INJECTION MOLD AND METHOD FOR PRODUCING A DOUBLE WALLED DRINKING VESSEL, THE DOUBLE WALLED DRINKING VESSEL COMPRISING AN OUTER CONTAINER AND AN INNER CONTAINER

Abstract

An injection mold for producing a double walled drinking vessel includes first and second mold portions. The first mold portion forms a first and second cavities corresponding to the outer shape of the outer container and the outer shape of the inner container, respectively. The first and second cavities are located concentrically with respect to a central axis. An index plate is rotatable and axially movable along the central axis relative to the first mold portion. The index plate includes a first core and a second core. The first cavity has a first cavity injection gate for injecting mold material into the first cavity for forming the outer container. The second cavity has a second cavity injection gate for injecting mold material into the second cavity for forming the inner container. The first cavity has a further injection gate for injecting joint material for joining the outer and inner containers.

Claims

1. A method for producing the double walled drinking vessel, the double walled drinking vessel comprising the outer container and the inner container using an injection mold machine having an injection mold comprising a first mold portion, a second mold portion facing the first mold portion, the first mold portion and the second mold portion being axially movable relative to each other, the first mold portion forming a first cavity corresponding to an outer shape of the outer container and a second cavity corresponding to an outer shape of the inner container, the first cavity and the second cavity located concentrically with respect to a central axis of the first mold portion, an index plate rotatable around and axially movable along the central axis relative to the first mold portion, the index plate comprising a first core corresponding to an inner shape of the outer container and a second core corresponding to an inner shape of the inner container, the first cavity having a first cavity injection gate for injecting a first mold material into the first cavity for forming the outer container, the second cavity having a second cavity injection gate for injecting a second mold material into the second cavity for forming the inner container, and the first cavity having a further injection gate for injecting a joint material for joining the outer container and the inner container, the method comprising: rotating the index plate into a position in which the first core is axially aligned with the first cavity and the second core is axially aligned with the second cavity, closing the injection mold by axially moving the first mold portion relative to the second mold portion, thereby inserting the first core into the first cavity and the second core into the second cavity, injecting the first mold material into the first cavity through the first cavity injection gate, thereby forming an outer container, injecting the second mold material into the second cavity through the second cavity injection gate, thereby forming an inner container, opening the injection mold by axially moving the first mold portion relative to the second mold portion, such that the outer container remains in the first cavity and the inner container is removed from the second cavity by the second core, rotating the index plate into a position in which the second core holding the inner container is axially aligned with the first cavity comprising the outer container, closing the injection mold, thereby inserting the inner container into the outer container, joining the outer container and the inner container by injecting the joint material through the further injection gate of the first cavity, and opening the injection mold and ejecting the double walled drinking vessel.

2. The method according to claim 1, comprising the further steps: rotating the index plate into a position in which two first cores of the first core are axially aligned with two first cavities of the first cavity, two second cores of the second core are axially aligned with two second cavities of the second cavity and two remaining second cores of the second core are axially aligned with two remaining first cavities of the first cavity, closing the injection mold by axially moving the first mold portion relative to the second mold portion, thereby inserting the first cores into the first cavities, the two second cores into the two second cavities and the two remaining second cores into the two remaining first cavities, injecting the first mold material into the first cavity into which the two first cores are inserted through the first cavity injection gate, thereby forming two outer containers, injecting the second mold material into the second cavity into which the two second cores are inserted through the second cavity injection gate, thereby forming two inner containers, opening the injection mold by axially moving the first mold portion relative to the second mold portion, such that the two outer containers remain in the first cavity and the two inner containers are removed from the second cavity by the second core, rotating the index plate forward by 45° into a position in which the second core holds the two inner containers, the two inner containers being axially aligned with the two first cavities comprising the two outer containers, the two first cores are axially aligned with the two first cavities and the two remaining second cores are axially aligned with the two second cavities, closing the injection mold, thereby inserting the two inner containers into the two outer containers, inserting the first core into the first cavity and inserting the two remaining second cores into the second cavities, joining the outer container and the inner container by injecting the joint material through the further injection gate of the first cavity, injecting the first mold material into the first cavity into which the two first cores are inserted through the first cavity injection gate, thereby forming two outer containers, injecting the second mold material into the second cavities into which the second cores are inserted through the second cavity injection gate, thereby forming two inner containers, opening the injection mold such that the two outer containers remain in the first cavity and the two inner containers are removed from the second cavity by the second cores, ejecting the two double walled drinking vessels, rotating the index plate backward by 45° into a position in which the second core holds the two inner containers are axially aligned with the two first cavities comprising the two outer containers, the two first cores are axially aligned with the two first cavities and the two remaining second cores are axially aligned with the two second cavities, and closing the injection mold and starting from the beginning again.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING

[0048] The foregoing summary, as well as the following detailed description of the preferred invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the preferred invention, there are shown in the drawings embodiments which are presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:

[0049] FIG. 1a is a cross-sectional view of a first embodiment of an injection molding machine according to the invention and FIGS. 1a-5b disclose different steps of a method by which the molding machine according to the first embodiment may be operated, by means of principle sketches;

[0050] FIG. 1b is a side view of the injection molding machine of FIG. 1a;

[0051] FIG. 1c is a cross-sectional view of a first cavity of the injection molding machine of FIG. 1a;

[0052] FIG. 1d is a cross-sectional view of a second cavity of the injection molding machine of FIG. 1a;

[0053] FIG. 2a is a cross-sectional view of the injection molding machine of FIG. 1a;

[0054] FIG. 2b is a cross-sectional view of the first cavity and a first core of the injection molding machine of FIG. 1a;

[0055] FIG. 3a is a cross-sectional view of the injection molding machine of FIG. 1a;

[0056] FIG. 3b is a cross-sectional view of the first cavity and the first core of the injection molding machine of FIG. 1a;

[0057] FIG. 4a is a cross-sectional view of the injection molding machine of FIG. 1a;

[0058] FIG. 4b is a cross-sectional view of the first cavity and a second core of the injection molding machine of FIG. 1a;

[0059] FIG. 5a is a cross-sectional view of the injection molding machine of FIG. 1a;

[0060] FIG. 5b is a cross-sectional view of the first cavity and the second core of the injection molding machine of FIG. 1a;

[0061] FIG. 6 is a perspective view of an index plate of a second embodiment of the molding machine according to the invention;

[0062] FIG. 7 is a perspective view of a first mold portion index plate of the second embodiment of the molding machine according to the invention,

[0063] FIG. 8 is a cross-sectional view of a molding machine according to the second embodiment and FIGS. 8-11 disclose different steps of a method by which the molding machine according to the second embodiment may be operated;

[0064] FIG. 9 is another cross-sectional view of the molding machine according to the second embodiment of FIG. 8;

[0065] FIG. 10 is another cross-sectional view of the molding machine according to the second embodiment of FIG. 8;

[0066] FIG. 11 is another cross-sectional view of the molding machine according to the second embodiment of FIG. 8;

[0067] FIG. 12 is a third embodiment of an injection molding machine; and

[0068] FIG. 13 is a fourth embodiment of the injection molding machine, by means of principle sketches.

DETAILED DESCRIPTION OF THE INVENTION

[0069] FIG. 1a shows a principle view on an injection molding machine 10.sub.1 according to a first embodiment and FIG. 1b a section along the section plane Z-Z as defined in FIG. 1a. For the sake of comprehensibility only the relevant parts of the injection molding machine are shown, particularly in FIG. 1a. The injection molding machine 10.sub.1 is configured to produce a double walled drinking vessel 12 having an outer container 14 and an inner container 16 (see FIGS. 4b and 5b).

[0070] The injection molding machine 10.sub.1 comprises an injection mold 18 having a first mold portion 20 and a second mold portion 22. The first mold portion 20 and the second mold portion 22 are facing each other and are axially movable along a central axis A of the injection molding machine 10.sub.1. To this end the first mold portion 20 and the second mold portion 22 are connected to a number of guide rods 24. Moreover the injection molding machine 10.sub.1 is equipped with driving means 26 for axially moving the first mold portion 20 and the second mold portion 22 along the guide rods 24.

[0071] The first mold portion 20 comprises one first cavity 28 and one second cavity 30 that are separately shown in FIGS. 1c and 1d, respectively. The first cavity 28 and the second cavity 30 are located opposite of the central axis A and thus enclose an angle of 180°. The first cavity 28 is equipped with a first cavity injection gate 32 for injecting a mold material into the first cavity 28, thereby forming the outer container 14. The second cavity 30 is ac-cordingly equipped with a second cavity injection gate 34 for injecting a mold material into the second cavity 30, thereby forming the inner container 16. The first cavity 28 comprises a further injection gate 36 for injecting a joint material into the first cavity 28. The injection molding machine 10.sub.1 comprises a manifold 38 for guiding the mold material to the first and second cavity injection gate 32, 34 and the joint material to the further injection gate 36.

[0072] Moreover, the injection molding machine 10.sub.1 comprises an index plate 40 which is mounted to the second mold portion 22 and thus movable along the central axis A together with the second mold portion 22. The index plate 40 is rotatable around the central axis A by means of a rotary drive means 44. The index plate 40 further comprises a first core 46 and a second core 48. The first core 46 has a shape defining the inner shape of the outer container 14 (see FIGS. 2b and 3b) whereas the second core 48 has a shape defining the inner shape of the inner container 16 (see FIGS. 4b and 5b).

[0073] As demonstrated in FIG. 1b the first core 46 is mounted on the index plate 40 axially movable along the central axis A. The index plate 40 comprises a preload element 50 forcing the first core 46 into a position in which the first core 46 maximally protrudes from the index plate 40.

[0074] The injection molding machine 10.sub.1 further comprises a control unit 42 to coordinate the movements of the first mold portion 20, the second mold portion 22 and the index plate 40 and to control the injection of the mold material and the joint material into the respective cavities.

[0075] In the following the different steps of a method will be explained by which the injection molding machine 10.sub.1 may be operated.

[0076] In FIGS. 1a and 1b the injection molding machine 10.sub.1 is opened and the index plate 40 is in a position in which neither the first core 46 nor the second core 48 are axially aligned with the first cavity 28 or the second cavity 30. As indicated by the arrow P the index plate 40 then turned counterclockwise, in this case by 90°, so that the first core 46 is axially aligned with the first cavity 28 and the second core 48 is axially aligned with the second cavity 30. This position is shown in FIG. 2a. Now the molding machine is closed thereby inserting the first core 46 into the first cavity 28, as shown in FIG. 2b, and the second core 48 into the second cavity 30 (not shown).

[0077] In remaining in this position the mold material is injected into the first cavity 28 through the first cavity injection gate 32, thereby forming an outer container 14 (FIG. 3b), and into the second cavity 30 through the second cavity injection gate 34, thereby forming an inner container 16 (not shown). The mold material may be a thermoplastic resin such as Tritan.

[0078] After the thermoplastic resin has cured the injection molding machine 10.sub.1 is opened by moving the first mold portion 20 and the second mold portion 22 axially away from each other along the central axis A. The second core 48 comprises holding means 52, in this case activatable suction means 54 that produce a negative pressure acting between the inner container 16 and the second core 48 (see FIGS. 4b and 5b). As a result the inner container 16 is removed from the second cavity 30 when the injection molding machine 10.sub.1 is opened. In contrast to that the outer container 14 remains in the first cavity 28. After that the index plate 40 is rotated by 180° and the injection molding machine 10.sub.1 is closed again.

[0079] When comparing the first cavity 28, e.g. shown in FIG. 1c, and the second cavity 30.sub.2, e.g. shown in FIG. 1d and/or when comparing the first core 46 and the second core 48, e.g. in FIG. 1b, it becomes clear that they are different in size. In consequence of that the second core 48 can completely be inserted into the first cavity 28 and the second cavity 30, whereas the first core 46 can only completely be inserted into the first cavity 28. Depending on the design of the double walled drinking vessel 12 the first core 46 may not at all or only partially be inserted into the second cavity 30. Without any countermeasures the first core 46 would impact on the first mold portion 20 and cause severe damages in the injection mold 18 when closing the injection molding machine 10.sub.1. For preventing such damages the first core 46 is mounted on the index plate 40 axially movable along the central axis A. The preload element 50 is forcing the first core 46 into a position in which the first core 46 maximally protrudes from the index plate 40. This position is shown in FIGS. 1b, 2b and 3b.

[0080] When the injection molding machine 10.sub.1 is closed the first core 46 is axially moved against the force exerted by the preload element 50. Concomitantly the second core 48 together with the inner container 16 is inserted into the first cavity 28 and into the outer container 14 as shown in FIG. 4b. As evident from FIG. 4b the outer container 14 and the inner container 16 are configured such that an annular space 56 near the opening of the outer container 14 and the inner container 16 is created. Moreover the outer container 14 and the inner container 16 encase a hollow space 58 between them.

[0081] Now a joint material is injected into the first cavity 28 through the further injection gate 36 (FIG. 5b). The further injection gate 36 is positioned such that the joint material is injected into the annular space 56. The joint material may be a thermoplastic resin and may be identical to the thermoplastic resin used as the mold material for producing the outer container 14 and the inner container 16. After the joint material is injected into the annular space 56 and has cured the double walled drinking vessel 12 is completed as shown in FIG. 5b. The injection molding machine 10.sub.1 is now opened and the double walled drinking vessel 12 is ejected.

[0082] In FIG. 6 the index plate 40 and in FIG. 7 the first mold portion 20 of a second embodiment of the injection molding machine 102 are shown each by means of a perspective view. In FIGS. 8 to 11 the method by which the injection mold 18 may be operated is shown comprising the index plate 40 and the first mold portion 20 illustrated in FIGS. 6 and 7.

[0083] Referring to FIG. 7 the first mold portion 20 comprises in total eight cavities, namely four first cavities 28.sub.1 to 28.sub.4 and four second cavities 30.sub.1 to 30.sub.4. The cavities 28, 30 are equally arranged around the central axis A so that they form an angle α of 45° as shown in FIG. 8. The first cavities 28.sub.1 to 28.sub.4 are grouped pairwise around the central axis A so that they form two first cavity pairs 28P1 and 28P2. The second cavities 30.sub.1 to 30.sub.4 are grouped pairwise around the central axis A so that they form two second cavity pairs 30P1 and 30P2. The first cavity pairs 28P1 and 28P2 are each arranged adjacent to the second cavity pairs 30P1 and 30P2. In FIG. 7 the further injection gates 36 of the first cavities 28.sub.1 to 28.sub.4 are clearly visible.

[0084] As shown in FIG. 6 the index plate 40 comprises two first cores 46.sub.1, 46.sub.2 and four second cores 48.sub.1 to 48.sub.4. The two first cores 46.sub.1, 46.sub.2 are arranged opposite to each other with reference to the central axis A. The two second cores 48.sub.1, 48.sub.2 are arranged adjacent to the first cores 46 and the two second cores 48.sub.3, 48.sub.4 are arranged adjacent to the first core 46.sub.2, the second cores 48.sub.1 to 48.sub.4 enclosing an angle of 45° with the adjacent first core 46.sub.1, 46.sub.2 with reference to the central axis A.

[0085] The second embodiment of the injection molding machine 102 may be operated as follows. In FIG. 8 the index plate 40 is placed in a position in which the first cores 46.sub.1, 46.sub.2 are inserted into the first cavities 28.sub.1, 28.sub.3 and two of the second cores 48.sub.1, 48.sub.3 are inserted into the second cavities 30.sub.2 and 30.sub.4 whereas the remaining two second cores 48.sub.2, 48.sub.4 are inserted into the remaining first cavities 28.sub.2, 28.sub.4. The mold material is injected into the first cavities 28.sub.1, 28.sub.3 into which the first cores 46.sub.1, 46.sub.2 are inserted and into the second cavities 30.sub.2, 30.sub.4 into which the second cores 48.sub.1, 48.sub.3 are inserted. It is noted that no mold material is injected into the remaining first cavities 28.sub.2, 28.sub.4 into which the remaining two second cores 48.sub.2, 48.sub.4 are inserted. Consequently two outer containers 14 are produced in the first cavities 28.sub.1, 28.sub.3 and two inner containers 16 are produced in the second cavities 30.sub.2, 30.sub.4.

[0086] Now the injection mold 18 is opened and the first cores 46.sub.1, 46.sub.2 and the second cores 48.sub.1 to 48.sub.4 are removed from the respective first and second cavities 28, 30. As already mentioned with reference to the first embodiment of the injection mold 10.sub.1 the second cores 48.sub.1, 48.sub.3 also withdraw the inner containers 16 from the respective second cavities 30.sub.2, 30.sub.4 whereas the outer containers 14 remain inside the first cavities 28.sub.1, 28.sub.3. The index plate 40 is now rotated by 45° into a first rotary direction indicated by the arrow P (FIG. 9). The injection mold 18 is closed again so that by means of the two second cores 48.sub.1, 48.sub.3 the two inner containers 16 are introduced into the first cavities 28.sub.1, 28.sub.3 comprising the outer containers 14. The first cores 46.sub.1, 46.sub.2 are now introduced into the first cavities 28.sub.2, 28.sub.4 and the two remaining second cores 48.sub.2, 48.sub.4 are now introduced into the two second cavities 30.sub.1, 30.sub.3. The joint material is now injected into the first cavities 28.sub.1, 28.sub.3 through the further injection gates 36, thereby completing two double walled drinking vessels 12 (see FIG. 10).

[0087] At the same time the mold material is introduced into the two first cavities 28.sub.2, 28.sub.4 and the two second cavities 30.sub.1, 30.sub.3 so that two outer containers 14 and two inner containers 16 are formed. After curing the injection mold 18 is opened and the two completed double walled drinking vessels 12 are ejected. After that the index plate 40 is rotated 45° into a second rotary direction opposite of the first rotary direction as indicated by the arrow P in FIG. 10 into a position shown in FIG. 11. The injection molding machine 102 is closed and by means of the second cores 48.sub.2, 48.sub.4 the two inner containers 16 are introduced into the first cavities 28.sub.2, 28.sub.4 comprising the outer containers 14. The joint material is injected into the first cavities 28.sub.2, 28.sub.4 through the further injection gates 36, thereby competing two double walled drinking vessels 12. At the same time mold material is injected into the first cavities 28.sub.1 and the second cavities 30.sub.2, 30.sub.4 thereby forming two outer containers 14 and two inner containers 16 as shown in FIG. 8. The described steps are now repeated.

[0088] By means of the method the injection molding machine 102 according to the second embodiment is operated two double walled drinking vessels 12 are completed and ejected each time the injection molding machine 102 is opened.

[0089] In FIG. 12a third embodiment of an injection molding machine 10.sub.3 is shown by means of a principle sketch. The first mold portion 20 comprises in total three cavities, namely one first cavity 28, one second cavity 30 and one additional cavity 60. The cavities 28, 30, 60 are equally arranged around the central axis A. The index plate 40 comprises one first core 46 and one second core 48 enclosing an angle α of 120° with reference to the central axis A. The additional cavity 60 is configured such that the first core 46 may be completely inserted into the additional cavity 60.

[0090] The injection molding machine 10.sub.3 is operated as follows. The index plate 40 is rotated into a position in which the first core 46 is aligned with the first cavity 28 and the second core 48 is aligned with the second cavity 30. The injection molding machine 10.sub.3 is closed, thereby inserting the first core 46 into the first cavity 28 and the second core 48 into the second cavity 30. The mold material is now injected into the first cavity 28 and the second cavity 30, thereby producing one outer container 14 and one inner container 16. The injection molding machine 10.sub.3 is now opened and the inner container 16 is withdrawn from the second cavity 30 by the second core 48. The index plate 40 is now rotated counterclockwise into a first rotational direction by 120° so that the second core 48 is axially aligned with the first cavity 28 and the first core 46 is axially aligned with the additional cavity 60. The injection molding machine 10.sub.3 is now closed and the joint material is injected into the first cavity 28 through the further injection gate 36, thereby completing one first double walled drinking vessel 12. After curing the injection molding machine 10.sub.3 is opened and the completed double walled drinking vessel 12 is ejected. The index plate 40 is rotated by 120° into a second rotational direction opposite the first rotational direction and the described steps are conducted again. In this embodiment one completed double walled drinking vessel 12 is ejected every second time the injection molding machine 10.sub.3 is opened.

[0091] In FIG. 13 a fourth embodiment of an injection molding machine 10.sub.4 is shown by means of a principle sketch. The first mold portion 20 comprises in total four cavities, namely two first cavities 28.sub.1, 28.sub.2 and two second cavities 30.sub.1, 30.sub.2. The cavities 28, 30 are equally arranged around the central axis A. The first cavities 28.sub.1, 28.sub.2 form a first cavity pair 28P and the second cavities 30.sub.1, 30.sub.2 form a second cavity pair 30P. The two first cavities 28.sub.1, 28.sub.2 enclose an angle α of 90° with each other with reference to the central axis A. The same is true for the second cavities 30.sub.1, 30.sub.2.

[0092] The index plate 40 comprises one first core 46 and two second cores 48.sub.1, 48.sub.2, the two second cores 48.sub.1, 48.sub.2 arranged opposite the central axis A and thus enclosing an angle of 180° with reference to the central axis A. The first core 46 is arranged in an angle of 90° with regard to the second cores 48.sub.1, 48.sub.2 and with reference to the central axis A.

[0093] The index plate 40 is rotated into a position in which the first core 46 is axially aligned with one of the first cavities 28, in this case with the first cavity 28.sub.2 and the second core 48.sub.1 is axially aligned with one of the second cavities 30, in this case with the second cavity 30.sub.1. The other second core 48.sub.2 is axially aligned with the other first cavity 28.sub.1. The injection molding machine 10.sub.4 is now closed and the mold material is injected into the first cavity 28.sub.2 into which the first core 46 is introduced and into the second cavity 30.sub.1 into which the second core 48.sub.1 is introduced, thereby producing an outer container 14 and one inner container 16. After that the injection molding machine 10.sub.4 is opened and the index plate 40 rotated by 90° counterclockwise into a first rotational direction so that the second core 48.sub.1 carrying the inner container 16 is axially aligned with the first cavity 28.sub.2 and the first core 46 is axially aligned with the other first cavity 28.sub.1. The other second core 48.sub.2 is now axially aligned with the other second cavity 30.sub.2. The injection molding machine 10.sub.4 is now closed and the joint material is injected into the first cavity 28.sub.2 through the further injection gate 36, thereby completing one double walled drinking vessel 12. At the same time the mold material is injected into the other first cavity 28.sub.1 and the second cavity 30.sub.2, thereby producing an outer container 14 and an inner container 16. The injection molding machine 10.sub.4 is opened and the completed double walled drinking vessel 12 is ejected. The index plate 40 is rotated by 90° in a second rotational direction opposite to the first rotational direction. The inner container 16 is introduced into the outer container 14 and the joint material is injected into the other first cavity 28.sub.1 through the further injection gate 36, thereby completing a double walled drinking vessel 12. Concomitantly molding material is injected into the first cavity 28.sub.2 into which the first core 46 is introduced and into the second cavity 30.sub.1 into which the second core 48.sub.1 is introduced, thereby producing an outer container 14 and an inner container 16. Now the described steps are repeated.

[0094] In this embodiment one completed double walled drinking vessel 12 is ejected each time the injection molding machine 10.sub.4 is opened.

[0095] It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.

REFERENCE LIST

[0096] 10, 10.sub.1-10.sub.4 injection molding machine [0097] 12 double walled drinking vessel [0098] 14 outer container [0099] 16 inner container [0100] 18 injection mold [0101] 20 first mold portion [0102] 22 second mold portion [0103] 24 guide rod [0104] 26 driving means [0105] 28, 28.sub.1-28.sub.4 first cavity [0106] 30, 30.sub.1-30.sub.2 second cavity [0107] 32 first cavity injection gate [0108] 34 second cavity injection gate [0109] 36 further injection gate [0110] 38 manifold [0111] 40 index plate [0112] 42 control unit [0113] 44 rotary drive means [0114] 46, 46.sub.1-46.sub.2 first core [0115] 48, 48.sub.1-48.sub.4 second core [0116] 50 preload element [0117] 52 holding means [0118] 54 suction means [0119] 56 annular space [0120] 58 hollow space [0121] 60 additional cavity [0122] A central axis [0123] P arrow