Blow molded case and method and apparatus for creating same

Abstract

A method and apparatus for blow molding a case for housing an object, such as a tool, is disclosed generally comprising first and second mold portions located adjacent each other to create separate cavities for forming base and lid portions of a case and a punch for each portion corresponding to the outline of an object. In certain embodiments, the punch protrudes into the cavity during blow molding to create a sidewall to facilitate a press fit. In some embodiments, additional punches and/or recesses are provided to produce additional apertures or flanges in the walls of the tool case.

1 . An apparatus for creating a blow-molded case for housing an object, comprising: 
 a mold comprising first and second mold portions that, when located adjacent each other, have first and second mold surfaces at least partially defining first and second cavities, the cavities having first and second cavity surfaces, respectively, against which first and second walls of the blow-molded case are blown, respectively, during blow molding; and    a first punch having a punching surface at least part of which corresponds to at least part of the outline of the object, wherein, when said first punch is in an unactivated position, the first cavity surface includes the first mold surface and at least part of said first punch and, when said first punch is in an activated position, at least part of said first punch is extended past the first wall of the blow-molded case and inside the first cavity such that a first hole, at least part of which corresponds to at least part of the outline of the object, is created in the first wall of the blow-molded case.    
     
     
         2 . The apparatus as claimed in  claim 1 , further comprising a second punch, wherein, when said second punch is in an unactivated position, the second cavity surface includes the second mold surface and at least part of said second punch and, when said second punch is in an activated position, at least part of said second punch is extended past the second wall of the blow-molded case and inside the second cavity such that a second hole is created in the second wall of the blow-molded case.  
     
     
         3 . The apparatus as claimed in  claim 2 , wherein said second punch has a punching surface at least part of which corresponds to at least part of the outline of the object, such that, when said second punch is moved from the unactivated position to the activated position, at least part of the second hole corresponds to at least part of the outline of the object.  
     
     
         4 . The apparatus as claimed in  claim 1 , wherein the outline of the object is the outline of a tool.  
     
     
         5 . The apparatus as claimed in  claim 1 , wherein the full perimeter of the first hole corresponds to the full outline of the object.  
     
     
         6 . The apparatus as claimed in  claim 1 , wherein, when said first punch is in the unactivated position, part of said first punch is protruding out beyond the first mold surface into the first cavity such that, when said first punch is in the unactivated position, the first wall of the blow-molded case is formed therearound and, when said first punch is in the activated position and the first hole has been created, a sidewall corresponding to the outline of the object exists along the perimeter of the hole.  
     
     
         7 . The apparatus as claimed in  claim 1 , wherein the second mold portion includes at least one boss extending into at least one of the first and second cavities such that at least one of the first and second walls of the blow-molded case is formed therearound.  
     
     
         8 . The apparatus as claimed in  claim 7 , wherein the outer surface of at least one boss corresponds to an outline of an aperture in the object.  
     
     
         9 . The apparatus as claimed in  claim 1 , wherein the first mold portion includes at least one boss extending into at least one of the first and second cavities such that at least one of the first and second walls of the blow-molded case is formed therearound.  
     
     
         10 . The apparatus as claimed in  claim 9 , wherein the outer surface of at least one boss is configured to produce an aperture in at least one of the first and second walls of the blow-molded case adapted to receive an accessory of the object.  
     
     
         11 . The apparatus as claimed in  claim 1 , further comprising an additional punch, wherein, when said additional punch is in an unactivated position, the first cavity surface includes at least part of said additional punch and, when said additional punch is in an activated position, said additional punch extends out beyond the first mold surface to a greater extent than when in the unactivated position such that an aperture is created in the first wall.  
     
     
         12 . The apparatus as claimed in  claim 11 , wherein, when said additional punch is in the activated position, said additional punch is extended past the first wall of the blow-molded case and inside the first cavity.  
     
     
         13 . The apparatus as claimed in  claim 11 , wherein said additional punch has a punching surface configured to produce an aperture in the first wall of the blow-molded case adapted to receive an accessory of the object.  
     
     
         14 . The apparatus as claimed in  claim 1 , wherein the first mold surface includes a recess adjacent said first punch such that a flange is formed in the first wall of the blow-molded case adjacent the first hole.  
     
     
         15 . The apparatus as claimed in  claim 1 , wherein the blow-molded case comprises a base portion formed in the first cavity and a lid portion formed in the second cavity.  
     
     
         16 . A method for creating a blow-molded object case for housing an object, the method comprising: 
 providing a mold having first and second mold portions;    providing a first punch, wherein said first punch has a punching surface at least part of which corresponds to at least part of the outline of the object;    moving the first mold portion adjacent to the second mold portion, thereby at least partially enclosing first and second cavities having first and second cavity surfaces, respectively;    blowing a first wall of the blow-molded case against the first cavity surface and a second wall of the blow-molded case against the second cavity surface; and    extending at least part of the first punch through the first wall of the blow-molded case and into the first cavity, thereby creating a first hole in the first wall of the blow-molded case.    
     
     
         17 . The method as claimed in  claim 16 , further comprising the steps of: 
 providing a second punch; and    extending at least part of the second punch through the second wall of the blow-molded case and into the second cavity, thereby creating a second hole in the second wall of the blow-molded case.    
     
     
         18 . The method as claimed in  claim 17 , wherein the second punch has a punching surface at least part of which corresponds to at least part of the outline of the object.  
     
     
         19 . The method as claimed in  claim 16 , wherein the outline of the object is the outline of a tool.  
     
     
         20 . The method as claimed in  claim 16 , wherein the full perimeter of the first hole corresponds to the full outline of the object.  
     
     
         21 . The method as claimed in  claim 16 , wherein the first mold portion has a first mold surface at least partially defining the first cavity, further comprising positioning the first punch so that part of the first punch is protruding out beyond the first mold surface into the first cavity when the first wall is blown against the first cavity surface such that the first wall is formed therearound, and such that, when at least part of the first punch is extended through the first wall, thereby creating the first hole, a sidewall corresponding to the outline of the object exists along the perimeter of the first hole.  
     
     
         22 . The method as claimed in  claim 16 , wherein the second mold portion includes at least one boss extending into at least one of the first and second cavities such that at least one of the first and second walls is formed therearound when blown against at least one of the first and second cavity surfaces.  
     
     
         23 . The method as claimed in  claim 22 , wherein the outer surface of at least one boss corresponds to an outline of an aperture in the object.  
     
     
         24 . The method as claimed in  claim 16 , wherein the first mold portion includes at least one boss extending into at least one of the first and second cavities such that at least one of the first and second walls is formed therearound when blown against at least one of the first and second cavity surfaces.  
     
     
         25 . The method as claimed in  claim 24 , wherein the outer surface of at least one boss is configured to produce an aperture in at least one of the first and second walls adapted to receive an accessory of the object.  
     
     
         26 . The method as claimed in  claim 16 , wherein the first mold portion has a first mold surface at least partially defining the first cavity, further comprising: 
 providing a additional punch in an unactivated position; and    extending the additional punch out beyond the first mold surface to a greater extent than when in the unactivated position, thereby creating an aperture in the first wall.    
     
     
         27 . The method as claimed in  claim 26 , wherein the step of extending the additional punch includes extending the additional punch past the first wall of the blow-molded case and into the first cavity.  
     
     
         28 . The method as claimed in  claim 26 , wherein the additional punch has a punching surface configured to produce an aperture in the first wall adapted to receive an accessory of the object.  
     
     
         29 . The method as claimed in  claim 16 , wherein the first and second mold portions have a first mold surface at least partially defining the first cavity, further comprising providing a recess adjacent the first punch such that a flange is formed in the first wall adjacent the first hole.  
     
     
         30 . The method as claimed in  claim 16 , wherein the blow-molded case comprises a base portion formed in the first cavity and a lid portion formed in the second cavity.  
     
     
         31 . A blow-molded case for housing an object, comprising: 
 a double wall base portion having a first cavity for housing at least part of the object;    a double wall lid portion connected to said base portion, said lid portion having a second cavity for housing at least part of the object; and    wherein one of said base and lid portions has a first punched hole at least part of which corresponds to at least part of the outline of the object for receiving the object.    
     
     
         32 . The case of  claim 31 , wherein the portion not having the first punched hole has a second punched hole for accommodating the object.  
     
     
         33 . The case of  claim 31 , wherein at least part of the second punched hole corresponds to at least part of the outline of the object.  
     
     
         34 . The case of  claim 31 , wherein the outline of the object is the outline of a tool.  
     
     
         35 . The case of  claim 31 , wherein the full perimeter of the first hole corresponds to the full outline of the object.  
     
     
         36 . The case of  claim 31 , further comprising a sidewall along the perimeter of the first punched hole.  
     
     
         37 . The case of  claim 31 , wherein the first cavity has a first cavity surface, the second cavity has a second cavity surface, and at least one of the first and second cavity surfaces has at least one boss.  
     
     
         38 . The case of  claim 37 , wherein the outer surface of at least one boss corresponds to an outline of an aperture in the object.  
     
     
         39 . The case of  claim 37 , wherein the inner surface of at least one boss is adapted to receive an accessory of the object.  
     
     
         40 . The case of  claim 31 , wherein a wall of the portion having the first punched hole has at least one aperture adapted to receive an accessory of the object.  
     
     
         41 . The case as claimed in  claim 31 , wherein the wall of the portion having the first punched hole includes a flange adjacent the hole.  
     
     
         42 . The case as claimed in  claim 31 , wherein said lid portion is integrally formed with said base portion.  
     
     
         43 . A method for creating a blow-molded case for housing an object, the method comprising: 
 moving a first mold portion adjacent to a second mold portion, thereby creating first and second cavities;    blowing first and second walls of the blow-molded case against the first and second cavities, respectively; and    punching a hole, at least part of which corresponds to at least part of the outline of the object, in the first wall of the blow-molded case.    
     
     
         44 . A method as claimed in  claim 43 , further comprising punching a hole in the second wall of the blow-molded case.  
     
     
         45 . A method as claimed in  claim 43 , wherein at least part of the hole in the second wall of the blow-molded case corresponds to at least part of the outline of the object.  
     
     
         46 . A method as claimed in  claim 43 , wherein the outline of the object is the outline of a tool.  
     
     
         47 . A method as claimed in  claim 43 , wherein the full perimeter of the hole corresponds to the full outline of the object.  
     
     
         48 . A method as claimed in  claim 43 , further comprising forming a sidewall along the perimeter of the hole.  
     
     
         49 . A method as claimed in  claim 43 , further comprising forming a boss in at least one of the first and second walls that extends into at least one of the first and second cavities.  
     
     
         50 . A method as claimed in  claim 49 , wherein the step of forming a boss includes forming a boss with an outer surface that corresponds to an outline of an aperture in the object.  
     
     
         51 . A method as claimed in  claim 49 , wherein the step of forming a boss includes forming a boss with an inner surface adapted to receive an accessory of the object.  
     
     
         52 . A method as claimed in  claim 43 , further comprising punching an aperture in the first wall adapted to receive an accessory of the object.  
     
     
         53 . A method as claimed in  claim 43 , further comprising forming a flange in the first wall of the blow-molded case adjacent the hole.  
     
     
         54 . A method as claimed in  claim 43 , wherein the blow-molded case comprises a base portion formed in the first cavity and a lid portion formed in the second cavity.