Molding systems and related methods

Abstract

A system for molding an object includes an articulated mold having an axis and a plurality of mold portions configured to collectively define a molding cavity for shaping the object when arranged in respective molding positions. The system includes a plurality of actuators, each operatively coupled to a respective mold portion and configured to move the respective mold portion along the axis from the respective molding position toward a respective ejecting position for releasing the object. The system includes a controller in communication with each of the plurality of actuators and configured to independently activate each of the plurality of actuators such that one of the plurality of mold portions moves along the axis from the respective molding position toward the respective ejecting position while at least one other of the plurality of mold portions remains stationary relative to the object in order to at least partially support the object.

What is claimed is: 
     
         1 . A system for molding an object, comprising:
 an articulated mold having an axis and including a plurality of mold portions configured to collectively define a molding cavity for shaping the object when arranged in respective molding positions;   a plurality of actuators, wherein each of the plurality of actuators is operatively coupled to a respective mold portion of the plurality of mold portions and configured to move the respective mold portion along the axis from the respective molding position toward a respective ejecting position for releasing the object; and   a controller in communication with each of the plurality of actuators and configured to independently activate each of the plurality of actuators such that one of the plurality of mold portions moves along the axis from the respective molding position toward the respective ejecting position while at least one other of the plurality of mold portions remains stationary relative to the object in order to at least partially support the object.   
     
     
         2 . The system of  claim 1 , wherein the molding cavity includes at least one of a tongue or a groove extending in a direction parallel to the axis. 
     
     
         3 . The system of  claim 1 , wherein the plurality of actuators are configured to move the respective mold portions along the axis from the respective molding positions toward the respective ejecting positions in a same direction. 
     
     
         4 . The system of  claim 1 , wherein the controller is configured to activate each of the plurality of actuators sequentially. 
     
     
         5 . The system of  claim 4 , wherein the plurality of mold portions includes a bottom portion and at least one side portion distributed along the axis. 
     
     
         6 . The system of  claim 5 , wherein the at least one side portion is configured to move along the axis from the respective molding position toward the respective ejecting position prior to the bottom portion moving along the axis from the respective molding position toward the respective ejecting position such that the bottom portion supports the object during movement of the at least one side portion. 
     
     
         7 . The system of  claim 4 , wherein the plurality of mold portions includes an upper side portion and a lower side portion distributed along the axis. 
     
     
         8 . The system of  claim 7 , wherein the lower side portion is configured to move along the axis from the respective molding position toward the respective ejecting position prior to the upper side portion moving along the axis from the respective molding position toward the respective ejecting position such that the upper side portion supports the object during movement of the lower side portion. 
     
     
         9 . The system of  claim 4 , wherein the plurality of mold portions includes first and second side-by-side portions distributed about the axis. 
     
     
         10 . The system of  claim 9 , wherein the first side-by-side portion is configured to move along the axis from the respective molding position toward the respective ejecting position prior to the second side-by-side portion moving along the axis from the respective molding position toward the respective ejecting position such that the second side-by-side portion supports the object during movement of the first side-by-side portion. 
     
     
         11 . A method of releasing a molded object from a molding cavity defined by a plurality of mold portions of an articulated mold having an axis, the method comprising:
 moving a first mold portion of the plurality of mold portions along the axis from a respective molding position toward a respective ejecting position, wherein during moving the first mold portion the object is supported by a second mold portion of the plurality of mold portions; and   subsequently moving the second mold portion along the axis from a respective molding position toward a respective ejecting position.   
     
     
         12 . The method of  claim 11 , wherein moving the first mold portion includes activating a first actuator operatively coupled to the first mold portion. 
     
     
         13 . The method of  claim 12 , wherein moving the second mold portion includes activating a second actuator operatively coupled to the second mold portion. 
     
     
         14 . The method of  claim 11 , wherein the first mold portion is arranged below the second mold portion along the axis when the first and second mold portions are in the respective molding positions. 
     
     
         15 . The method of  claim 11 , wherein the first mold portion is arranged above the second mold portion along the axis when the first and second mold portions are in the respective molding positions. 
     
     
         16 . The method of  claim 11 , wherein the first and second mold portions are arranged side-by-side about the axis when the first and second mold portions are in the respective molding positions. 
     
     
         17 . A method of manufacturing an object in an articulated mold having an axis, comprising:
 arranging a plurality of mold portions of the articulated mold into respective molding positions to define a molding cavity;   molding the object in the molding cavity;   moving a first mold portion of the plurality of mold portions along the axis from the respective molding position toward a respective ejecting position, wherein during moving the first mold portion the object is supported by a second mold portion of the plurality of mold portions; and   subsequently moving the second mold portion along the axis from a respective molding position toward a respective ejecting position.   
     
     
         18 . The method of  claim 17 , wherein moving the first mold portion includes activating a first actuator operatively coupled to the first mold portion. 
     
     
         19 . The method of  claim 18 , wherein moving the second mold portion includes activating a second actuator operatively coupled to the second mold portion. 
     
     
         20 . The method of  claim 17 , wherein the first mold portion is arranged below the second mold portion along the axis when the first and second mold portions are in the respective molding positions. 
     
     
         21 . The method of  claim 17 , wherein the first mold portion is arranged above the second mold portion along the axis when the first and second mold portions are in the respective molding positions. 
     
     
         22 . The method of  claim 17 , wherein the first and second mold portions are arranged side-by-side about the axis when the first and second mold portions are in the respective molding positions. 
     
     
         23 . The method of  claim 17 , wherein molding the object includes blow molding the object from a preform. 
     
     
         24 . The method of  claim 23 , wherein blow molding the object includes stretch blow molding the object from the preform. 
     
     
         25 . The method of  claim 23 , further comprising conditioning the preform prior to blow molding, wherein conditioning the preform includes:
 positioning the preform in a heating cavity; and   forcing a heated gas into the heating cavity onto an exterior surface of the preform.   
     
     
         26 . The method of  claim 25 , wherein conditioning the preform further includes positioning a nozzle having at least one sidewall within the heating cavity to at least partially surround the preform. 
     
     
         27 . The method of  claim 26 , wherein the at least one sidewall includes at least one aperture, and wherein forcing the heated gas into the heating cavity includes directing the heated gas through the at least one aperture. 
     
     
         28 . The method of  claim 27 , wherein directing the heated gas through the at least one aperture includes directing the heated gas to a predetermined portion of the exterior surface of the preform.