of PET from a central melt channel. When the cavity is almost filled, the valve member returns briefly to the second position for filling before returning to the closed position for ejection.
Description
FOUR POSITION VALVE MEMBER ACTUATING MECHANISM
BACKGROUrND OF THE INVENTION
This invention relates generally to a: multi-cavity injection molding apparatus for five layer molding and more particularly i~o such apparatus having actuating mechanisms for reciprocating elongated valve members between four different ;positions.
Multi-cavity injection molding apparatus for making five layer protective containers for food or preforms or parisons fcr beverage bottles are known. Two layers of a barrier material such as ethylene vinyl alcohol copolymer (EVOH) or nylon are typically molded between two outer layers and a central layer of a polyethylene terephthalate (PET) type material. However, this has previously been done by sequentially injecting first the PET, then the barrier material and finally the PET again.
BACKGROUrND OF THE INVENTION
This invention relates generally to a: multi-cavity injection molding apparatus for five layer molding and more particularly i~o such apparatus having actuating mechanisms for reciprocating elongated valve members between four different ;positions.
Multi-cavity injection molding apparatus for making five layer protective containers for food or preforms or parisons fcr beverage bottles are known. Two layers of a barrier material such as ethylene vinyl alcohol copolymer (EVOH) or nylon are typically molded between two outer layers and a central layer of a polyethylene terephthalate (PET) type material. However, this has previously been done by sequentially injecting first the PET, then the barrier material and finally the PET again.
While this is satisfactory for some applications, sequential molding has the disadvantage that it requires relatively expensive tooling.
Valve gated mufti-cavity injection molding apparatus having elongated valve members which reciprocate are also known. For instance, U.S. Patent No. 4,657,496 to Ozeki et al. which issued April 14, 1987 shows an actuating mechanism having an outer piston reciprocating in an outer cylinder and a inner piston reciprocating in yin inner io cylinder. The inner piston drives the elongatE:d valve member and the outer piston drives a stem surrounding the elongated valve member and they operate in a controlled injection cycle to sequentially mold three layer products.
None of the prior art actuating mechanisms are capable of reciprocating the elongated valve members between four different positions according to the present invention to provide five layer molding by simultaneous injection.
SUN~IAR~C OF THE INVENTION
Accordingly, it is an object of the present invention to at least partially overcome the disadvantages of the prior art by providing a valve gated mufti-cavity injection molding apparatus for five layer moldin~~ having fluid actuating mechanisms for reciprocating each e:Longated valve member between four different positions.
Valve gated mufti-cavity injection molding apparatus having elongated valve members which reciprocate are also known. For instance, U.S. Patent No. 4,657,496 to Ozeki et al. which issued April 14, 1987 shows an actuating mechanism having an outer piston reciprocating in an outer cylinder and a inner piston reciprocating in yin inner io cylinder. The inner piston drives the elongatE:d valve member and the outer piston drives a stem surrounding the elongated valve member and they operate in a controlled injection cycle to sequentially mold three layer products.
None of the prior art actuating mechanisms are capable of reciprocating the elongated valve members between four different positions according to the present invention to provide five layer molding by simultaneous injection.
SUN~IAR~C OF THE INVENTION
Accordingly, it is an object of the present invention to at least partially overcome the disadvantages of the prior art by providing a valve gated mufti-cavity injection molding apparatus for five layer moldin~~ having fluid actuating mechanisms for reciprocating each e:Longated valve member between four different positions.
To this end, in one of its aspects, the :invention provides a multi-cavity sprue gated injection molding apparatus for mufti-la~~er molding having at least one melt distribution manifold with a front face and a plurality of heated nozzles mounted in a mold. Each heated nozzle has a rear end abutting against the melt distribution manifold and a front end adjacent a gate leading to a caviity in the mold. Each heated noz2;le has a first central meli~ channel and second and third melt channels extending the~:ethrough from the rear end to the front end. An elongated valve member has a rear end a:nd a front end extending through the melt distribution manifold into the central melt channel in each heated nozzle. The rear end of each elongai:ed valve member is operatively connected to valve member ~~ctuating mechanism mounted in t:he mold. A first melt pasaage for conveying melt from a first melt source branches in the melt distribution mania=old dividing to extend both around the elongated valve nnember in the first central melt channel and through thsa third melt channel in each heated nozzle to the gate. A. second melt passage for conveying melt from a second melt source branches in ithe melt distribution manifold and extends through the second melt channel in each heated nozzle to the gate. Each valve member actuating mechanism reciprocates the elongai:ed valve member between a first closed position and second, third .CA 02219235 1997-10-23 and fourth positions according to a continuous predetermined injection. cycle. Each valve member actuating mechanism comprises means to retract the elongated valve member from the first closed position to the: second 5 position wherein the front end of the elongate=d valve member is retracted sufficiently to allow melt from the first melt source flow through the third melt channel in the nozzle and the gate into the cavity for a predeaermined period of time. It also comprises means to them further retract the elongated valve member to the third position wherein the front end of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the second melt source through the second melt: channel in the nozzle and from the first melt source through the third melt channel in the nozzle and the gate into the cavity for'a predetermined period of time. Each aictuating mechanism also include:: means to then further retract the elongated valve member to the fourth fully retracaed open position wherein the front end of the elongat~ad valve member is retracted suf:Eiciently to allow simultanEaous flow of melt from the f first melt source through the central melt channel in the nozzle, melt from the second melt source through the second melt channel in the nozzle and melt from the first melt source through the third melt channE:l in the nozzle and the gate until the cavity is almost filled. It also includes means to then return the elongated valve member to the second position until the cavity i:a filled, and means to first .drive the elongated valve member forwardly to the first. closed position wherein t:he front end of the elongated valve member is seated in thc~ gate to allow for ejection.
In another of its aspects, the invention provides a multi-cavity sprue gated injection molding apparatus for multi-layer molding having at least one melt disi_ribution io manifold with a front: face and a plurality of heated nozzles mounted in a mold. Each heated nozzle h2~s a rear end abutting against the melt distribution manifold and a front , end adj acent a gate leading to a cavity in i:he mold.
Each heated nozzle has'. a first central melt channel and second and third melt channels extending therethrough from the rear erid to the front end. An elongated valve member has a rear end and a front end extending through the melt distribution manifold into the central melt channel in each heated nozzle. The rear end of each elongated val~re member 2o is operatively connected to valve member ~~ctuating mechanism mounted in the mold. A first melt passage for conveying melt from a first melt source branches in the melt distribution manifold dividing to extend both around the elongated valve member in the first central melt channel and through the: third melt channel in each heated .' nozzle to the gate. 1?~ second melt passage for conveying melt from a second welt source branches in 'the melt distribution manifold and extends through the se<:ond melt channel in each heated nozzle to the gate. Each valve member actuating mechanism comprises a front cyl~Lnder and a rear cylinder both. aligned in the mold with each elongated valve member. A first piston is seated in the front cylinder and connected to the rear end. of the elongated valve member. A second piston is seatsad in the rear cylinder. A third piston is seated behind the second piston in the rear cylinder. The third piston has a stem portion which extends forwardly through an opening in the second piston into the: first cylinder. First and second fluid lines from fluid pressure means are connected to the front cylinder on opposite sides of the first piston. A
third fluid line from fluid pressure means is connected to the rear cylinder on t:he front side of the second piston, and a fourth fluid line from fluid pressure means is connected to the rear cylinder on the rear side of the third piston. Fluid pressure applied through t)!ie first, second, third and fourth fluid pressure lines rec:Lprocates the elongated valve mernber between a first closed position and second, third and fourth positions accordLng to a continuous predetermined injection cycle.
During this cycle, fluid pressure from t:he second fluid line is first released and fluid pressure is applied from the fourth fluid :Line to drive the second and third pistons forwardly and iEluid pressure is applied from the first fluid line to drive the first piston and the elongated valve member rearwardly from the firsvt closed position until the re<~r end of the first piston abuts against the front end of the third piston in the second position. In the seca~nd position, the front end of the elongated valve member is retracted sufficiently to allow melt f low from the f irsi~ melt source through the third melt channel in the nozzle: and the gate. After a short predetermined period of time, fluid pressure is applied from the third fluid line to drive the second piston to a rear position which a:Llows the fluid pressure From the first fluid line to drive the first piston and the elongated member further rearwardly to the third ~~osition.
In the third position, the front end of the elongated valve member is retracted suf:Eiciently to allow simultaneous flow of melt from the second melt source through the second melt channel in the nozzle and melt from the first melt source through the third melt channel in the nozzle and the gate into the cavity. Then iEluid pressure from the fourth fluid line is released and fluid pressure from the first fluid line then drives the first and second pistons and the elongated valve member to the fourth fully retracaed open position. In the fourth position, the front en<i of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the first melt: source through the central me7.t channel in the nozzle, melt from the second melt source through the second melt channel in the nozzle and melt from the first melt source through the third melt channel in 'the nozzle and the gate. When the cavity is almost filled, fluid pressure from the third fluid line is released <~nd fluid pressure is reapplied from the fourth fluid line to drive the first, second amd third pistons forwardly and return the elongated valve member to the second position until the cavity is filled. TPien fluid pressure is applied from the second fluid line to drive the first piston and the elongated valve member forwardly to the first closed position wherein the front end of the elongated valve member is seated in the gate to allow for ejection.
In still another of its aspects, the invention further provides a meth~~d of continuously injection molding multi-layer products i:n a multi-cavity injection molding apparatus having at least one melt distribution manifold with a front face and a plurality of heated nozzles mounted in a mold. Each heated nozzle has a rear end abutting against the melt distribution manifold and a front end adjacent a gate leading to a cavity in the mold. Each , heated nozzle has a first central melt channel and second and third melt channels extending therethrough :From the rear end to the front e:nd. An elongated valve member has a rear end and a front end extending through 'the melt 5 distribution manifold into the central melt channe:L in each heated nozzle. The rear end of each elongated valve member is operatively connected to valve member actuating mechanism mounted in the mold. A first melt passage for conveying melt from a first melt source branchea in the 10 melt distribution manifold dividing to extend both around the elongated valve member in the first cent~~al melt channel and through ths: third melt channel in each heated nozzle to the gate. A. second melt passage for conveying melt from a second melt source branches in i~he melt distribution manifold and extends through the second melt channel in each heated nozzle to the gate. The method comprises the steps of :First retracting the elongai~ed valve member from a first closed position to a second position wherein the front end of the elongated valve member is retracted sufficiently to allow melt from the first melt source flow through the third melt channel in the nozzle and the gate into the cavity for a predetermined period of time. Then further retracting the elongated valve member to a third position wherein the front end of the elongated valve member is retracted sufficiently t~~ allow x simultaneous flow of melt from the second melt source through the second melt channel in the nozzle and from the ffirst melt source through the third melt channel in the nozzle and the gate into the cavity for a predetermined period of time. Then further retracting the elongated valve member to a fourth fully retracted open position wherein the front endl of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the first melt source to the central melt channel in the nozzle, melt from the second melt source through the second melt channel in the nozzle and melt from the first melt source through the third melt channel in t:he nozzle and the gate until t:he cavity is almost filled. Then returning the elongated valve member to the secondlposition until the cavity is filled, and finally driving the elongated valve member forwardly to the firsot closed position wherein the front end of the elongai:ed valve member is seated in the gate to allow for ejection.
Further objects and advantages of the invention will appear from the following description taken togethers with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a sectional view of a p~~rtion of valve gated multi-cavity , injection molding apparatus according to a first embodiment of the invention, showing the elongated valve member in a first closed position, Figure 2 is a partial sectional view of the same apparatus showing the elongated valve member in a second partially retracted position, Figure 3 is a similar view showing the elongated valve member in a third further retracted position, Figure 4 is a similar view showing the elongated valve member in a fourth fully retracted open position, Figure 5 is an enlarged view of a portion of Figure 4 showing the melt flow into the cavity, and Figure 6 is a sectional view of a portion of a multi-cavity sprue gated injection molding apparatus according to another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference is first made to Figure 1 which shows a portion of valve gated multi-cavity injection molding apparatus for molding five layer preforms or other products by a combination of sequential and simultaneous coinjection. As indicated above, two layers of a barrier material such as ethylene vinyl alcohol copolymer (EVOH) or nylon are molded between two outer layers and a central layer of a polyethylene terephthalate (PET) type material.
However, other materials having suitable characteristics ,, can be used in other embodiments. A number oi: heated nozzles 10 are mounted in a mold 12 with a rear end 14 abutting against the front face 16 of a first front steel melt distribution manifold 18. While the mold 12 can have a greater number of planes depending upon the application, in this case, only a nozzle retainer plate 20, a manifold retainer plate 22 and a cylinder plate 24 secured together by bolts 26, as well as a cavity retainer plate: 28 are shown for ease of illustration. The front tip end 30 of l0 each heated nozzle 10 is aligned with a gate 32 extending through a cooled gate insert 34 to a cavity 36. This cavity 36 for making beverage bottle preforms extends between a cavity insert 38 and the mold core 40 in a conventional manner. Wlaile only a single heated nozzle 10 is shown for ease of illustration, in a typical configuration there wil:L be many heated nozzles 10 (eg. 32, 48 or 64) seated in the mold 12 each aligned with a gate 32.
Each nozzle 10 is preferably heated by an integral electrical heating element 42 having a terminal 44. Each heated nozzle: 10 is seated in an opening 46 in the nozzle retainer plate 20 with a rear collar portion 48 of each heated nozzle :LO received in a circular locating seat 50 extending around the opening 46. This provides an insulative air space 52 between the heated nozzle: 10 and the surrounding mold 12 which is cooled by pumping' cooling water through cooling conduits 54.
Each heated nozzle 10 has a central melt. channel 56 extending from its rear end 14 to its front endl 30. In this configuration shown, each heated nozzle 1C: has an insert portion 58 which is secured in a seat 60 by a threaded nozzle seal 62 which is screwed into place and forms the front tip end 30 of the heated nozzle 10 ~. As can better be seen in Figure 2, the insert portion 58 is made of several pieces 64 which fit together to form an inner annular melt channel 66 extending around the central melt channel 56 to the front end 30 and an outer annL:lar melt channel 68 extending around the inner annular melt, channel 66 and the central melt channel 56 to the front end 30. In this configuration, the: heated nozzle 10 has a single melt bore 70 extending from its rear end 14 to connect to the first or inner annular'melt channel 64. A circle of spaced holes 72 are drilled in the rear end 14 of the heated nozzle 10 around the melt bore 70 to provide thermal separation for the melt flowing through the melt bore 70.
The configuration shown also has four spaced melt bores 74 extending from the rear end 14 of the heated nozzle 10 to the outer annular melt channel 68.
The first front melt distribution manif~~ld 18 is heated by an electrica?L heating element 76. It i:a located by a central locating rang 78 and screws 80 extending into each heated nozzle 10 to provide an insulative air space 82 extending between it and the surrounding cooled mold 12.
A second rear steel melt distribution manifold 84 is 5 mounted in the mold 1.2 by a number of insulat:ive and resilient spacers 86 extending between it and the cylinder plate 24 to extend parallel to the front melt distribution manifold 18. As can be seen, the two manifolds 18, 84 are separated by thermal insulating melt transfer spacers 88 10 positioned between them. As described in morE: detail below, the rear melt distribution manifold 84 is heated by an integral electrica7L heating element 90 to a lower operating temperature than the front melt distribution manifold 18, and the air space 92 provided by the thermal 15 insulating melt transfer spacers 88 between the two manifolds 18, 84 provides thermal separation between them.
A first melt passage 94 extends from .a common inlet 96 through a cylindrical manifold extension 98 and branches in the first front melt distribution manifold 18, and, in this configuration, extends through a melt dividing bushing 100 seated in t:he front face 16 of the front melt distribution manifold 18 in alignment with each heated nozzle l0. The melt dividing bushing 100 is preferably made of three steel layers integrally brazed together as described in co-pending Canadian Application Serial No.
In another of its aspects, the invention provides a multi-cavity sprue gated injection molding apparatus for multi-layer molding having at least one melt disi_ribution io manifold with a front: face and a plurality of heated nozzles mounted in a mold. Each heated nozzle h2~s a rear end abutting against the melt distribution manifold and a front , end adj acent a gate leading to a cavity in i:he mold.
Each heated nozzle has'. a first central melt channel and second and third melt channels extending therethrough from the rear erid to the front end. An elongated valve member has a rear end and a front end extending through the melt distribution manifold into the central melt channel in each heated nozzle. The rear end of each elongated val~re member 2o is operatively connected to valve member ~~ctuating mechanism mounted in the mold. A first melt passage for conveying melt from a first melt source branches in the melt distribution manifold dividing to extend both around the elongated valve member in the first central melt channel and through the: third melt channel in each heated .' nozzle to the gate. 1?~ second melt passage for conveying melt from a second welt source branches in 'the melt distribution manifold and extends through the se<:ond melt channel in each heated nozzle to the gate. Each valve member actuating mechanism comprises a front cyl~Lnder and a rear cylinder both. aligned in the mold with each elongated valve member. A first piston is seated in the front cylinder and connected to the rear end. of the elongated valve member. A second piston is seatsad in the rear cylinder. A third piston is seated behind the second piston in the rear cylinder. The third piston has a stem portion which extends forwardly through an opening in the second piston into the: first cylinder. First and second fluid lines from fluid pressure means are connected to the front cylinder on opposite sides of the first piston. A
third fluid line from fluid pressure means is connected to the rear cylinder on t:he front side of the second piston, and a fourth fluid line from fluid pressure means is connected to the rear cylinder on the rear side of the third piston. Fluid pressure applied through t)!ie first, second, third and fourth fluid pressure lines rec:Lprocates the elongated valve mernber between a first closed position and second, third and fourth positions accordLng to a continuous predetermined injection cycle.
During this cycle, fluid pressure from t:he second fluid line is first released and fluid pressure is applied from the fourth fluid :Line to drive the second and third pistons forwardly and iEluid pressure is applied from the first fluid line to drive the first piston and the elongated valve member rearwardly from the firsvt closed position until the re<~r end of the first piston abuts against the front end of the third piston in the second position. In the seca~nd position, the front end of the elongated valve member is retracted sufficiently to allow melt f low from the f irsi~ melt source through the third melt channel in the nozzle: and the gate. After a short predetermined period of time, fluid pressure is applied from the third fluid line to drive the second piston to a rear position which a:Llows the fluid pressure From the first fluid line to drive the first piston and the elongated member further rearwardly to the third ~~osition.
In the third position, the front end of the elongated valve member is retracted suf:Eiciently to allow simultaneous flow of melt from the second melt source through the second melt channel in the nozzle and melt from the first melt source through the third melt channel in the nozzle and the gate into the cavity. Then iEluid pressure from the fourth fluid line is released and fluid pressure from the first fluid line then drives the first and second pistons and the elongated valve member to the fourth fully retracaed open position. In the fourth position, the front en<i of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the first melt: source through the central me7.t channel in the nozzle, melt from the second melt source through the second melt channel in the nozzle and melt from the first melt source through the third melt channel in 'the nozzle and the gate. When the cavity is almost filled, fluid pressure from the third fluid line is released <~nd fluid pressure is reapplied from the fourth fluid line to drive the first, second amd third pistons forwardly and return the elongated valve member to the second position until the cavity is filled. TPien fluid pressure is applied from the second fluid line to drive the first piston and the elongated valve member forwardly to the first closed position wherein the front end of the elongated valve member is seated in the gate to allow for ejection.
In still another of its aspects, the invention further provides a meth~~d of continuously injection molding multi-layer products i:n a multi-cavity injection molding apparatus having at least one melt distribution manifold with a front face and a plurality of heated nozzles mounted in a mold. Each heated nozzle has a rear end abutting against the melt distribution manifold and a front end adjacent a gate leading to a cavity in the mold. Each , heated nozzle has a first central melt channel and second and third melt channels extending therethrough :From the rear end to the front e:nd. An elongated valve member has a rear end and a front end extending through 'the melt 5 distribution manifold into the central melt channe:L in each heated nozzle. The rear end of each elongated valve member is operatively connected to valve member actuating mechanism mounted in the mold. A first melt passage for conveying melt from a first melt source branchea in the 10 melt distribution manifold dividing to extend both around the elongated valve member in the first cent~~al melt channel and through ths: third melt channel in each heated nozzle to the gate. A. second melt passage for conveying melt from a second melt source branches in i~he melt distribution manifold and extends through the second melt channel in each heated nozzle to the gate. The method comprises the steps of :First retracting the elongai~ed valve member from a first closed position to a second position wherein the front end of the elongated valve member is retracted sufficiently to allow melt from the first melt source flow through the third melt channel in the nozzle and the gate into the cavity for a predetermined period of time. Then further retracting the elongated valve member to a third position wherein the front end of the elongated valve member is retracted sufficiently t~~ allow x simultaneous flow of melt from the second melt source through the second melt channel in the nozzle and from the ffirst melt source through the third melt channel in the nozzle and the gate into the cavity for a predetermined period of time. Then further retracting the elongated valve member to a fourth fully retracted open position wherein the front endl of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the first melt source to the central melt channel in the nozzle, melt from the second melt source through the second melt channel in the nozzle and melt from the first melt source through the third melt channel in t:he nozzle and the gate until t:he cavity is almost filled. Then returning the elongated valve member to the secondlposition until the cavity is filled, and finally driving the elongated valve member forwardly to the firsot closed position wherein the front end of the elongai:ed valve member is seated in the gate to allow for ejection.
Further objects and advantages of the invention will appear from the following description taken togethers with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a sectional view of a p~~rtion of valve gated multi-cavity , injection molding apparatus according to a first embodiment of the invention, showing the elongated valve member in a first closed position, Figure 2 is a partial sectional view of the same apparatus showing the elongated valve member in a second partially retracted position, Figure 3 is a similar view showing the elongated valve member in a third further retracted position, Figure 4 is a similar view showing the elongated valve member in a fourth fully retracted open position, Figure 5 is an enlarged view of a portion of Figure 4 showing the melt flow into the cavity, and Figure 6 is a sectional view of a portion of a multi-cavity sprue gated injection molding apparatus according to another embodiment of the invention.
DETAILED DESCRIPTION OF THE INVENTION
Reference is first made to Figure 1 which shows a portion of valve gated multi-cavity injection molding apparatus for molding five layer preforms or other products by a combination of sequential and simultaneous coinjection. As indicated above, two layers of a barrier material such as ethylene vinyl alcohol copolymer (EVOH) or nylon are molded between two outer layers and a central layer of a polyethylene terephthalate (PET) type material.
However, other materials having suitable characteristics ,, can be used in other embodiments. A number oi: heated nozzles 10 are mounted in a mold 12 with a rear end 14 abutting against the front face 16 of a first front steel melt distribution manifold 18. While the mold 12 can have a greater number of planes depending upon the application, in this case, only a nozzle retainer plate 20, a manifold retainer plate 22 and a cylinder plate 24 secured together by bolts 26, as well as a cavity retainer plate: 28 are shown for ease of illustration. The front tip end 30 of l0 each heated nozzle 10 is aligned with a gate 32 extending through a cooled gate insert 34 to a cavity 36. This cavity 36 for making beverage bottle preforms extends between a cavity insert 38 and the mold core 40 in a conventional manner. Wlaile only a single heated nozzle 10 is shown for ease of illustration, in a typical configuration there wil:L be many heated nozzles 10 (eg. 32, 48 or 64) seated in the mold 12 each aligned with a gate 32.
Each nozzle 10 is preferably heated by an integral electrical heating element 42 having a terminal 44. Each heated nozzle: 10 is seated in an opening 46 in the nozzle retainer plate 20 with a rear collar portion 48 of each heated nozzle :LO received in a circular locating seat 50 extending around the opening 46. This provides an insulative air space 52 between the heated nozzle: 10 and the surrounding mold 12 which is cooled by pumping' cooling water through cooling conduits 54.
Each heated nozzle 10 has a central melt. channel 56 extending from its rear end 14 to its front endl 30. In this configuration shown, each heated nozzle 1C: has an insert portion 58 which is secured in a seat 60 by a threaded nozzle seal 62 which is screwed into place and forms the front tip end 30 of the heated nozzle 10 ~. As can better be seen in Figure 2, the insert portion 58 is made of several pieces 64 which fit together to form an inner annular melt channel 66 extending around the central melt channel 56 to the front end 30 and an outer annL:lar melt channel 68 extending around the inner annular melt, channel 66 and the central melt channel 56 to the front end 30. In this configuration, the: heated nozzle 10 has a single melt bore 70 extending from its rear end 14 to connect to the first or inner annular'melt channel 64. A circle of spaced holes 72 are drilled in the rear end 14 of the heated nozzle 10 around the melt bore 70 to provide thermal separation for the melt flowing through the melt bore 70.
The configuration shown also has four spaced melt bores 74 extending from the rear end 14 of the heated nozzle 10 to the outer annular melt channel 68.
The first front melt distribution manif~~ld 18 is heated by an electrica?L heating element 76. It i:a located by a central locating rang 78 and screws 80 extending into each heated nozzle 10 to provide an insulative air space 82 extending between it and the surrounding cooled mold 12.
A second rear steel melt distribution manifold 84 is 5 mounted in the mold 1.2 by a number of insulat:ive and resilient spacers 86 extending between it and the cylinder plate 24 to extend parallel to the front melt distribution manifold 18. As can be seen, the two manifolds 18, 84 are separated by thermal insulating melt transfer spacers 88 10 positioned between them. As described in morE: detail below, the rear melt distribution manifold 84 is heated by an integral electrica7L heating element 90 to a lower operating temperature than the front melt distribution manifold 18, and the air space 92 provided by the thermal 15 insulating melt transfer spacers 88 between the two manifolds 18, 84 provides thermal separation between them.
A first melt passage 94 extends from .a common inlet 96 through a cylindrical manifold extension 98 and branches in the first front melt distribution manifold 18, and, in this configuration, extends through a melt dividing bushing 100 seated in t:he front face 16 of the front melt distribution manifold 18 in alignment with each heated nozzle l0. The melt dividing bushing 100 is preferably made of three steel layers integrally brazed together as described in co-pending Canadian Application Serial No.
2,219,054 entitled, "Injection Molding Apparatus Having Melt Dividing Bushings" filed concurrently herewith. In this configuration, the melt dividing bushing 100 has a neck portion 102 extending rearwardly through an opening 104 in the front melt distribution manifold 18 to the rear melt distribution manifold 84. The first melt passage 94 divides again in each melt dividing bushing 100 and extends through the four melt bores 74 to the outer annular melt channel 66 as well as to the central melt channel 56 in each heated nozzle 10. A second melt passage 106 extends from a second inlet 108 and branches in the rear melt distribution manifold 84 to extend through a central bore 110 in each melt transfer spacer 88 to the aligned melt bore 70 extending from the rear end 14 of each heated nozzle 10 to the inner annular melt channel 66.
An elongated valve member 112 having a rear head 114 and a front end 116 which fits in the gate 32 extends through a bore 118 in the rear manifold 84, through an aligned central bore 120 in the melt dividing bushing 100 into the aligned central melt channel 56 in each heated nozzle 10. Each elongated valve member 112 is reciprocated through four different positions during the injection cycle by actuating mechanism 122 mounted in the cylinder plate 24 according to the invention. The elongated valve member 112 fits in part of the central bore 120 in the melt dividing bushing 100 tightly enough to prevent melt leakage: around the elongated valve member 112 as it reciprocates.. While hydraulic actuating mechanisms 122 are shown, of course, ' pneumatic actuating mechanisms can be used fo~c other applications. In this embodiment of the invention, the head 114 of the elongated valve member 112 is connected to a first piston 124 seated in a front cylinder 126. Each actuating mechanism 122 also includes second and third pistons 128, 130 seated in a rear cylinder 132 aligned with the front cylinder 126. The third piston 130 is. seated behind the second piston 128 and has a stem portion 134 which extends forwardly through a bore 136 in the: second piston 128 into the front cylinder 126. As can k>e seen, first and second hydraulic lines 138, 140 extend to the front cylinder 126 on opposite sides of the first: piston 124. A third hydraulic line 142 extends to the rear cylinder 132 on the front side of the second piston 128.
A fourth hydraulic line 144 extends to the rear cylinder 132 on the rear side of the third piston 130. These hydraulic lines 138, 190, 142, 144 extend from a, source (not shown) which apx>lies hydraulic pressure to the different lines according to a predetermined program controlled by the injection cycle to reciproc~~te the elongated valve member 112 between first, second, third and fourth positions.
An elongated valve member 112 having a rear head 114 and a front end 116 which fits in the gate 32 extends through a bore 118 in the rear manifold 84, through an aligned central bore 120 in the melt dividing bushing 100 into the aligned central melt channel 56 in each heated nozzle 10. Each elongated valve member 112 is reciprocated through four different positions during the injection cycle by actuating mechanism 122 mounted in the cylinder plate 24 according to the invention. The elongated valve member 112 fits in part of the central bore 120 in the melt dividing bushing 100 tightly enough to prevent melt leakage: around the elongated valve member 112 as it reciprocates.. While hydraulic actuating mechanisms 122 are shown, of course, ' pneumatic actuating mechanisms can be used fo~c other applications. In this embodiment of the invention, the head 114 of the elongated valve member 112 is connected to a first piston 124 seated in a front cylinder 126. Each actuating mechanism 122 also includes second and third pistons 128, 130 seated in a rear cylinder 132 aligned with the front cylinder 126. The third piston 130 is. seated behind the second piston 128 and has a stem portion 134 which extends forwardly through a bore 136 in the: second piston 128 into the front cylinder 126. As can k>e seen, first and second hydraulic lines 138, 140 extend to the front cylinder 126 on opposite sides of the first: piston 124. A third hydraulic line 142 extends to the rear cylinder 132 on the front side of the second piston 128.
A fourth hydraulic line 144 extends to the rear cylinder 132 on the rear side of the third piston 130. These hydraulic lines 138, 190, 142, 144 extend from a, source (not shown) which apx>lies hydraulic pressure to the different lines according to a predetermined program controlled by the injection cycle to reciproc~~te the elongated valve member 112 between first, second, third and fourth positions.
In use, the inj ection molding system is assembled as shown in Figure 1 and operates to form f iv~e layer preforms or other products as follows. First, electrical power is applied to the heating element 76 in the front melt distribution manifold 18 and the heating elements 42 in the heated nozzles 10 to heat them to the operating temperature of the plasitic material to be injected through the central melt channel 56. In a preferred embodiment, this material is a polyethylene terephthalate (PI:.T) type material which has a melt temperature of about: 565F.
Electrical power is also applied to the heating element 90 in the rear melt distrix>ution manifold 84 to heat it to the operating temperature of the plastic material that is injected through the inner annular melt channel 66. This usually is a barrier material such as ethylene vinyl copolymer (EVOH) which has an operating temperature of about 400F, but it can also be nylon. Water is supplied to the cooling conduits 54 to cool the mold 12 and the gate inserts 34. Hot pressurized melt is then injecited from 2o separate injection cylinders (not shown) into the first and second melt passages 94, 106 through inlets 96, 108 according to a predetermined injection cycle. A;s noted, the melt injected into the first melt passage 94 is a polyethylene terephthalate (PET) type material. The first melt passage 94 branches in the front melt distribution manifold 18 and extends to each melt dividing bushing 100 where it divides again and flows to the central melt channel 56 of the aligned heated nozzle 10 around the elongated valve member 112 as well as into four spaced holes 72 aligned with t:he four melt bores 74 in the rear end 14 of the heated nozzle 10 to the outer annu:Lar melt channel 68.
Usually, as noted, the melt injected into the second melt passage 106 is a barrier material such as ethylene vinyl copolymer (EVOH) or nylon. The second melt passage 106 branches in the rear melt distribution:manifold 84--arid extends --through--the - central bore 110 in e~~ah melt transfer spacer 88 and the aligned melt bore 70 extending from the rear end of t:he heated nozzle 10 to the inner annular melt channel 66.
As also seen in Figures 2, 3 and 4, the flow of PET from the first melt passage 94 and the barrier material from the second melt pa;asage 106 through each gate 32 into the cavity 36 is controlled by the actuating mechanism 122 reciprocating the elongated valve member 112 between first, second, third and fourth positions during the injection cycle as follows. Initially, hydraulic pressure is applied from the second hydrau7.ic line 140 to the front cylinder 126 behind the front piston 124 which drives tree first piston 124 and the elongated valve member 112 forwardly to .' the first closed position shown in Figure 1 wherein the front end 116 of the elongated valve member 112 i:~ seated in the gate 32.
Next, the hydraulic pressure from the second 5 hydraulic line 140 is released, and hydraulic pre;~sure is applied from the fourth hydraulic line 144 to t:he rear cylinder 132 behind the third piston 130 which drives the second and third pistons 128, 130 forwardly. At lthe same time, fluid pressure i~~ applied from the first h;Ydraulic 10 line 138 to the front cylinder 126 in front of the first piston 124 which drives the first piston 124 and the elongated valve member 112 rearwardly until they are stopped by the rear send 146 of the first piston 124 abutting against the front end 148 of the stem portion 134 15 of the rear cylinder 13:z in the second position.
In this second position shown in Figurs: 2, the front end 116 of the. elongated valve member 112 is retracted sufficiently i~o allow PET to flow from tlhe outer annular melt channel 68 through the gate 32 to the' cavity 20 36. Thus, a predetermined initial quantity of PE~C 149 is injected into the cavities 36 through the first melt passage 94 and part of it adheres to the sides 15~) of the cavities 36.
A short. time after the start of PET injection, hydraulic pressure is applied from the third hydraulic line :.
Electrical power is also applied to the heating element 90 in the rear melt distrix>ution manifold 84 to heat it to the operating temperature of the plastic material that is injected through the inner annular melt channel 66. This usually is a barrier material such as ethylene vinyl copolymer (EVOH) which has an operating temperature of about 400F, but it can also be nylon. Water is supplied to the cooling conduits 54 to cool the mold 12 and the gate inserts 34. Hot pressurized melt is then injecited from 2o separate injection cylinders (not shown) into the first and second melt passages 94, 106 through inlets 96, 108 according to a predetermined injection cycle. A;s noted, the melt injected into the first melt passage 94 is a polyethylene terephthalate (PET) type material. The first melt passage 94 branches in the front melt distribution manifold 18 and extends to each melt dividing bushing 100 where it divides again and flows to the central melt channel 56 of the aligned heated nozzle 10 around the elongated valve member 112 as well as into four spaced holes 72 aligned with t:he four melt bores 74 in the rear end 14 of the heated nozzle 10 to the outer annu:Lar melt channel 68.
Usually, as noted, the melt injected into the second melt passage 106 is a barrier material such as ethylene vinyl copolymer (EVOH) or nylon. The second melt passage 106 branches in the rear melt distribution:manifold 84--arid extends --through--the - central bore 110 in e~~ah melt transfer spacer 88 and the aligned melt bore 70 extending from the rear end of t:he heated nozzle 10 to the inner annular melt channel 66.
As also seen in Figures 2, 3 and 4, the flow of PET from the first melt passage 94 and the barrier material from the second melt pa;asage 106 through each gate 32 into the cavity 36 is controlled by the actuating mechanism 122 reciprocating the elongated valve member 112 between first, second, third and fourth positions during the injection cycle as follows. Initially, hydraulic pressure is applied from the second hydrau7.ic line 140 to the front cylinder 126 behind the front piston 124 which drives tree first piston 124 and the elongated valve member 112 forwardly to .' the first closed position shown in Figure 1 wherein the front end 116 of the elongated valve member 112 i:~ seated in the gate 32.
Next, the hydraulic pressure from the second 5 hydraulic line 140 is released, and hydraulic pre;~sure is applied from the fourth hydraulic line 144 to t:he rear cylinder 132 behind the third piston 130 which drives the second and third pistons 128, 130 forwardly. At lthe same time, fluid pressure i~~ applied from the first h;Ydraulic 10 line 138 to the front cylinder 126 in front of the first piston 124 which drives the first piston 124 and the elongated valve member 112 rearwardly until they are stopped by the rear send 146 of the first piston 124 abutting against the front end 148 of the stem portion 134 15 of the rear cylinder 13:z in the second position.
In this second position shown in Figurs: 2, the front end 116 of the. elongated valve member 112 is retracted sufficiently i~o allow PET to flow from tlhe outer annular melt channel 68 through the gate 32 to the' cavity 20 36. Thus, a predetermined initial quantity of PE~C 149 is injected into the cavities 36 through the first melt passage 94 and part of it adheres to the sides 15~) of the cavities 36.
A short. time after the start of PET injection, hydraulic pressure is applied from the third hydraulic line :.
142 to the rear cylinder 132 in front of the second piston 128 which drives the second piston 128 to a rear 'position against stop 152. This allows the hydraulic pressure from the first hydraulic line 138 to drive the first p3.ston 124 and the elongated valve member 112 further rearw~~rdly to the third position. In this third position shown in Figure 3, the front end 116 of the elongated valve member 112 is further retracted sufficiently to allow both PET from the outer annular melt channel 68 and barrier material from the inner annular melt channel 66 to be coinjected simultaneously through the gate 32 to the cavity 36. As can be seen, the flow of the less viscous barrier material splits the flow of PET into two outer layers 154.
After the simultaneous flow of PET and the barrier material has been established, hydraulic pressure from the fourth hydraulic line 144 is released and the hydraulic pressure from the first fluid line :L38 then drives the first and second pistons 124, 128 and the elongated valve member 112 to the fourth fully retracted open position. In this fourth open position chown in Figures 4 and 5, the front end of the elongated valve member 112 is retracted further sufficiently to also allow simultaneous flow of PET from the central melt channel 56 through the gate 32 to the cavity 36. As can be seen in Figure 5, this inner flow of PET, in turn, splits the flow of the barrier material into two layers 156 on both sides of an inner layer 158 of PET.
When the cavities 36 are almost filled, the hydraulic pressure froxa the third hydraulic line: 142 is released and hydraulic: pressure is reapplied from the fourth hydraulic line 144 which drives the first, second and third pistons 124, 128, 130 forivardly and retwrns the elongated valve member :112 to the second position shown in Figure 2 which stops i:he flow of the barrier material.
After another small quantity of PET has been inj acted to complete filling of the cavities 36, the hydraulic :pressure is then released from the fourth hydraulic line 144 and reapplied from the second hydraulic line 140 to return the first piston 124 and the elongated valve member 112 to the first closed position. After a short cooling period, the mold 12 is -opened for ejection. After ejection, 'the mold is closed and the injeci~ion cycle is repeated continuously every 15 to 30 seconds :with a frequency depending 'upon the wall thickness and the number and size of the cavities 36 and the exact materials being molded.
Reference is now made to Figure 6 showing injection molding apparatus according to another embodiment of the invention for valve gating five layer preoorms or other products by a combination of sequent_Lal and simultaneous coinjection. As many of the elements are the same or similar to those described above, not all elements common to both embodims:nts are described again and those that are described again have the same reference .numerals as before. In this case, the rear melt distribution manifold 84 rather tlZan the front melt distribution manifold 18 has the manifold extension 98. Thus, the first melt passage 94 extends from the inlet 96 in the .manifold extension 98 and branclhes in the rear melt distribution manifold 84 rather than the front melt distribution manifold 18. Furthermore, the second melt pas.:age 106 extends from the second inlet 108 through the front melt distribution manifold 18 rather than the rear melt distribution manifold 8.4.
As can be seen, a melt transfer and .dividing bushing 160 is mounted behind each heated nozzle 10 in a cylindrical opening 162 extending through the front melt distribution manifold 118 with its front end 164 .abutting against the rear end 14 of the heated nozzle 10. In this embodiment, the rear e:nd 166 of the melt transfer and dividing bushing 160 abuts against the rear melt distribution manifold 84 with a neck portion 168 e;Ktending into an opening 170 in i:he rear melt distribution manifold 84, but in other embodiments, the rear end 166 of 'the melt transfer and dividing bushing 160 can be seated in the rear melt distribution maniiEold 84. Each melt transfer and dividing bushing 160 is made by integrally joining together a first steel layer 172 at its rear end 166 with the neck portion 168, a third steel layer 174 at its front end 164 and a second steel layer 176 between the first and third layers 172, 174 as described in co-pending Canadian application serial no. 2,219,197 entitled "Injection Molding Apparatus Having Melt Transfer and Dividing Bushing" filed concurrently herewith. The first rear layer 172 has a hole 178 extending therethrough from an inlet 180 at the rear end 166. The third front layer 174 has four holes 182 extending therethrough to four outlets 184, each aligned with one of the four melt bores 74 extending to the outer annular channel 68 in the heated nozzle 10. The front face 186 of the first rear layer 172 and the rear face 188 of the second layer 176 are machined to have matching grooves which join when the three layers are joined together to form a first melt conduit 190 which branches to extend from the hole 178 in the first rear layer 172 to a central bore 192 through the melt transfer and dividing bushing 160 as well as to two spaced holes-(not shown) which extend through the second layer 176 to two outlets on the front face 194 of the second layer 176.
The front face 194 of the second layer 176 and the rear face 196 of the third front layer 174 are also machined to have two matching grooves which join when the three layers are joined together to form two curved second melt conduits 198. Each curved second melt conduit 198 branches from one of the outlets from th~a holes through the second layer to two of the four spaced holes 182 extending through the 5 third layer 174 to the four outlets 184 at the front end 164 of the melt transfer and dividing bushing 160. Each of these four outlets 184 is aligned with one of the i:our melt bores 74 extending from the rear end 14 of the heated nozzle 10 to the outer annular melt channel 68. ~~hus, the 1o first melt passage 94 which branches in the rear melt distribution manifold 8.4 to each melt transfer and dividing bushing 160 divides again as it passes through each melt transfer and dividing bushing 160 to extend to the: central melt channel 56 and the outer annular melt channel 68 in 15 each heated nozzle 10.
In this embodiment, the third front layer 174 of each melt transfer and dividing bushing 160 has an L-shaped melt passage 200 aligned with the second melt passage 106 which branches in the front melt distribution manifold 18 2o and the single melt bore 70 extendina from the rear enr7 is of the heated nozzle 10 to the inner annular melt channel 66 to form part of the second melt passage 106. A small dowel 202 extends from a. melt transfer and dividing bushing 160 into the rear. melt distribution manifold 84 t~~ locate 25 the melt transfer and dividing bushing 160 with ithe four spaced outlets 184 in alignment with the four melt bores 74 extending from the rea~~ end 14 of the heated noz2;le 10 to the outer annular channel 68. The operation of this embodiment of the invention is the same as that described above, and need not be repeated.
While the description of the valve gated inj ection molding apparatus for f ive layer molding has been given with respect to preferred embodiments, it will be evident that various modifications are possible without departing from the scope of the invention as understood by those skilled in the art and as defined in the following claims. For instance, other materials having suitable characteristics can be: used rather' than PET, hVOH and nylon.
After the simultaneous flow of PET and the barrier material has been established, hydraulic pressure from the fourth hydraulic line 144 is released and the hydraulic pressure from the first fluid line :L38 then drives the first and second pistons 124, 128 and the elongated valve member 112 to the fourth fully retracted open position. In this fourth open position chown in Figures 4 and 5, the front end of the elongated valve member 112 is retracted further sufficiently to also allow simultaneous flow of PET from the central melt channel 56 through the gate 32 to the cavity 36. As can be seen in Figure 5, this inner flow of PET, in turn, splits the flow of the barrier material into two layers 156 on both sides of an inner layer 158 of PET.
When the cavities 36 are almost filled, the hydraulic pressure froxa the third hydraulic line: 142 is released and hydraulic: pressure is reapplied from the fourth hydraulic line 144 which drives the first, second and third pistons 124, 128, 130 forivardly and retwrns the elongated valve member :112 to the second position shown in Figure 2 which stops i:he flow of the barrier material.
After another small quantity of PET has been inj acted to complete filling of the cavities 36, the hydraulic :pressure is then released from the fourth hydraulic line 144 and reapplied from the second hydraulic line 140 to return the first piston 124 and the elongated valve member 112 to the first closed position. After a short cooling period, the mold 12 is -opened for ejection. After ejection, 'the mold is closed and the injeci~ion cycle is repeated continuously every 15 to 30 seconds :with a frequency depending 'upon the wall thickness and the number and size of the cavities 36 and the exact materials being molded.
Reference is now made to Figure 6 showing injection molding apparatus according to another embodiment of the invention for valve gating five layer preoorms or other products by a combination of sequent_Lal and simultaneous coinjection. As many of the elements are the same or similar to those described above, not all elements common to both embodims:nts are described again and those that are described again have the same reference .numerals as before. In this case, the rear melt distribution manifold 84 rather tlZan the front melt distribution manifold 18 has the manifold extension 98. Thus, the first melt passage 94 extends from the inlet 96 in the .manifold extension 98 and branclhes in the rear melt distribution manifold 84 rather than the front melt distribution manifold 18. Furthermore, the second melt pas.:age 106 extends from the second inlet 108 through the front melt distribution manifold 18 rather than the rear melt distribution manifold 8.4.
As can be seen, a melt transfer and .dividing bushing 160 is mounted behind each heated nozzle 10 in a cylindrical opening 162 extending through the front melt distribution manifold 118 with its front end 164 .abutting against the rear end 14 of the heated nozzle 10. In this embodiment, the rear e:nd 166 of the melt transfer and dividing bushing 160 abuts against the rear melt distribution manifold 84 with a neck portion 168 e;Ktending into an opening 170 in i:he rear melt distribution manifold 84, but in other embodiments, the rear end 166 of 'the melt transfer and dividing bushing 160 can be seated in the rear melt distribution maniiEold 84. Each melt transfer and dividing bushing 160 is made by integrally joining together a first steel layer 172 at its rear end 166 with the neck portion 168, a third steel layer 174 at its front end 164 and a second steel layer 176 between the first and third layers 172, 174 as described in co-pending Canadian application serial no. 2,219,197 entitled "Injection Molding Apparatus Having Melt Transfer and Dividing Bushing" filed concurrently herewith. The first rear layer 172 has a hole 178 extending therethrough from an inlet 180 at the rear end 166. The third front layer 174 has four holes 182 extending therethrough to four outlets 184, each aligned with one of the four melt bores 74 extending to the outer annular channel 68 in the heated nozzle 10. The front face 186 of the first rear layer 172 and the rear face 188 of the second layer 176 are machined to have matching grooves which join when the three layers are joined together to form a first melt conduit 190 which branches to extend from the hole 178 in the first rear layer 172 to a central bore 192 through the melt transfer and dividing bushing 160 as well as to two spaced holes-(not shown) which extend through the second layer 176 to two outlets on the front face 194 of the second layer 176.
The front face 194 of the second layer 176 and the rear face 196 of the third front layer 174 are also machined to have two matching grooves which join when the three layers are joined together to form two curved second melt conduits 198. Each curved second melt conduit 198 branches from one of the outlets from th~a holes through the second layer to two of the four spaced holes 182 extending through the 5 third layer 174 to the four outlets 184 at the front end 164 of the melt transfer and dividing bushing 160. Each of these four outlets 184 is aligned with one of the i:our melt bores 74 extending from the rear end 14 of the heated nozzle 10 to the outer annular melt channel 68. ~~hus, the 1o first melt passage 94 which branches in the rear melt distribution manifold 8.4 to each melt transfer and dividing bushing 160 divides again as it passes through each melt transfer and dividing bushing 160 to extend to the: central melt channel 56 and the outer annular melt channel 68 in 15 each heated nozzle 10.
In this embodiment, the third front layer 174 of each melt transfer and dividing bushing 160 has an L-shaped melt passage 200 aligned with the second melt passage 106 which branches in the front melt distribution manifold 18 2o and the single melt bore 70 extendina from the rear enr7 is of the heated nozzle 10 to the inner annular melt channel 66 to form part of the second melt passage 106. A small dowel 202 extends from a. melt transfer and dividing bushing 160 into the rear. melt distribution manifold 84 t~~ locate 25 the melt transfer and dividing bushing 160 with ithe four spaced outlets 184 in alignment with the four melt bores 74 extending from the rea~~ end 14 of the heated noz2;le 10 to the outer annular channel 68. The operation of this embodiment of the invention is the same as that described above, and need not be repeated.
While the description of the valve gated inj ection molding apparatus for f ive layer molding has been given with respect to preferred embodiments, it will be evident that various modifications are possible without departing from the scope of the invention as understood by those skilled in the art and as defined in the following claims. For instance, other materials having suitable characteristics can be: used rather' than PET, hVOH and nylon.
Claims (24)
1. In a multi-cavity sprue gated injection molding apparatus for multi-layer molding having at least one melt distribution manifold with a front face and a plurality of heated nozzles mounted in a mold, each heated nozzle having a rear end abutting against the at least one melt distribution manifold and a front end adjacent a gate leading to a cavity in the mold, each heated nozzle having a first central melt channel and second and third melt channels extending therethrough from the rear end to the front end, an elongated valve member having a rear end and a front end extending through the at least one melt distribution manifold into the central melt channel in each heated nozzle, the rear end of each elongated valve member being operatively connected to valve member actuating mechanism mounted in the mold, a first melt passage for conveying melt from a first melt source branching in the at least one melt distribution manifold dividing to extend both around the elongated valve member in the first central melt channel and through the third melt channel in each heated nozzle to the gate, and a second melt passage for conveying melt from a second melt source branching in the at least one melt distribution manifold and extending through the second melt channel in each heated nozzle to the gate, the improvement wherein;
each valve member actuating mechanism reciprocates the elongated valve member between a first closed position and second, third and fourth positions according to a continuous predetermined injection cycle, each valve member actuating mechanism comprising;
(a) means to retract the elongated valve member from the first closed position to the second position wherein the front end of the elongated valve member is retracted sufficiently to allow melt from the first melt source flow through the third melt channel in the heated nozzle and the gate into the cavity for a predetermined period of time, (b) means to then further retract the elongated valve member to the third position wherein the front end of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the second melt source through the second melt channel in the heated nozzle and from the first melt source through the third melt channel in the heated nozzle and the gate into the cavity for a predetermined period of time, (c) means to then further retract the elongated valve member to the fourth fully retracted open position wherein the front end of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the first melt source through the central melt channel in the heated nozzle, melt from the second melt source through the second melt channel in the heated nozzle and melt from the first melt source through the third melt channel in the heated nozzle and the gate until the cavity is almost filled, (d) means to then return the elongated valve member to the second position until the cavity is filled, and (e) means to first drive the elongated valve member forwardly to the first closed position wherein the front end of the elongated valve member is seated in the gate to allow for ejection.
each valve member actuating mechanism reciprocates the elongated valve member between a first closed position and second, third and fourth positions according to a continuous predetermined injection cycle, each valve member actuating mechanism comprising;
(a) means to retract the elongated valve member from the first closed position to the second position wherein the front end of the elongated valve member is retracted sufficiently to allow melt from the first melt source flow through the third melt channel in the heated nozzle and the gate into the cavity for a predetermined period of time, (b) means to then further retract the elongated valve member to the third position wherein the front end of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the second melt source through the second melt channel in the heated nozzle and from the first melt source through the third melt channel in the heated nozzle and the gate into the cavity for a predetermined period of time, (c) means to then further retract the elongated valve member to the fourth fully retracted open position wherein the front end of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the first melt source through the central melt channel in the heated nozzle, melt from the second melt source through the second melt channel in the heated nozzle and melt from the first melt source through the third melt channel in the heated nozzle and the gate until the cavity is almost filled, (d) means to then return the elongated valve member to the second position until the cavity is filled, and (e) means to first drive the elongated valve member forwardly to the first closed position wherein the front end of the elongated valve member is seated in the gate to allow for ejection.
2. ~Injection molding apparatus as claimed in claim 1 wherein the second melt channel through each heated nozzle includes an inner annular melt channel extending around the central melt channel to the front end, and the third melt channel through each heated nozzle includes an outer annular melt channel extending around the inner annular melt channel to the front end.
3. Injection molding apparatus as claimed in claim 2 wherein the melt from the first source is polyethylene terephthalate (PET).
4. Injection molding apparatus as claimed in claim 3 wherein the melt from the second source is ethylene vinyl alcohol copolymer (EVOH).
5. Injection molding apparatus as claimed in claim 3 wherein the melt from the second source is nylon.
6. Injection molding apparatus as claimed in claim 2 wherein the first and third melt passages from the first melt source branch in a front melt distribution manifold mounted in the mold and the second melt passage from the second melt source branches in a rear melt distribution manifold mounted in the mold.
7. Injection molding apparatus as claimed in claim 3 wherein the front melt distribution manifold extends substantially parallel to and is spaced a predetermined distance from the rear melt distribution manifold and the second melt passage from the second melt source branches in the rear melt distribution manifold and then extends through melt bores in the front melt distribution manifold.
8. Injection molding apparatus as claimed in claim 2 wherein the first and third melt passages from the first melt source branch in a rear melt distribution manifold mounted in the mold and the second melt passage from the second melt source branches in a front melt distribution manifold mounted in the mold.
9. Injection molding apparatus as claimed in claim 8 wherein the front melt distribution manifold extends substantially parallel to and is spaced a predetermined distance from the rear melt distribution manifold and the first and third melt passage from the first melt source branch in the rear melt distribution manifold and then extends through melt bores in the front melt distribution manifold.
10. In a multi-cavity sprue gated injection molding apparatus for multi-layer molding having at least one melt distribution manifold with a front face and a plurality of heated nozzles mounted in a mold, each heated nozzle having a rear end abutting against the at least one melt distribution manifold and a front end adjacent a gate leading to a cavity in the mold, each heated nozzle having a first central melt channel and second and third melt channels extending therethrough from the rear end to the front end, an elongated valve member having a rear end and a front end extending through the at least one melt distribution manifold into the central melt channel in each heated nozzle, the rear end of each elongated valve member being operatively connected to valve member actuating mechanism mounted in the mold, a first melt passage for conveying melt from a first melt source branching in the at least one melt distribution manifold dividing to extend both around the elongated valve member in the first central melt channel and through the third melt channel in each heated nozzle to the gate, and a second melt passage for conveying melt from a second melt source branching in the at least one melt distribution manifold and extending through the second melt channel in each heated nozzle to the gate, the improvement wherein;
each valve member actuating mechanism comprises a front cylinder and a rear cylinder both aligned in the mold with each elongated valve member, a first piston seated in the front cylinder and connected to the rear end of the elongated valve member, a second piston seated in the rear cylinder, and a third piston seated behind the second piston in the rear cylinder, the third piston having a stem portion which extends forwardly through an opening in the second piston into the first cylinder, first and second fluid lines from fluid pressure means connected to the front cylinder on opposite sides of the first piston, a third fluid line from fluid pressure means connected to the rear cylinder on the front side of the second piston, and a fourth fluid line from fluid pressure means connected to the rear cylinder on the rear side of the third piston, whereby applying fluid pressure through the first, second, third and fourth fluid pressure lines reciprocates the elongated valve member between a first closed position and second, third and fourth positions according to a continuous predetermined injection cycle wherein fluid pressure from the second fluid line is first released and fluid pressure is applied from the fourth fluid line to drive the second and third pistons forwardly and fluid pressure is applied from the first fluid line to drive the first piston and the elongated valve member rearwardly from the first closed position until the rear end of the first piston abuts against the front end of the third piston in the second position wherein the front end of the elongated valve member is retracted sufficiently to allow melt flow from the first melt source through the third melt channel in the heated nozzle and the gate, after a short predetermined period of time, fluid pressure is applied from the third fluid line to drive the second piston to a rear position which allows the fluid pressure from the first fluid line to drive the first piston and the elongated member further rearwardly to the third position wherein the front end of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the second melt source through the second melt channel in the heated nozzle and melt from the first melt source through the third melt channel in the heated nozzle and the gate into the cavity, and then fluid pressure from the fourth fluid line is released and fluid pressure from the first fluid line then drives the first and second pistons and the elongated valve member to the fourth fully retracted open position wherein the front end of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the first melt source through the central melt channel in the heated nozzle, melt from the second melt source through the second melt channel in the heated nozzle and melt from the first melt source through the third melt channel in the heated nozzle and the gate, when the cavity is almost filled, fluid pressure from the third fluid line is released and fluid pressure is reapplied from the fourth fluid line to drive the first, second and third pistons forwardly and return the elongated valve member to the second position until the cavity is filled, and then fluid pressure is applied from the second fluid line to drive the first piston and the elongated valve member forwardly to the first closed position wherein the front end of the elongated valve member is seated in the gate to allow for ejection.
each valve member actuating mechanism comprises a front cylinder and a rear cylinder both aligned in the mold with each elongated valve member, a first piston seated in the front cylinder and connected to the rear end of the elongated valve member, a second piston seated in the rear cylinder, and a third piston seated behind the second piston in the rear cylinder, the third piston having a stem portion which extends forwardly through an opening in the second piston into the first cylinder, first and second fluid lines from fluid pressure means connected to the front cylinder on opposite sides of the first piston, a third fluid line from fluid pressure means connected to the rear cylinder on the front side of the second piston, and a fourth fluid line from fluid pressure means connected to the rear cylinder on the rear side of the third piston, whereby applying fluid pressure through the first, second, third and fourth fluid pressure lines reciprocates the elongated valve member between a first closed position and second, third and fourth positions according to a continuous predetermined injection cycle wherein fluid pressure from the second fluid line is first released and fluid pressure is applied from the fourth fluid line to drive the second and third pistons forwardly and fluid pressure is applied from the first fluid line to drive the first piston and the elongated valve member rearwardly from the first closed position until the rear end of the first piston abuts against the front end of the third piston in the second position wherein the front end of the elongated valve member is retracted sufficiently to allow melt flow from the first melt source through the third melt channel in the heated nozzle and the gate, after a short predetermined period of time, fluid pressure is applied from the third fluid line to drive the second piston to a rear position which allows the fluid pressure from the first fluid line to drive the first piston and the elongated member further rearwardly to the third position wherein the front end of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the second melt source through the second melt channel in the heated nozzle and melt from the first melt source through the third melt channel in the heated nozzle and the gate into the cavity, and then fluid pressure from the fourth fluid line is released and fluid pressure from the first fluid line then drives the first and second pistons and the elongated valve member to the fourth fully retracted open position wherein the front end of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the first melt source through the central melt channel in the heated nozzle, melt from the second melt source through the second melt channel in the heated nozzle and melt from the first melt source through the third melt channel in the heated nozzle and the gate, when the cavity is almost filled, fluid pressure from the third fluid line is released and fluid pressure is reapplied from the fourth fluid line to drive the first, second and third pistons forwardly and return the elongated valve member to the second position until the cavity is filled, and then fluid pressure is applied from the second fluid line to drive the first piston and the elongated valve member forwardly to the first closed position wherein the front end of the elongated valve member is seated in the gate to allow for ejection.
11. Injection molding apparatus as claimed in claim 10 wherein the second melt channel through each heated nozzle includes an inner annular melt channel extending around the central melt channel to the front end, and the third melt channel through each heated nozzle includes an outer annular melt channel extending around the inner annular melt channel to the front end.
12. A method of continuously injection molding five layer products of two different materials in a multi-cavity injection molding apparatus having at least one melt distribution manifold with a front face and a plurality of heated nozzles mounted in a mold, each heated nozzle having a rear end abutting against the at least one melt distribution manifold and a front end adjacent a gate leading to a cavity in the mold, each heated nozzle having a first central melt channel and second and third melt channels extending therethrough from the rear end to the front end, an elongated valve member having a rear end and a front end extending through the at least one melt distribution manifold into the central melt channel in each heated nozzle, the rear end of each elongated valve member being operatively connected to valve member actuating mechanism mounted in the mold, a first melt passage for conveying melt from a first melt source branching in the at least one melt distribution manifold dividing to extend both around the elongated valve member in the first central melt channel and through the third melt channel in each heated nozzle to the gate, and a second melt passage for conveying melt from a second melt source branching in the at least one melt distribution manifold and extending through the second melt channel in each heated nozzle to the gate, comprising the steps of;
(a) retracting the elongated valve member from a first closed position to a second position wherein the front end of the elongated valve member is retracted sufficiently to allow melt from the first melt source flow through the third melt channel in the heated nozzle and the gate into the cavity for a predetermined period of time, (b) further retracting the elongated valve member to a third position wherein the front end of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the second melt source through the second melt channel in the heated nozzle and from the first melt source through the third melt channel in the heated nozzle and the gate into the cavity for a predetermined period of time, (c) further retracting the elongated valve member to a fourth fully retracted open position wherein the front end of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the first melt source to the central melt channel in the heated nozzle, melt from the second melt source through the second melt channel in the heated nozzle and melt from the first melt source through the third melt channel in the heated nozzle and the gate until the cavity is almost filled, (d) then returning the elongated valve member to the second position until the cavity is filled, and (e) driving the elongated valve member forwardly to the first closed position wherein the front end of the elongated valve member is seated in the gate to allow for ejection.
(a) retracting the elongated valve member from a first closed position to a second position wherein the front end of the elongated valve member is retracted sufficiently to allow melt from the first melt source flow through the third melt channel in the heated nozzle and the gate into the cavity for a predetermined period of time, (b) further retracting the elongated valve member to a third position wherein the front end of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the second melt source through the second melt channel in the heated nozzle and from the first melt source through the third melt channel in the heated nozzle and the gate into the cavity for a predetermined period of time, (c) further retracting the elongated valve member to a fourth fully retracted open position wherein the front end of the elongated valve member is retracted sufficiently to allow simultaneous flow of melt from the first melt source to the central melt channel in the heated nozzle, melt from the second melt source through the second melt channel in the heated nozzle and melt from the first melt source through the third melt channel in the heated nozzle and the gate until the cavity is almost filled, (d) then returning the elongated valve member to the second position until the cavity is filled, and (e) driving the elongated valve member forwardly to the first closed position wherein the front end of the elongated valve member is seated in the gate to allow for ejection.
13. A method of injection molding as claimed in claim 12 wherein the melt from the first melt source flows through an outer annular melt channel extending in each heated nozzle around the inner annular melt channel to the front end, and the melt from the second melt source flows through an inner annular melt channel extending in each heated nozzle around the central melt channel to the front end.
14. A method of injection molding as claimed in claim 12 wherein the melt from the first source is polyethylene terephthalate (PET).
15. A method of injection molding as claimed in claim 12 wherein the melt from the second source is ethylene vinyl alcohol copolymer (EVOH).
16. A method of injection molding as claimed in claim 12 wherein the melt from the second source is nylon.
17. A method of injection molding as claimed in claim 12 wherein the melt from the first melt source flowing through the first and third melt passages branches in a front melt distribution manifold mounted in the mold and the melt from the second melt source flowing through the second melt passage branches in a rear melt distribution manifold mounted in the mold.
18. A method of injection molding as claimed in claim 17 wherein the front melt distribution manifold extends substantially parallel to and is spaced a predetermined distance from the rear melt distribution manifold and the melt from the second melt source flowing through the second melt passage branches in the rear melt distribution manifold and then flows through melt bores in the front melt distribution manifold.
19. A method of injection molding as claimed in claim 12 wherein the melt from the first melt source flowing through the first and third melt passages branches in a rear melt distribution manifold mounted in the mold and the melt from the second melt source flowing through the second melt passage branches in a front melt distribution manifold mounted in the mold.
20. A method of injection molding as claimed in claim 19 wherein the front melt distribution manifold extends substantially parallel to and is spaced a predetermined distance from the rear melt distribution manifold and the melt from the first melt source flowing through the first and third melt passage branches in the rear melt distribution manifold and then flows through melt bores in the front melt distribution manifold.
21. A method of manufacturing a molded article from two different materials to form a five layer wall structure comprising the steps of:
(a) injecting a certain amount of first material through a first melt channel of an injection nozzle, (b) injecting a certain amount of a second material through a second melt channel of said injection nozzle, while continuing to inject a certain amount of the first material, (c) injecting a certain amount of the first material through a third melt channel of said injection nozzle, while continuing to inject said second material through said second melt channel and said first material through said first melt channel, and (d) closing said second melt channel and said third melt channel and injecting a final amount of the first material through said first melt channel of said injection nozzle.
(a) injecting a certain amount of first material through a first melt channel of an injection nozzle, (b) injecting a certain amount of a second material through a second melt channel of said injection nozzle, while continuing to inject a certain amount of the first material, (c) injecting a certain amount of the first material through a third melt channel of said injection nozzle, while continuing to inject said second material through said second melt channel and said first material through said first melt channel, and (d) closing said second melt channel and said third melt channel and injecting a final amount of the first material through said first melt channel of said injection nozzle.
22. A method of manufacturing a molded article from two different materials to form a five layer wall structure according to claim 21 whereby a movable valve pin regulates the flow through said first, second and third melt channels.
23. A method of manufacturing a molded article from two different materials to form a five layer wall structure according to claim 21, whereby one of the two materials travels through the nozzle via two separate and concentric melt channels.
24. A method of manufacturing a molded article from two different materials to form a five layer wall structure comprising the steps of:
(a) providing a first source of a first molten material, and a second source of a second molten material, (b) providing separate heated manifolds for the first and second molten materials, (c) providing at least one injection nozzle in fluid communication with both manifolds having first and third melt channels for the first molten material and a second channel for the second molten material, (d) providing a valve gating device to control the flow of the two molten materials through the channels through the nozzle, and (e) injecting the first molten material into a mold cavity through the first melt channel, then sequentially injecting the second molten material through the second melt channel while the first molten material is being injected and then sequentially injecting the first molten material through the third melt channel while the molten material flows through the first and second melt channels to form in the cavity an article having three layers of a first material and two layers of a second material.
(a) providing a first source of a first molten material, and a second source of a second molten material, (b) providing separate heated manifolds for the first and second molten materials, (c) providing at least one injection nozzle in fluid communication with both manifolds having first and third melt channels for the first molten material and a second channel for the second molten material, (d) providing a valve gating device to control the flow of the two molten materials through the channels through the nozzle, and (e) injecting the first molten material into a mold cavity through the first melt channel, then sequentially injecting the second molten material through the second melt channel while the first molten material is being injected and then sequentially injecting the first molten material through the third melt channel while the molten material flows through the first and second melt channels to form in the cavity an article having three layers of a first material and two layers of a second material.
Priority Applications (10)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002219235A CA2219235C (en) | 1997-10-23 | 1997-10-23 | Five layer injection molding apparatus having four position valve member actuating mechanism |
| US08/977,676 US6074191A (en) | 1997-10-23 | 1997-11-24 | Five layer injection molding apparatus having four position valve member actuating mechanism |
| DE19848818A DE19848818A1 (en) | 1997-10-23 | 1998-10-22 | Five-layer injection molding device with four position valve actuation mechanisms |
| AT98120005T ATE236002T1 (en) | 1997-10-23 | 1998-10-22 | INJECTION MOLDING DEVICE WITH FOUR-POSITION VALVE PART FOR PRODUCING FIVE-LAYER OBJECTS |
| DE69812835T DE69812835T2 (en) | 1997-10-23 | 1998-10-22 | Injection molding device with four-position valve part for the production of five-layer objects |
| EP98120005A EP0911134B1 (en) | 1997-10-23 | 1998-10-22 | Five layer injection molding apparatus having four position valve member actuating mechanism |
| BR9804434-6A BR9804434A (en) | 1997-10-23 | 1998-10-22 | Multi-layer injection molding machine with four-position valve member drive mechanism and method for molding multi-layer products by continuous injection |
| CN98120197A CN1102097C (en) | 1997-10-23 | 1998-10-23 | Multi-cavity injection molding apparatus |
| JP10302754A JPH11235737A (en) | 1997-10-23 | 1998-10-23 | Injection molding apparatus and injection molding method |
| US09/327,641 US6274075B1 (en) | 1997-10-23 | 1999-06-08 | Five layer injection molding apparatus having four position valve member actuating mechanism |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002219235A CA2219235C (en) | 1997-10-23 | 1997-10-23 | Five layer injection molding apparatus having four position valve member actuating mechanism |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2219235A1 CA2219235A1 (en) | 1999-04-23 |
| CA2219235C true CA2219235C (en) | 2006-12-12 |
Family
ID=4161684
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002219235A Expired - Fee Related CA2219235C (en) | 1997-10-23 | 1997-10-23 | Five layer injection molding apparatus having four position valve member actuating mechanism |
Country Status (8)
| Country | Link |
|---|---|
| US (2) | US6074191A (en) |
| EP (1) | EP0911134B1 (en) |
| JP (1) | JPH11235737A (en) |
| CN (1) | CN1102097C (en) |
| AT (1) | ATE236002T1 (en) |
| BR (1) | BR9804434A (en) |
| CA (1) | CA2219235C (en) |
| DE (2) | DE69812835T2 (en) |
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| DE3478211D1 (en) * | 1983-09-03 | 1989-06-22 | Hennecke Gmbh Maschf | Multiple nozzle for bringing together at least two free-flowing reactants forming plastic, in particular foamed plastic, in order to start the reaction by mixing, and method of operating said multiple nozzle |
| US4657496A (en) * | 1984-06-04 | 1987-04-14 | Gifu Husky Co., Ltd. | Hot-runner mold for injection molding |
| US4808101A (en) * | 1986-05-12 | 1989-02-28 | Husky Injection Molding Systems Ltd. | Tri-injection of hollow articles |
| GB8616460D0 (en) * | 1986-07-05 | 1986-08-13 | Metal Box Plc | Manufacture of articles |
| US4863665A (en) * | 1987-05-18 | 1989-09-05 | Husky Injection Molding Systems, Ltd. | Tri-injection of hollow articles |
| US5049345A (en) * | 1988-11-01 | 1991-09-17 | Continental Pet Technologies, Inc. | Method of forming a multi-layer preform |
| US5032341A (en) * | 1988-12-30 | 1991-07-16 | Continental Pet Technologies, Inc. | Method of forming two material three/five layer preform |
| US5098274A (en) * | 1989-01-25 | 1992-03-24 | Continental Pet Technologies, Inc. | Apparatus for injection molding of multilayer preforms |
| JP2890607B2 (en) * | 1990-02-16 | 1999-05-17 | 凸版印刷株式会社 | Injection molding nozzle |
| EP0480223B1 (en) * | 1990-10-12 | 1995-08-30 | Jobst Ulrich Gellert | Multi-cavity injection moulding system |
| US5143733A (en) * | 1991-04-19 | 1992-09-01 | Husky Injection Molding Systems Ltd. | Injection molding apparatus |
| US5972258A (en) * | 1997-10-20 | 1999-10-26 | Husky Injection Molding Systems Ltd. | Method of using a multiple gating nozzle |
| CA2219260C (en) * | 1997-10-23 | 2006-12-05 | Mold-Masters Limited | Injection molding apparatus having inter-manifold melt transfer bushings |
| CA2219257C (en) * | 1997-10-23 | 2005-05-31 | Mold-Masters Limited | Sprue gated five layer injection molding apparatus |
| CA2219247C (en) * | 1997-10-23 | 2006-12-05 | Mold-Masters Limited | Injection molding apparatus having a melt bore through the front end of the pin |
| CA2219197C (en) * | 1997-10-23 | 2006-12-05 | Mold-Masters Limited | Injection molding apparatus having melt transfer and dividing bushing |
| CA2225287C (en) * | 1997-12-18 | 2005-09-13 | Mold-Masters Limited | Multi-layer injection molding apparatus having three position valve member |
-
1997
- 1997-10-23 CA CA002219235A patent/CA2219235C/en not_active Expired - Fee Related
- 1997-11-24 US US08/977,676 patent/US6074191A/en not_active Expired - Lifetime
-
1998
- 1998-10-22 DE DE69812835T patent/DE69812835T2/en not_active Expired - Lifetime
- 1998-10-22 BR BR9804434-6A patent/BR9804434A/en not_active IP Right Cessation
- 1998-10-22 EP EP98120005A patent/EP0911134B1/en not_active Expired - Lifetime
- 1998-10-22 DE DE19848818A patent/DE19848818A1/en not_active Withdrawn
- 1998-10-22 AT AT98120005T patent/ATE236002T1/en not_active IP Right Cessation
- 1998-10-23 JP JP10302754A patent/JPH11235737A/en not_active Withdrawn
- 1998-10-23 CN CN98120197A patent/CN1102097C/en not_active Expired - Lifetime
-
1999
- 1999-06-08 US US09/327,641 patent/US6274075B1/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| US6274075B1 (en) | 2001-08-14 |
| CN1102097C (en) | 2003-02-26 |
| CA2219235A1 (en) | 1999-04-23 |
| DE69812835T2 (en) | 2003-11-06 |
| DE19848818A1 (en) | 1999-04-29 |
| US6074191A (en) | 2000-06-13 |
| EP0911134A3 (en) | 2000-05-17 |
| DE69812835D1 (en) | 2003-05-08 |
| JPH11235737A (en) | 1999-08-31 |
| EP0911134A2 (en) | 1999-04-28 |
| BR9804434A (en) | 1999-11-23 |
| EP0911134B1 (en) | 2003-04-02 |
| CN1215657A (en) | 1999-05-05 |
| ATE236002T1 (en) | 2003-04-15 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| MKLA | Lapsed |