ROTARY HIGH SPEED LOW COMPRESSION THERMOPLASTIC MOLDING METHOD AND APPARATUS

Abstract

A molding apparatus includes a plurality of deep-draw compression molds. Each of the molds includes a mold cavity and an associated mold core. A rotating support structure operatively supports the mold cavities and the mold cores relative to each other. The molds open and close as they travel around a closed path defined by the support structure. A mold material discharge mechanism deposits a predetermined amount of mold material in each of the molds. A heat source superheats the molds, and a mold closing mechanism closes the superheated molds, compressing the mold material between the mold cavities and the mold cores to form a deep-draw component A coolant source rapidly and actively cools the molds, and a mold opening mechanism opens the cooled molds. An ejector is disposed to eject the deep draw components from the molds. A method of molding deep-draw components is also disclosed. The system and method of the present invention facilitate compression molding of deep-draw components.

Claims

1-19. (canceled)

20. A molding apparatus comprising: a plurality of deep-draw compression molds, each of said molds including a mold cavity and an associated mold core, wherein said deep-draw compression molds have a depth to diameter ratio that is greater than one and at least a portion of the associated mold core fits into said mold cavity when said mold is closed; a rotating support structure operatively supporting said mold cavities and said mold cores relative to each other, said molds opening and closing as they travel around a closed path defined by said support structure; a mold material discharge mechanism operative to sequentially deposit a slug including a predetermined amount of mold material onto the mold core of each of said molds and/or into the mold cavity of each of said molds as said molds pass a first predetermined position along said closed path; a heat source physically coupled to the mold cavity and the mold core, the heat source preheating said molds to a temperature exceeding 212 degrees Fahrenheit before said molds are closed and continuing to heat said mold cavities and mold cores after said molds are closed as said molds travel between said first predetermined position and a second predetermined position along said closed path; a mold closing mechanism disposed to close said heated molds, compressing said mold material between said mold cavities and said mold cores to form a deep-draw component having the depth to diameter ratio that is greater than one, as said molds travel between said second predetermined position and a third predetermined position along said closed path, said heat source continuing to heat said mold cavities and said mold cores after said molds are closed; a coolant source coupled to cool said mold cavities and said mold cores while said molds are closed, wherein the coolant source cools said molds as said molds travel between said third predetermined position and a fourth predetermined position along said closed path; a mold opening mechanism disposed to open said cooled molds as said molds travel between said fourth predetermined position and a fifth predetermined position along said closed path; and an ejector disposed to eject said deep-draw components from said molds as said molds pass a sixth predetermined position along said closed path.

21. The molding apparatus of claim 20, wherein said depth to diameter ratio of said deep-draw compression molds is greater than ten.

22. The molding apparatus of claim 20, wherein said heat source conducts super-heated water.

23. The molding apparatus of claim 20, wherein said heat source conducts steam.

24. The molding apparatus of claim 20, wherein said deep-draw compression molds are designed to mold syringe barrels.

25. The molding apparatus of claim 20, wherein said deep-draw compression molds are symmetrical about an axis passing through said mold.

26. The molding apparatus of claim 20, wherein said mold cores retract after said molds are opened.

27. The molding apparatus of claim 20, wherein said deep-draw compression molds have an elliptical or polygonal cross-section.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The present invention is described with reference to the following drawings, wherein like reference numbers denote substantially similar elements:

[0020] FIG. 1 is a representational diagram of a rotary compression molding apparatus;

[0021] FIG. 2 shows a compression mold at various stages of a compression molding process; and

[0022] FIG. 3 is a flow chart summarizing one method of compression molding a deep draw component.

DETAILED DESCRIPTION

[0023] The present invention overcomes the problems associated with the prior art, by providing a high-speed rotary compression molding method and apparatus. The method and apparatus facilitate compression molding of deep-draw components such as syringe barrels by super-heating the compression molds using, for example, steam or super-heated water. In the following description, numerous specific details are set forth (e.g., number of molds, shape of path of mold travel, etc.) in order to provide a thorough understanding of the invention. Those skilled in the art will recognize, however, that the invention may be practiced apart from these specific details. In other instances, details of well known compression molding practices (e.g., plumbing and wiring details of machine, specific molding materials, etc.) and components (e.g., plumbing and wiring details of machines, etc.) have been omitted, so as not to unnecessarily obscure the present invention.

[0024] FIG. 1 is a top view of a representational diagram of a rotary high-speed, low compression thermoplastic molding machine. Rotary compression molding machines are generally known in the art and commercially available. However, except as modified by the present invention, known compression molding machines are considered to be incapable of successfully molding deep-draw, thin walled components.

[0025] Molding machine 100 includes a plurality (32 in this particular example) of deep-draw compression molds 102, which are supported by a rotating support structure 103. In this embodiment, support structure 103 is circular, so that the molds repeatedly traverse a circular path during the operation of molding machine 100. However, neither the shape of the path, nor the number of molds, is essential to the practice of the invention.

[0026] Indeed, the path and the number of molds can be modified to provide more heating and/or cooling time, as might be required for a particular molding process. Extending the path by adding additional molds will increase the time allowed for each molded component to be heated or cooled, but will not adversely affect the overall production rate, because the molds are continuously (one at a time) filled and emptied.

[0027] Molding machine 100 further includes a mold material (e.g., thermoplastic) discharge mechanism 104 that sequentially deposits a predetermined amount of mold material 106 into each compression mold 102, as each mold 102 passes between a first position 108 and a second position 110 along the mold's path of travel.

[0028] As a particular mold 102 travels between second position 110 and a third position 112, mold 102 is super-heated and closed, and as mold 102 passes between third position 112 and a fourth position 114 the mold compresses the molding material to form a deep-draw component. Between fourth position 114 and a fifth position 116, the mold 102 is actively and rapidly cooled. Then, between fifth position 116 and a sixth position 118, mold 102 is opened.

[0029] Molding machine 100 further includes an ejector 120 that removes the molded deep-draw components 126 from molds 102, as molds 102 pass between sixth position 118 and first position 108, where mold 102 begins the next cycle of operation. A transfer mechanism 122 receives deep-draw components 126 from ejector 120 and transfers the components 126 to a conveyor system 124, which transports the finished deep-draw components 126 away from molding machine 100.

[0030] Superheating molds 102 significantly reduces the viscosity of the molding material 106 and facilitates the compression molding of deep-draw components, even deep-draw components having thin walls. Deep-draw components have a depth-to-diameter ratio of greater than one, and components having a depth-to-diameter ratio of greater than ten can be molded using the process. Although the present inventive method is not limited to deep-draw components having a circular cross section, particularly good results are achieved when the deep draw component is symmetrical about a longitudinal axis passing through the component. Nevertheless, deep-draw components having elliptical, polygonal, and even irregular cross-sections can be successfully molded using the present invention.

[0031] In general, superheating is considered to be heating to temperatures exceeding the normal boiling point of water (212 degrees Fahrenheit). Superheating of molds 102 can be accomplished using steam, superheated water, or any other suitable thermal regulating fluid. The thermal regulating fluid (e.g., steam) is conducted through fluid passages (not shown) formed in the molds 102. Known molds already include fluid passages for heating and cooling fluids of more moderate temperatures. Therefore, these existing fluid passages can be used to superheat the molds, with little or no modification.

[0032] FIG. 2 is a time sequential diagram of a deep-draw compression mold 102, over one cycle of the compression molding process of the present invention. Each mold 102 includes a mold cavity 202 and a mold core 204. Between a first time 208 and a second time 210, mold material discharge mechanism 104 places a slug of mold material 106 on mold core 204. Then, between second time 210 and a third time 212, mold cavity 202 and mold core 204 are superheated. Next, between third time 212 and a fourth time 214, mold 102 is closed, heating of cavity 202 and core 204 continues, and compression molding of material 106 to form a deep-draw component occurs. Then, between fourth time 214 and a fifth time 216, the cavity 202 and the core 204 of mold 102 are actively and rapidly cooled. Next, between fifth time 216 and a sixth time 218, mold 102 is opened. Finally, after sixth time 218, core 204 retracts, and the formed deep-draw component 220 is removed from mold 102.

[0033] FIG. 3 is a flow chart summarizing one example method of molding a deep-draw component according to the present invention. In a first step 302, a plurality of deep-draw molds are provided. Then, in a second step 304, the molds are arranged on a support structure. Next, in a third step 306, the molds are caused to traverse a closed path. Then, in a fourth step 308, a predetermined amount of mold material is sequentially deposited in each mold. Next, in a fifth step 310, the molds are superheated. Then, in a sixth step 312, the mold material is compressed in the superheated molds to form deep-draw components. Next, in a seventh step 314, the molds are rapidly and actively cooled. Then, in an eighth step 316, the molds are opened, and in a ninth step 318, the deep-draw components are ejected from the molds. It should be understood, that the present method is sequentially performed on a plurality of molds, so that the steps of the process are performed with each mold at slightly different times.

[0034] The description of particular embodiments of the present invention is now complete. Many of the described features may be substituted, altered or omitted without departing from the scope of the invention. For example, alternate heaters (e.g., resistive electrical heaters), may be substituted for the thermal regulating fluid used to superheat molds 102. As another example, a greater number of molds and a longer process path can be employed to allow greater cooling time. These and other deviations from the particular embodiments shown will be apparent to those skilled in the art, particularly in view of the foregoing disclosure.