In-mold assembly system for an injection molding machine

Abstract

An injection molding machine comprises a machine base, a first platen for supporting a first mold half, and a second platen for supporting a second mold half. At least one of the platens is translatable along a machine axis for moving the mold halves between a mold-open and a mold-closed position. The first and second mold halves define a first set of cavities for forming a first set of articles, and a second set of cavities for forming a second set of articles. The machine further comprises a manipulator comprising a first set of first receivers for receiving the first set of articles. The manipulator is moveable among a retracted position, a first advanced position, and a second advanced position. When in the retracted position, the manipulator is clear of the mold halves. When in the first advanced position, the first set of first receivers is aligned with the first set of cavities for receiving the first set of articles. When in the second advanced position, the first set of first receivers is aligned with the second set of cavities for receiving the second set of articles in an assembled condition with the first set of articles.

1 . An injection molding machine, comprising:
 a) a machine base;   b) a first mold support for supporting a first mold half and a second mold support for supporting a second mold half, the mold supports mounted on the machine base, at least one of the mold supports translatable along a machine axis for moving the mold halves between a mold-open and a mold-closed position, the first and second mold halves defining a set of first cavities for forming a set of first articles and a set of second cavities for forming a set of second articles; and   c) a manipulator comprising a first set of first receivers for receiving the set of first articles, the manipulator movable among a retracted position, a first advanced position, and a second advanced position, wherein,
 i) when in the retracted position, the manipulator is clear of the mold halves, 
 ii) when in the first advanced position, the first set of first receivers is aligned with the set of first cavities for receiving the set of first articles, and 
 iii) when in the second advanced position, the first set of first receivers is aligned with the set of second cavities for receiving the set of second articles in an assembled condition with the set of first articles. 
   
     
     
         2 . The injection molding machine of  claim 1 , further comprising at least one ejector for ejecting the set of second articles from the second cavities into assembled condition with the set of first articles. 
     
     
         3 . The injection molding machine of  claim 1 , wherein the manipulator comprises a tooling plate mounted to an arm, and the first set of first receivers is fixed to the tooling plate. 
     
     
         4 . The injection molding machine of  claim 3 , further comprising a linear actuator for moving the manipulator along a linear axis between the retracted position and at least one linear advanced position, the at least one linear advanced position corresponding to at least one of the first advanced position and the second advanced position. 
     
     
         5 . The injection molding machine of  claim 4 , wherein the first and second advanced positions are spaced apart from each other along the linear axis and correspond to distinct first and second linear advanced positions. 
     
     
         6 . The injection molding machine of  claim 5 , further comprising a first set ejector associated with the set of first cavities for transferring the set of first articles to the first set of first receivers when in the first advanced position, and a second set ejector associated with the set of second cavities for transferring the set of second articles into assembled condition with the set of first articles in first set of first receivers when in the second advanced position. 
     
     
         7 . The injection molding machine of  claim 4 , wherein the tooling plate is rotatably mounted to the arm, and is rotatable between first and second rotary positions, the first rotary position associated with the first advanced position, and the second rotary position associated with the second advanced position. 
     
     
         8 . The injection molding machine of  claim 7 , wherein the first and second advanced positions have a common linear advanced position. 
     
     
         9 . The injection molding machine of  claim 8 , wherein the manipulator further comprises a second set of second receivers, and when in the first advanced position, the first set of first receivers is aligned with the set of first cavities and the second set of second receivers is aligned with the set of second cavities. 
     
     
         10 . The injection molding machine of  claim 9 , wherein the first receivers and second receivers are identical. 
     
     
         11 . The injection molding machine of  claim 9 , further comprising a first set ejector for ejecting the first set of molded articles from the first cavities to the first receivers when the manipulator is in the first advanced position, and a second set ejector for ejecting, in a subsequent cycle, the set of second molded articles from the second cavities into assembled engagement with the set of first molded articles in the second receivers when the manipulator is in the second advanced position. 
     
     
         12 . The injection molding machine of  claim 9 , further comprising a dual set ejector, the dual set ejector simultaneously transferring (i) the first set of articles to the first set of first receivers and (ii) the second set of articles into assembled relation with another set of first articles already received in the second set of second receivers from a previous cycle. 
     
     
         13 . The injection molding machine of  claim 1 , further comprising a first injection barrel to inject resin into the first set of cavities, and a second injection barrel to inject resin into the second set of cavities. 
     
     
         14 . An injection molding machine, comprising:
 a) a machine base;   b) a first platen and a second platen, the platens supported by the machine base, at least one of the platens translatable along a machine axis for opening and closing a mold defined at least in part by respective first and second mold halves mounted to the first and second platens;   c) a mold center section between the first and second platens; and   d) a manipulator comprising a first tooling plate rotatably mounted to a first arm and a second tooling plate rotatably mounted to a second arm, each tooling plate rotatable between first and second rotary positions, the first and second tooling plates reaching between the first and second platens on opposite sides of the mold center section when in a linearly advanced position.   
     
     
         15 . The machine of  claim 14 , further comprising a first set of first receivers and a second set of second receivers affixed to the first tooling plate, wherein when in the linearly advanced position and the first rotary position, the first set of first receivers and the second set of second receivers are aligned with a set of first mold cores and a set of second mold cores, respectively, provided in the first mold half, and when in the linearly advanced position and the second rotary position, the first set of first receivers and the second set of second receivers face and are aligned with the set of second mold cores and the set of first mold cores, respectively. 
     
     
         16 . The machine of  claim 15 , further comprising a third set of third receivers and a fourth set of fourth receivers affixed to the second tooling plate, wherein when in the linearly advanced position and the first rotary position, the third set of third receivers and the fourth set of fourth receivers face and are aligned with a set of third mold cores and a set of fourth mold cores, respectively, provided in the second mold half, and when in the linearly advanced position and the second rotary position, the third set of third receivers and the fourth set of fourth receivers face and are aligned with the set of fourth mold cores and the set of third mold cores, respectively. 
     
     
         17 . The machine of  claim 16 , further comprising a first dual-set ejector mounted to the first platen for transferring a set of first articles from the first mold cores to the first set of first receivers, and transferring a set of second articles from the second mold cores into assembled condition with another set of first articles in the second set of second receivers. 
     
     
         18 . The machine of  claim 17 , further comprising a second dual-set ejector mounted to the second platen for transferring a set of third articles from the third mold cores to the third set of third receivers, and transferring a set of fourth articles from the fourth mold cores into assembled condition with another set of third articles in the fourth set of fourth receivers. 
     
     
         19 . A method for injection molding comprising:
 a) forming a set of first articles in a mold of an injection molding machine;   b) forming a set of second articles in the mold of the injection molding machine;   c) transferring the set of first articles from the mold to a first set of first receivers;   d) moving the first set of first receivers to align with the set of second articles; and   e) after step d, transferring the set of second articles from the mold to the first set of first receivers into assembled condition with the set of first articles.   
     
     
         20 . The method of  claim 19 , wherein step d) comprises linearly displacing the first set of first receivers. 
     
     
         21 . The method of  claim 20 , wherein step a) and step b) occur during a single machine cycle. 
     
     
         22 . The method of  claim 19 , wherein step c) occurs before step b), and the method further comprises retracting the first set of first receivers to a retracted position clear of the mold prior to step b). 
     
     
         23 . The method of  claim 22 , wherein step d) comprises rotating a tooling plate to which the first set of first receivers is affixed. 
     
     
         24 . The method of  claim 23 , wherein during step e) another set of first articles is transferred from the mold to a second set of second receivers affixed to the tooling plate. 
     
     
         25 . The method of  claim 19 , wherein step c) occurs after step b).