Abstract
A modular mold assembly comprising two mold halves wherein each mold half comprises separable and interchangeable components that allow for the production of a plurality of unique glass containers is discloses. A new method of manufacturing customized glass containers which utilizes such modular mold assembly is also disclosed.
Claims
1. A modular mold assembly used to make a glass container having a unique shape and/or design, the modular mold assembly comprising: two modular mold half shells, a first modular mold half shell and a second modular half shell, wherein each modular half shell comprises separable and interchangeable components wherein the components are releasably secured together; a neck ring and a bottom plate.
2. The modular mold assembly of claim 1, wherein each modular half shell comprises separable and interchangeable components comprising an upper mold component releasably secured to a receiver mold component which is releasably secured to a lower mold component.
3. The modular mold assembly of claim 2, wherein each upper mold component comprises upper inner walls that are configured to define an upper cavity when the upper mold components of each half shell are pressed together during glass container formation, wherein the upper cavity has a shape and design which conforms to the shape and design of the upper portion of the glass container to be formed, wherein each receiver mold component comprises receiver inner walls that are configured to define a middle cavity when the receiver mold components of each half shell are pressed together during glass container formation, wherein the receiver cavity has a shape and design which conforms to the shape and design of the receiver portion of the glass container to be formed; and wherein each lower mold component comprises lower inner walls that are configured to define a lower cavity when the lower mold components of each half shell are pressed together during glass container formation, wherein the lower cavity has a shape and design which conforms to the shape and design of the lower portion of the glass container to be formed.
4. A method of manufacturing customized glass containers, the method comprising the following step of: (a) using a modular mold assembly having a unique shape and/or design in a glass formation machine, the modular mold assembly comprising: (1) two modular mold half shells, a first modular mold half shell and a second modular half shell, wherein each modular half shell comprises separable and interchangeable components wherein the components are releasably secured together; (2) a neck ring and (3) a bottom plate.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] The present disclosure will be better understood by reference to the following detailed description when considered in conjunction with the following drawings wherein:
[0020] FIG. 1 is a plan view of the modular mold assembly according to a sample embodiment;
[0021] FIG. 2A is a exploded view of the main components of a modular mold assembly of FIG. 1;
[0022] FIG. 2B is a side perspective view of the modular mold assembly of FIG. 1;
[0023] FIG. 3A is an exploded view of the main components of a non modular mold assembly;
[0024] FIG. 3B is a side perspective view of a non modular mold assembly of FIG. 3A;
[0025] FIG. 4 is a perspective view of the inner walls of a mold half shell of a modular mold assembly comprising separable and interchangeable components according to one example embodiment;
[0026] FIG. 5 is a partial enlarged perspective view of the inner walls of an upper mold component of the mold half shell of FIG. 4;
[0027] FIG. 6 is a partial enlarged perspective view of the inner walls of a receiver mold component of the mold half shell of FIG. 4;
[0028] FIG. 7 is a partial enlarged perspective view of the inner walls of a lower mold component of the mold half shell of FIG. 4;
[0029] FIG. 8 is a partial enlarged side sectional view of the upper mold components of modular mold assembly of FIG. 2A according to one example embodiment;
[0030] FIG. 9 is a partial enlarged side section view of the upper mold components according to a second example embodiment;
[0031] FIG. 10 is a partial enlarged side section view of the receiver mold components of modular mold assembly of FIG. 2A according to one example embodiment;
[0032] FIG. 11 is a partial enlarged side section view of the lower mold components of modular mold assembly of FIG. 2A according to one example embodiment;
[0033] FIG. 12 is a side sectional view of the modular mold assembly as seen at line A-A in FIG. 1;
[0034] FIG. 13 depicts customized bottles produced by the modular mold assembly according to one example embodiment;
[0035] FIG. 14 depicts a blank mold used to manufacture a parison;
[0036] FIG. 15 depicts customized bottles produced by the modular mold assembly according to a second example embodiment;
[0037] FIG. 16 depicts an additional view of the bottles shown in FIG. 15;
[0038] FIG. 17 is a perspective view of the inner walls of a mold half shell of a modular mold assembly comprising separable and interchangeable components according to a second example embodiment;
[0039] FIG. 18 is a perspective view of the outer walls of the mold half shell of the modular mold assembly of FIG. 17;
[0040] FIG. 19 is an exploded view of the inner walls of the main components of the mold half shell of a modular mold assembly of FIG. 17;
[0041] FIG. 20 is a exploded rear view of the main components of the mold half shell of a modular mold assembly of FIG. 17;
[0042] FIG. 21 depicts customized glass containers produced by the modular mold assembly according to a third example embodiment;
[0043] FIG. 22 depicts an additional view of the glass containers shown in FIG. 22;
[0044] FIG. 23 is a perspective view of the inner walls of a mold half shell of a modular mold assembly comprising separable and interchangeable components according to a further example embodiment;
[0045] FIG. 24 is an exploded perspective view of the separable and interchangeable components of a mold half shell of a modular mold assembly of FIG. 23.
[0046] FIG. 25 is an exploded perspective view of the separable and interchangeable components of FIG. 23.
[0047] FIG. 26 is a perspective view of the assembled components of FIG. 23 positioned in front on the module component holder of FIG. 23.
[0048] FIG. 27 is a rear perspective view of FIG. 23.
[0049] FIG. 28 is a rear perspective view of FIG. 25.
DETAILED DESCRIPTION
[0050] As set forth above and incorporated herein, the manufacturing process of glass containers involves a detailed process. Glass container manufacturing starts with a design of the glass container to be formed during the manufacturing process. Glass manufacturers work closely with their customers to make sure that the design provides the best combination of appearance, strength, weight and ease of handling. Designers concentrate on each area of the container including the finish, closure, neck, shoulder, sidewall, heel and bottom. Once the design of the glass container is determined, a mold set for a blank mold and a blow mold is manufactured based on the custom design. Once the mold set for the blank mold and blow mold have been tested and approved for the manufacture of the desired glass container, a plurality of mold sets are produced and implemented into the individual sections of a forming machine. Each section of a forming machine comprises one or more mold sets determined by the size of the container to be formed. A typical mold set for the blow mold comprises: two standard mold halves, a mold bottom plate and a neck ring. Both the blow mold and the blank mold comprise two mold half shells made of metal, wherein the mold halves close together within the forming machine to form the parison (by the blank mold) or the final container (by the blow mold).
[0051] Referring to FIGS. 1 and 2, a modular mold assembly 100 comprising a plurality of separable and interchangeable components used to produce a plurality of glass containers each with a unique design is disclosed. In one embodiment, a modular mold assembly 100 may be used in the glass container manufacturing process to form the final container such as a bottle or jar. A modular mold assembly provides the same function in the glass container manufacturing process as a blow mold.
[0052] Referring now to FIG. 2A, in one embodiment, a modular mold assembly 100 used to form a glass container comprises two modular mold half shells: a first modular mold half shell 200, a second modular mold half shell 202, a neck ring 204 and a bottom plate 206. Each modular mold half shell 200 and 202 comprises a plurality of separable and interchangeable components that allow for the production of a plurality of glass containers each having a unique, customized design. Referring to FIGS. 3A and 3B, a non modular mold assembly 300 is shown wherein the mold half shells 302 and 304 each comprise one unitary, non-modular component which limits such non modular mold assembly to producing a plurality of glass containers each having the same design. Non modular mold assembly 300 includes neck ring 306 and bottom plate 308.
[0053] Referring now to FIG. 4, in one embodiment, modular half shell 200 comprises an upper mold component 408, a receiver mold component 410 and a lower mold component 412, wherein the three components are releasably secured together. In one embodiment, the three components are releasably secured together by a plurality of screws. The plurality of components may be secured together by other means as desired by one of skill in the art. Modular half shell 200 corresponds with modular half shell 202 (not shown in FIG. 4) to form a blow mold. During the forming process, the half shells 200 and 202 close together to shape and form a glass container 414.
[0054] Referring now to FIGS. 5, 8 and 9, in one embodiment, the upper mold components 408 and 508 of both the first and second modular mold half shells 200 and 202 have upper inner walls that define an upper cavity whose shape and design conform to the shape and design of the upper portion of the container to be formed. The upper portion of the container to be formed comprises the shoulder and neck of the container to be formed. Referring now to FIGS. 6 and 10, the receiver mold components 410 and 510 of both the first and second modular mold half shells have receiver inner walls that define a middle cavity whose shape and design conform to the shape and design of the middle portion of the container to be formed. The middle portion of the container to be formed comprises the sidewall. Referring to FIGS. 7 and 11, the lower mold components 412 and 512 of both the first and second modular mold half shells have lower inner walls that define a lower cavity whose shape and design conform to the shape and design of the lower portion of the container to be formed. The lower portion of the container to be formed comprises the heel of the bottle.
[0055] Referring now to FIGS. 8-12, in one embodiment, an upper mold component 408 of the first modular half shell is releasably secured to a receiver mold component 410 of the first modular half shell. Upper mold component 508 of the second modular half shell is releasably secured to a receiver mold component 510 of the second modular half shell. In one embodiment, the upper mold components 408 and 508 of the first and/or second modular half shells, wherein each upper mold component comprises upper inner walls that define an upper cavity having a first particular shape and design, may be interchanged with another upper mold component having upper inner walls that define an upper cavity having a second particular shape and design as long as the structure of the upper mold components of the first and second modular half shells allows the upper mold components of the first and second modular half shells to be releasably secured to the corresponding receiver mold components of the first and second modular half shell. The shape and design of the upper inner walls that define an upper cavity may vary as desired by one of skill in the art to create a plurality of unique, customized containers, as long as the structure of the upper mold component allows the upper mold component to be releasably secured to its corresponding receiver mold component.
[0056] Referring to FIGS. 8, 9, and 11, in one embodiment, upper and lower mold components comprise an interlocking section that travels along the outside circumference of the components. Interlocking section of both upper and lower mold components comprises a vertical curved outer wall 802 and a horizontal ledge 804 perpendicular to the vertical outer wall.
[0057] In one embodiment, each receiver mold component comprises an upper receiving section 900 and a lower receiving section 902. Upper receiving section receives and interlocks with interlocking section of upper mold component. Lower receiving section of receiver mold component receives and interlocks with interlocking section of lower mold components Each receiving section of receiver mold component comprises a vertical curved inner wall and a horizontal ledge perpendicular to the vertical inner wall. In one embodiment, vertical curved inner wall of each receiving section comprises three apertures configured to align with three corresponding apertures on upper and lower mold components. In one embodiment, the apertures may be threaded to receive screws. In one example embodiment, screws may be used to secure receiver mold component to the corresponding upper and lower mold component to form a first and second modular half shell. In another embodiment, cap screws designed to be seated in countersunk apertures are used to secure receiver mold component to the corresponding upper and lower mold components to form a first and second modular half shell.
[0058] In one embodiment, a receiver (or middle) mold component of a first modular half shell may be releasably secured to both an upper mold component of a first modular half shell and a lower mold component of a first modular half shell. A receiver (or middle) mold component of a second modular half shell may be releasably secured to both an upper mold component of a second modular half shell and a lower mold component of a second modular half shell. One or both of the receiver mold components of a first and/or second modular half shell, wherein the receiver mold components comprise receiver inner walls that define a receiver cavity having a first particular shape and design, may be interchanged with another receiver mold component having receiver inner walls that define a receiver cavity having a second unique shape and design as long as the structure of the receiver mold components of the first and second modular half shells allows the receiver mold components of the first and second modular half shells to be releasably secured to both a corresponding upper and lower mold component. The shape and design of the receiver inner walls that define a receiver cavity may vary as desired by one of skill in the art to create a plurality of unique, customized glass containers, as long as the structure of the receiver mold component allows the receiver mold component to be releasably secured to both a corresponding upper mold component and a lower mold component.
[0059] In another embodiment, a lower mold component of the first modular half shell is releasably secured to a corresponding receiver mold component of the first modular half shell. A lower mold component of the second modular half shell is releasably secured to a corresponding lower mold component of the second modular half shell. In one embodiment, one or both lower mold components of the first and/or second modular half shells, wherein the lower mold components comprise lower inner walls that define a lower cavity having a first particular shape and design, may be interchanged with one or both alternative lower mold components having lower inner walls that define a lower cavity having a second particular shape and design as long as the structure of the lower mold components of the first and/or second modular half shells allows the lower mold components of the first and second modular half shells to be releasably secured to the corresponding receiver mold components of the first and second modular half shell. The shape and design of the lower inner walls that define a lower cavity may vary as desired by one of skill in the art to create a plurality of unique, customized containers, as long as the structure of the upper mold component allows the upper mold component to be releasably secured to the receiver mold component.
[0060] Referring now to FIG. 13, in one example embodiment, modular mold assembly 100 may be used to produce a glass container shape which may be customized to suit the custom needs of a variety of customers. In one example embodiment, modular mold assembly 100 comprising separable and interchangeable upper, receiver, and lower mold components allows various custom styles of a container to be manufactured at a minimized cost. Each of the exemplary customized bottles, shown in FIG. 13, would typically utilize the same blank mold but would require a different blow mold, thus requiring an entire mold set to be manufactured for each customized bottle. Modular mold assembly 100 allows the formation of custom glass containers as exemplified in FIG. 13 without the formation of a complete mold set for each custom designed glass container. In one embodiment, glass container A may be formed with a modular mold assembly comprising upper, receiver and lower components releasably secured together wherein the inner walls that define the cavities of each of the upper, receiver and lower mold components has a basic shape and design used to form glass container A. Glass container B may be formed with a modular mold assembly wherein the receiver and lower mold components (as well as the neck ring and bottom plate) are the same as those used to form glass container A but wherein one of the upper mold components used to produce glass container A may be interchanged with an upper mold component having upper inner walls that define a upper cavity having a unique shape and design used to form glass container B. Glass container C was formed with a modular mold assembly of glass container A but wherein one of the receiver mold components used to produce glass container A was interchanged with a receiver mold component having receiver inner walls that define a receiver cavity having a unique shape and design used to form glass container C. Glass container D may be formed with a modular mold assembly of glass container A but wherein one of the lower mold components used to produce glass container A was interchanged with a lower mold component having lower inner walls that define a lower cavity having a unique shape and design used to form glass container D. Glass container E may be formed with a modular mold assembly having one of the upper, receiver and lower mold components interchanged with the upper, receiver, and lower mold components of glass container A, wherein the upper, receiver and lower mold components each has inner walls that define the cavity of each of the upper, receiver and lower mold components having a unique shape and design used to form glass container E. Each glass container shown in FIG. 13 was formed by using the same blank mold (shown in FIG. 14) which forms the parison as well as the same neck ring and bottle plate therefore considerably reducing the cost involved for customized design glass bottles or other containers.
[0061] Referring now to FIGS. 15 and 16, in a second example embodiment, the modular mold assembly 100 may be used to produce a bottle shape which may be customized to suit the custom needs of a variety of customers. In one example embodiment, the modular mold assembly 100 comprising separable and interchangeable upper, receiver, and lower mold components allows several custom styles of a container to be manufactured at a minimized cost. Each of the customized bottles, shown in FIGS. 15 and 16, would typically require a different blow mold, but the modular mold assembly allows the formation of custom glass containers as exemplified herein. In one embodiment, glass container A may be formed with a modular mold assembly comprising upper, receiver and lower components releasably secured together wherein the inner walls that define the cavities of each of the upper, receiver and lower mold components have a basic shape and design used to form glass container A. Glass container B may be formed with a modular mold assembly wherein the receiver mold components (as well as the neck ring and bottom plate) are the same as those used to form glass container A but wherein the upper and lower mold components used to produce glass container A may be interchanged with upper and lower mold components having upper inner walls and lower inner walls that define a upper cavity and lower cavity, respectively, each having a unique shape and design used to form glass container B. Glass container C may be formed with a modular mold assembly wherein the receiver mold components (as well as the neck ring and bottom plate) are the same as those used to form glass container A and glass container B but wherein the upper and lower mold components used to produce glass containers A and B may be interchanged with upper and lower mold components having upper inner walls and lower inner walls that define a upper cavity and lower cavity, respectively, each having a unique shape and design used to form glass container C. Glass container D may be formed with a modular mold assembly of glass container A but wherein the lower mold components used to produce glass container A are interchanged with lower mold components having lower inner walls that define a lower cavity having a unique shape and design used to form glass container D. Each bottle shown in FIGS. 15 and 16 was formed by using the same blank mold, shown in FIG. 14, which forms the parison as well as the same neck ring and bottle plate therefore considerably reducing the cost involved for customized design glass bottles or other containers.
[0062] Referring now to FIGS. 17 to 20, another example embodiment of a first modular mold half shell is disclosed. Such modular mold half shell may be used in conjunction with a second modular mold half shell, a neck ring and a bottom plate to form a modular mold assembly which is used to form a glass container such as a jar. Each modular mold half shell comprises a plurality of separable and interchangeable components, including an upper and lower mold components as well as a receiver mold component, which allow for the production of a plurality of glass containers each having a unique, customized design. Modular mold assembly 100 may be used to produce a glass container shapes, such as the glass jars shown in FIGS. 21 and 22, which may be customized to suit the custom needs of a variety of customers. In one example embodiment, modular mold assembly 100 comprising separable and interchangeable upper, receiver, and lower mold components allows various custom styles of a glass container to be manufactured at a minimized cost. Each of the exemplary customized glass jars, shown in FIG. 21, would typically utilize the same blank mold but would require a different blow mold, thus requiring an entire mold set to be manufactured for each customized bottle. Modular mold assembly 100 allows the formation of custom glass containers as exemplified in FIG. 21 without the formation of a complete mold set for each custom designed glass container.
[0063] Referring now to FIGS. 23 to 28, modular mold assembly 100 may comprise a module holder configured to receive the upper, receiver, and lower mold components. In the example embodiment, each of the upper, receiver and lower mold components comprise projection protruding from the rear side of the component, best seen in FIG. 28. The module holder comprises a plurality of apertures configured to receive each projection located on the lower, upper and receiver mold components. The mold component projections may be attached to the module holder with screws, but other forms of attachment may be used as desired by one of skill in the art.
[0064] A new method of manufacturing customized glass containers which utilizes such modular mold assembly is also disclosed. A method of manufacturing customized glass containers, the method comprising the following step of: (a) using a modular mold assembly having a unique shape and/or design in a glass formation machine, the modular mold assembly comprising: (1) two modular mold half shells, a first modular mold half shell and a second modular half shell, wherein each modular half shell comprises separable and interchangeable components wherein the components are releasably secured together; (2) a neck ring and (3) a bottom plate.
[0065] The foregoing disclosure has been set forth merely to illustrate the invention and is not intended to be limiting. Since modifications of the disclosed embodiments incorporating the spirit and substance of the invention may occur to persons skilled in the art, the invention should be construed to include everything within the scope of the disclosed invention and equivalents thereof.
