The present invention relates to blow molded cases. More specifically, the invention relates to blow molded cases having a double wall base portion with a hole in the outer wall thereof for accommodating additional objects, such as drawers or removable containers, as well as a system for creating such cases.
The use of blow-molding as a method for manufacturing various sorts of articles is generally well known. Typically, this process involves the use of a mold consisting of two separate halves or portions having cavities of particularly desired shapes and sizes. Usually, one extrudes a large-diameter, sealed tube of molten material (commonly referred to as a “parison”), places the tube between the mold halves, and closes the mold around the tube. Fluid pressure is then introduced into the tube, forcing the molten tube against the walls of the cavities, conforming the tube to the shape thereof. The pressure is maintained until the molten material cools and solidifies. The pressure is then released, the mold halves are pulled apart, and the hardened article is ejected therefrom.
One such article that is commonly manufactured in this manner is double wall cases. By producing cases in this manner, one is able to produce a device that is capable of carrying and protecting tools placed inside the case that has a multitude of desirable physical characteristics—such as rigidity, scuff resistance, and impact absorption—yet that is relatively inexpensive to manufacture. In some instances, these cases are formed as single-piece cases using the process described above, where one mold half forms the exterior of both the base and lid portions of the case, while the other mold half forms the interior of both base and lid portions. Usually, the mold half forming the exterior of the case forms a wall with a smooth, attractive shape, while the mold half that forms the interior of the case is often molded with compartments to hold specific contents. In other instances, the process described above can be used to separately create the base and lid portions of the case, which can subsequently be connected together.
Though such cases are generally well known in the art, efforts have been made to increase the carrying capacity of such cases while reducing the size of the case, as attempts to increase the interior space of the case can quickly increase the weight and size of the case due to its double wall nature. Accordingly, it has been suggested to cut out sections of the interior walls of the case in order to utilize the wasted volume of space between the double walls. By doing so, the case can be made smaller in light of the fact that this previously unused space is now being used to house the objects being carried in the case. Moreover, by removing sections of the walls, the case also decreases significantly in weight.
For example, U.S. Pat. Nos. 3,317,955 and 3,327,841 to Schurman, et al., disclose cases in which a portion of the case wall is cut out after blow-molding. Specifically, the '955 patent, which discloses the earliest known double wall case blow-molded case, illustrates a rectangular cutout of most of the inside wall of the base portion. Similarly, the '841 patent discloses a partial cutout shaped to accommodate the outline of a pistol-type soldering gun, where the gun is further supported by a cradle molded in the outside wall of the base portion of the case, while the space under the uncut portion of the inside base is usable for storage of an electric cord, thereby facilitating the use of what was previously wasted, unused space. In these particular examples, because the blow molding process involves the use of a parison with a continuous, unbroken surface (and thus, the mold itself cannot produce any holes in the blow-molded wall other than the hole or holes through which the fluid pressure is introduced), a section of the case wall is cut or burned after the blow molding process is completed and the case has been ejected from the mold. For example, cutting the inner wall was often accomplished with the use of a small circular saw blade mounted to a router and guided by a molded vertical lip surrounding the area to be cut. The router was fixed and the case was moved around the router axis by hand or by mechanical means. Round holes were often cut with hole saws, or occasionally, were burned.
Another, more improved method of removing a section of the inner wall of the case is to punch a hole in this wall during the blow molding process. Examples of such methods are disclosed in U.S. patent application Ser. Nos. 10/958,824 and 11/105,721, each of which is assigned to the assignee of the present application and are incorporated herein by reference. In these varieties, punches are used during the blow-molding process to produce the desired holes. The punch, when in an unactivated position, forms a portion of mold surface, against which the walls of the blow molded case are blown. Then, at a predetermined interval, before the walls of the case are fully hardened, the punch is moved to an activated position, creating a hole in the wall of the case.
One limitation such cases may still have in some applications, however, is their ability to accommodate compartments for accessories. For example, one common use for such cases is tools, such as a drill, which, in addition to the main tool, include other accessories, such as drill bits. However, when a hole is created in an inner case wall, a fair amount of the remaining portions of the wall may be required to provide support for the perimeter of the hole, which retains the main tool. Accordingly, the available space for additional holes in this inner wall for accommodating accessories is sometimes limited.
What is desired, therefore, is a blow molded case for housing an object as well as accessories of the object. What is further desired is a blow molded case that has a high carry capacity, yet is not heavy or cumbersome. What is also desired is a blow molded case that is easy and inexpensive to manufacture, does not produce residual sawdust and/or charred plastic, and does not require a long blow molding cycle.
Accordingly, it is an object of the present invention to provide a blow molded case that maximizes the amount of useable space between the inner and outer walls of the base portion of the case.
It is a further object of the present invention to provide a blow molded case that minimizes the size of the exterior of the case.
It is yet another object of the present invention to provide a blow molded case that does not require additional manufacturing steps after the blowing cycle.
In order to overcome the deficiencies of the prior art and to achieve at least some of the objects and advantages listed, the invention comprises a blow molded case for housing a first object and a second object, including a blow-molded, double wall base portion, the base portion comprising an outer case wall, an inner case wall for accommodating at least part of the first object, and a cavity at least partially enclosed by the inner and outer walls, and a lid portion connected to the base portion and moveable from an open position to a closed position such that, when in the closed position, the lid portion at least partially covers the inner case wall of the base portion, wherein the outer wall of the base portion has a hole therethrough for passing the second object through the outer wall and into the cavity.
In some these embodiments, the hole is a punched hole that corresponds to at least part of the outline of the second object. In some embodiments, the base portion has a mold parting line, the outer wall of the base portion includes a sidewall extending substantially perpendicular to the parting line, and the hole is located in the sidewall of the base portion. In certain of these embodiments, the sidewall of the base portion is arcuate, such that the hole therethrough is multi-planar. In some embodiments, the sidewall of the base portion includes a recess adjacent the hole.
In some these embodiments, the invention includes a receptacle insertable through the hole and into the cavity.
In other embodiment, the invention comprises a blow molded case for housing a first object and a second object, including a blow-molded, double wall base portion, the base portion comprising an outer case wall and an inner case wall for accommodating at least part of the first object, and a blow-molded, double wall lid portion connected to the base portion, the lid portion comprising an outer case wall and an inner case wall at least partially enclosing a cavity, the lid portion being moveable from an open position to a closed position such that, when in the closed position, the inner case wall of the lid portion at least partially covers the inner case wall of the base portion, wherein the outer wall of the lid portion has a hole therethrough for passing the second object through the outer wall of the lid portion and into the cavity.
In still another embodiment, the invention comprises a method for creating the base portion of a blow molded case having inner and outer case walls, the method including the steps of moving a first mold portion adjacent a second mold portion along a seam, thereby creating a cavity having a cavity surface, blowing the inner and outer case walls of the base portion of a case against the cavity surface, and creating a hole in the outer case wall of the base portion.
In some of these embodiments, the invention includes extending at least part of a punch parallel to the seam, through the outer case wall and into the cavity.
In yet another embodiment, the invention comprises an apparatus for creating the base portion of a blow molded case having inner and outer case walls, including a mold having first and second mold portions that, when located adjacent each other along a seam, at least partially enclose at least one cavity having a cavity surface, wherein the cavity surface includes outer and inner case wall portions, against which the outer and inner walls of the base portion of the case are blown, respectively, during blow-molding, and a punch having a punching surface, wherein, when the punch is in an unactivated position, the outer case wall portion of the cavity surface includes the punching surface and, when the punch is in an activated position, the punch is extended past the outer wall of the case and into the cavity such that a hole is created in the outer wall of the case.
In some of these embodiments, the outer case wall portion of the cavity surface includes a section substantially perpendicular to the seam, against which a sidewall of the outer wall of the base portion of the case is blown during blow molding, and the substantially perpendicular section includes the punching surface when the punch is in an unactivated position, and the punch is extended past the sidewall when the punch is in an activated position.
In certain of these embodiments, the substantially perpendicular section of the outer case wall portion of the cavity surface has a non-planar area. In some embodiments, the substantially perpendicular section of the outer case wall portion of the cavity surface or the punching surface of the punch includes a protuberance extending into the cavity adjacent the punching surface when the punch is in an unactivated position, such that a recess is formed in an outer surface of the outer case wall during blow molding.
The basic components of one embodiment of a blow molded case in accordance with the invention are illustrated in
The case 10 includes a double wall base portion 12 and a lid portion 14 connected thereto. In some embodiments, the lid portion 14 is a separate piece that is connected to the base portion 12 after the blow molding process is completed via a hinge mechanism 15. However, like the base portion 12, the lid portion 14 may also be a blow molded article, and thus, in certain embodiments, the lid portion 14 is integrally formed with the base portion 12 during a single blow molding process.
The base portion 12 has an inner case wall 22 and an outer case wall 24, which at least partially enclose a cavity 26 (which is best illustrated in
Any of various configurations may be employed for the surface of the inner case wall 22, including various recesses and/or holes therethrough in whatever shapes and sizes as may be appropriate to accommodate the tool, as well as any other accessories that it may be desired to carry in the case 10. For example, the inner case wall 22 may have a recess 60 for accommodating the first object 21, which may, as examples, be a tool or a primary container, and may, in some embodiments, include additional recesses 62 for accessories. In certain advantageous embodiments, the inner case wall 22 includes holes, such as punched holes 64, 66, for receiving the objects and utilizing some of the cavity 26 for accommodating same. Various mold planes and punches can be used to create any variety of through-holes, blind holes, flanges, or sidewalls for accommodating, and providing support for, these various objects, as is more fully taught in U.S. patent application Ser. Nos. 10/958,824 and 11/105,721. Similarly, the lid portion 14 may also include an inner case wall 37 with recesses and/or holes for accommodating the top of the objects when the case 10 is closed, as is described in the aforementioned applications.
The outer case wall 24 includes a sidewall 25 that runs around the perimeter of the base portion 12, including the front, back, and ends of the case 10 when oriented in an upright position. The sidewall 25 extends in a direction substantially perpendicular to a mold parting line 23 of the base portion 12, which parting line is the result of the inner and outer case walls 22, 24 being blown against a seam joining first and second portions of a mold, as is further explained below.
The sidewall 25 has at least one hole 20 that corresponds to the outline of a second object 31, which may, for instance, be a receptacle for holding various parts or accessories of a tool, such as a tray, a drawer, or a removable container of some sort. Accordingly, the receptacle 31 may be inserted through the hole 20 and into the cavity 26 between the inner and outer case walls 22, 24.
In embodiments where the lid portion 14 is also a double wall, blow molded article, the hole 20 may be formed in the outer case wall 38 of the lid portion 14 instead of the base portion 12. In other embodiments, a hole may be formed in both the base and lid portions 12, 14, such that the hole 20 in the lid portion 14 can accommodate a third object.
As shown in
In some embodiments, the base portion 12 includes a smaller cavity 33 near the top edge thereof, which creates a sort of pocket above the receptacle 31. This can be useful particularly, for example, in embodiments employing a drawer, as the cavity 33 can be employed to help retain the drawer 31 in a desired position or to provide a track feature if so desired.
As shown in
For example, in some embodiments, a protrusion is specifically sized and shaped to correspond to a particular portion of the first object 21, and may be shaped to fit into a particular aperture or recess thereof, while in other embodiments, a protrusion may merely be shaped to correspond to a particular portion of the outline of the object 21 in order to help keep it in place, while in still other embodiments, protrusions may simply be positioned at a location that corresponds to the length or width of the object 21 in order to restrain its movement. In this way, various compartments may be created for various objects, such as a main section for the object 21 and auxiliary sections for cords or other accessories, as is more fully explained in the aforementioned applications.
In certain advantageous embodiments, a protrusion 46 is specifically positioned at a location corresponding to the length of the receptacle 31 in order to limit its movement into the cavity 26.
In some embodiments, the sidewall 25 is non-planar. For example, as shown most clearly in
In some embodiments, the receptacle 31 includes a number of small bosses 35 on the underside 34 thereof for further engaging the ribs 32 and providing a small locking effect as the receptacle 31 is slid into the cavity 26. In certain embodiments, the receptacle 31 also includes tracks 36 along its sides for guiding and/or retaining the receptacle 31 in a particular portion of the case 10. For example, as shown in
As illustrated in
The operation of the mold portions 52, 54 and the punches 56, 57, 58 will now be described. When the first mold portion 52 is adjacent the second mold portion, a cavity 70 is formed. For example, referring to
As shown in
After a predetermined time interval, the punches 56, 57, 58 are moved from an unactivated position to an activated position, as illustrated in
In some embodiments, a punch is partially extended when in the unactivated position in order to further shape the case walls 22, 24. For example, when in the unactivated position, punch 58 may protrude out beyond the mold surface 72 into the cavity 70. As a result, when the outer case wall 24 is blown against the cavity surface 80 (which includes part of the punch 58), the case wall 24 is formed around the punch 58. In this way, a recessed portion is formed in the sidewall 25.
This is particularly useful in embodiments where one desires an outer case wall 24 having a hole 20 where the hole itself is multi-planar. For example, while the finger-grip recess 27 discussed above may be created by using a mold portion 54 having a protuberance (not shown) extending into the cavity 70 parallel to the seam 53, this may also be accomplished with a punch 57 having a multi-planer punching surface 67. As shown in
In certain advantageous embodiments, the second mold portion 54 includes a protuberance 84 that extends into the cavity 70. The protuberance 84 can be any shape or size appropriate to create the desired protrusion 46 in the outer case wall 24. Accordingly, when the case wall 24 is blown against the cavity surface 80, protrusion 46 is created. In some embodiments, the protuberance 84 is specifically positioned at a location corresponding to the length of a receptacle 31 to be inserted through the punched hole 20. In certain embodiments, a protuberance 85 is provided to create the corresponding rib 32 for engaging the bottom of the receptacle 31. In yet other embodiments, a protuberance 87 is provided in the top mold portion 52, which can be used, for instance, to create the pocket 33.
It should be understood that the foregoing is illustrative and not limiting, and that obvious modifications may be made by those skilled in the art without departing from the spirit of the invention. Accordingly, reference should be made primarily to the accompanying claims, rather than the foregoing specification, to determine the scope of the invention.
This is a continuation of co-pending U.S. patent application Ser. No. 11/180,230, filed Jul. 13, 2005, now U.S. Pat. No. 7,455,513.
Number | Date | Country | |
---|---|---|---|
Parent | 11180230 | Jul 2005 | US |
Child | 12273189 | US |