Patent Application
20210129403
The present invention is directed to an alignment lock assembly configured to retain and re-lubricate its engagement surfaces with applied lubricant longer to reduce wear, and more particularly to a self-lubricating alignment lock assembly that also is of self-cleaning construction to reduce abrasive wear ordinarily caused by debris by cleaning away debris during use and operation.
Mold locks, such as alignment interlocks, are used on reciprocating equipment, such as injection molds, to facilitate alignment of components, namely mold halves, as they are brought together and then moved apart during molding of a part during cycling of the mold during operation. As the mold halves are brought together during closing of the mold during a molding cycle, such alignment interlocks, also known as mold interlocks, are first to make contact and help guide the mold halves into proper alignment as they come together. As the mold is closed, opposed engagement surfaces of each interlock come into slidable contact with one another helping to compensate for mold misalignment of one mold half relative to the other mold half by aligning or realigning the mold halves as they are being brought together so that the cavity formed by the mated mold halves is aligned during injection of molten material, e.g., molten plastic, into the cavity.
While various mold lock arrangements are known, virtually all of them employ a male lock half that slidably registers with a female lock half during closing and opening of the mold during a mold cycle. The female lock half has a male lock receiving channel formed by a pair of spaced apart inwardly facing and opposed male lock engagement surfaces, which can define a male lock receiving receptacle, and the male lock half has an elongate head with a pair of outwardly facing and opposed female lock engagement surfaces slidably received in the channel.
One commonly used mold lock is a mold interlock that is an assembly that employs a female lock half where the male lock receiving channel has an endwall defining a male lock head receiving receptacle, and a male lock half having an outwardly extending head that is received in the receptacle during mold closing. The head of the male lock half has a profile that is generally complementary to the receptacle of the female lock half to facilitate slidable guiding of the head into the receptacle in a manner that also compensates for some misalignment in the mold halves being brought together during closure. Such a male lock head profile typically has one or both leading edges formed with a ramp that facilitates mold-aligning entry of the head into the female receptacle.
As a result of the relatively frequent and rapid cycling of the mold haves being opened and closed over and over again during reciprocating mold operation, engagement between the male lock head half with the female lock half during reciprocation of the head into and out of the female receptacle produces a considerable amount of friction leading to undesirable mold interlock wear. Excessive premature interlock wear over time not only leads to premature interlock replacement or even failure, it also undesirably increases the amount of misalignment between the mold halves that occurs during mold operation. Mold misalignment caused by excessive interlock wear not only can lead to the production of reduced or inferior quality molded parts, it can also result in damage to the mold, such as when the mold halves clash during cycling due to the misalignment.
To prevent these and other interlock wear related problems, mold interlocks in the past needed to be lubricated, which at times undesirably required mold down-time to do so. However, even despite frequent lubrication, excessive premature wear nonetheless still occurred too often because the lubricant frequently did not stay where most needed on the engaging surfaces of the male and female lock halves. This is because the lubricant was frequently “wiped away” by a line or region of contact of the engaging surfaces of the lock halves formed during interlock engagement and disengagement that moved in one direction during engagement during mold closing and in an opposite direction during mold opening.
To try to extend the length of time applied lubrication remained effective, mold interlocks have been made with relatively large, wide and deep grease channels and dimples formed in their engagement surfaces. Because of their size and depth, it can be difficult to remove all of the corrosion-inhibiting oil prior to installation of the interlock on a mold resulting in an oil film left within the channels or dimples, which can undesirably inhibit adhesion of any lubrication applied. Poor lubricant adhesion is problematic as it defeats the very purpose of the channels and dimples because it leads to premature exhaustion or loss of lubricant on the interlock engagement surfaces undesirably causing premature interlock wear.
Just as bad, if not worse, is the fact that the rather large size, width and depth of these grease channels and dimples also cause them to accumulate debris, such as dirt, chips, flakes, grit, and the like, during mold cycling. Accumulation of debris not only reduces grease-holding capacity, undesirably reducing the length of time before application of lubricant is needed, but the debris can be pulled out of the channels and dimples by the wiping action of the slidable moving contact between the interlock engagement surfaces during mold cycling. Unfortunately, accumulated debris pulled out of the channels and dimples typically becomes deposited on the interlock engagement surfaces, which can cause abrasive wear. When this happens, the excessive abrasive wear can not only lead to premature replacement or failure of the interlock, but it typically also undesirably increases tolerances of the interlock disadvantageously reducing the amount of mold misalignment compensation provided by the interlock. Should such abrasion wear induced tolerances increase too much and mold misalignment compensation correspondingly become too poor, it can produce mold misalignment so great during mold closure that it can adversely impact molded component fit, finish and quality.
U.S. Pat. No. 8,821,144, is directed to a mold interlock with non-uniformly arranged rows and columns of relatively large and deeply recessed-donut shaped particle wells or rings in which lubricating grease applied to the interlock accumulates. As with the aforementioned channels and dimples, the particle rings are designed to accumulate grease when the engagement surface of the interlock is lubricated that is used to re-lubricate the engagement surfaces during engagement and disengagement of the interlock during cycling of the mold.
Unfortunately, the non-uniform arrangement of the rows and columns of particle rings also results in engagement surfaces having regions where the particle rings of adjacent rows and columns either do not overlap or do not uniformly overlap. Such non-uniform or lacking overlapping of particle rings of adjacent rows and columns produces non-uniform re-lubrication of the adjacent engagement surface during engagement and disengagement of the interlock during mold cycling. This causes areas of the adjacent engagement surfaces to either be poorly re-lubricated or not be re-lubricated at all during interlock engagement and disengagement during mold cycling. Those regions of the interlock engagement surface where re-lubrication is poor or lacking can prematurely accelerate interlock wear and failure while also undesirably reducing the amount of mold misalignment compensation the interlock can correct during use and operation.
Just as bad, if not worse, is that the particle rings are also so large, wide and/or deep that debris also tends to easily get trapped in them during engagement and disengagement of the interlock during mold cycling. Where too much debris accumulates and is not removed, it reduces the particle ring volume available for grease thereby reducing re-lubrication of areas of the engagement surface adjacent debris-filled rings undesirably increasing interlock wear. Where accumulated debris is discharged from particle rings during interlock engagement and disengagement during mold cycling, the freed debris undesirably causes abrasive wear of the interlock disadvantageously even further accelerating interlock wear. Such accelerated wear not only can require premature interlock replacement or lead to premature interlock failure, it typically also results in the interlock providing less mold misalignment compensation than desired or permitted before replacement or failure. When the interlock is worn so much it cannot provide proper mold misalignment compensation, it can result in the mold halves being misaligned so much when closed that the resultant molded component or components are out of tolerance, are misshapen, or are of such poor quality that they are not suitable for use.
What is needed is an improved mold lock that not only significantly extends how long applied lubricant remains available on the lock to re-lubricate the engagement surfaces of the lock to reduce and preferably minimize wear. What also is needed is such an improved mold lock that minimizes the amount of debris that can become trapped to further minimize wear, particularly abrasive wear.
The present invention is directed to a high-lubricity self-cleaning alignment lock assembly, preferably an alignment interlock assembly, such as a mold lock, bar lock, or parting line lock, which is configured to facilitate reciprocating mold alignment, and which employs relatively shallow lubricant-retaining recesses formed in engagement surfaces of the assembly that readily accumulates lubricant, e.g., grease, while preventing accumulation of debris thereby minimizing lock wear and extending lock life during reciprocating mold cycling. The lubricant-retaining recesses define a three-dimensionally contoured lubricant film retaining region of the engagement surfaces of the lock assembly that has a maximum depth shallow enough so a wiping action produced by the engagement surfaces of the lock assembly cleans the recesses of debris, such as dirt, chips, dust, grit, and the like, therefrom while also spreading lubricant accumulated therein along substantially the entire lubricant film retaining region to maintain a lubricant film thereon. The lock assembly can be and preferably is configured with at least one debris repository well formed in or alongside each engagement surface equipped with a three-dimensionally contoured lubricant film retaining region for accumulating debris wiped therefrom into the well producing a self-cleaning lock assembly.
The lock assembly has a male lock half carried by one component of a reciprocating machine, such as a molding machine, which is disposed operable cooperation with a female lock assembly carried by another component of the reciprocating machine that facilitates alignment of the one component, e.g., mold half, relative to the another component, e.g., another mold half, during reciprocating cycling of the components during reciprocating machine, e.g., molding machine, operation. Each lock half has at least one and preferably a pair of engagement surfaces that can slidably contact one another during reciprocating machine, e.g., molding machine, operation. Each engagement surface is configured with a three-dimensionally contoured lubricant film retaining region having relatively shallow recesses configured to accumulate and release lubricant and also to readily shed debris therefrom during the wiping action of opposed engagement surfaces of the lock halves when being in slidable moving contact with one another during reciprocating machine, e.g., molding machine, operation.
Each recess is relatively shallow having a depth no greater than 25 microns and preferably between 25 microns and 5 microns producing a recess deep enough to accumulate lubricant therein that is squeegeed and dispensed by the wiping action to re-lubricate the three-dimensionally contoured lubricant film retaining region while being shallow enough to cause any debris in the recesses to be wiped away by the same wiping action. Each recess is defined by a sidewall and a bottom wall that is generally flat. In a preferred embodiment, each recess is formed of a generally round, circular, oval or oblong pocket recessed into the engagement surface in the three-dimensionally contoured lubricant film retaining region of the engagement surface. In a preferred embodiment, each recess, preferably each pocket, is formed by laser etching or laser cutting with the sidewall defining each recess, preferably each pocket, being an ablation region produced during laser etching or cutting.
There can be and preferably is at least one debris repository well formed in or alongside each engagement surface equipped with a three-dimensionally contoured lubricant film retaining region for accumulating debris wiped therefrom into the well producing a self-cleaning lock assembly. In a preferred embodiment, at least one of the engagement surfaces equipped with a three-dimensionally contoured lubricant film retaining region has debris repository well that is disposed along each side or end of the corresponding adjacent three-dimensionally contoured lubricant film retaining region bracketing the three-dimensionally contoured lubricant film retaining region to collect debris wiped from the three-dimensionally contoured lubricant film retaining region during reciprocating cycling in one direction, e.g., during mold closing, as well as during reciprocating cycling in the opposite direction, e.g., during mold opening.
The recesses, preferably pockets, are uniformly spaced apart from one another forming at least a plurality of pairs, i.e., at least three, rows and columns uniformly spaced from one another and staggered so as to produce a three-dimensionally contoured lubricant film retaining region where each recess, preferably pocket, in each one of the rows or columns overlaps at least 25% and preferably at least 33% of the closest or adjacent-most recess, preferably pocket, of each adjacent one of the rows or columns in or along a direction generally transverse to the row or column. Such an array of uniformly spaced rows and columns of recesses, preferably pockets, each with at least a plurality of pairs, i.e., at least three, recesses, preferably pockets, advantageously produces a three-dimensionally contoured lubricant film retaining region that builds, maintains and re-lubricates a lubricant film thereon during reciprocating machine, e.g., molding machine, operation.
Each debris repository well preferably has a depth greater than that of the maximum depth of the recesses or pockets of the three-dimensionally contoured lubricant film retaining region such that debris wiped free of the three-dimensionally contoured lubricant film retaining region is deposited in an adjacent well where it remains. In one preferred embodiment, each debris repository well has a depth at least twice as great as the maximum depth of the lubricant-retaining recesses or pockets helping ensure debris wiped free of the three-dimensionally contoured lubricant film retaining region and deposited in such a debris repository well remains trapped or collected in the debris repository well. In another preferred embodiment, each such debris repository well has a depth at least three times as great as the maximum depth of the lubricant-retaining recesses or pockets of the three-dimensionally contoured lubricant film retaining region.
One preferred mold lock assembly is a self-lubricating mold lock, such as a mold interlock or bar lock, having at least one mold lock engagement surface that slidably contacts and wipes another mold lock engagement surface during mold cycling with at least one of the engagement surfaces configured with such relatively shallow lubricant-retaining recesses in the form of nanoscale size micro-retention grease retention pockets formed therein that are smaller in size relative to the debris normally encountered during mold cycling to prevent debris from also accumulating therein. The mold lock also is self-cleaning as the micro-retention pockets are nanoscale in size such that the pockets preferably are also shallower in depth relative to such debris to not only help prevent debris accumulation in the pockets, but also so any debris small enough to make it into any of the pockets is readily removed therefrom by a wiping action produced as a sliding line or region of contact between the engaging lock surfaces moves during opening and closing of the mold.
A preferred embodiment of the present invention is directed to a re-lubricating self-cleaning alignment interlock for aligning one component or a reciprocating machine relative to another component of the reciprocating machine during reciprocable movement of one component toward the other component and as the components are coming together preferably in mating contact therewith. A re-lubricating self-cleaning mold interlock of the present invention has a male lock carried by one reciprocating machine component with an elongate outwardly extending alignment-seeking head that is slidably and releasably received in a receptacle formed in a female lock carried by the other reciprocating machine component that is configured to provide at least one lubricant reservoir which lubricant is re-applied on at least one of the contacting surfaces of the male and/or female lock during insertion of the male lock head into the female lock receptacle and/or removal of the head from the receptacle. At least one of the contacting surfaces of the male lock head and/or which define a portion of the female lock receptacle have at least a plurality of pairs, i.e., at least three, of micro-grease retention pockets formed therein distributed throughout at least a substantial portion of the contacting surface(s) for holding grease in each pocket therein that helps maintain a lubricious film of the lubricating grease on one or both contacting surfaces during male lock insertion into or withdrawal from the female lock receptacle in a localized region of and adjacent each pocket. Each one of the micro-grease retention pockets is deep enough to hold lubricating grease when re-lubricated during one of male lock insertion into and/or removal from the female lock receptacle to help maintain a lubricating film of the grease throughout substantially the entire contacting surface(s) of the male and female locks of the interlock. Each one of the grease micro-retention pockets is shallow enough to prevent debris, e.g., chips, dirt, grit, dust, etc., from accumulating or otherwise becoming trapped therein and which preferably is so shallow that such debris is swept out by a debris-cleaning wiping action that occurs when the contacting surfaces of the male lock head and female lock receptacle slidably and movably contact each other during one or both male lock head insertion into and/or removal from the female lock receptacle.
Various other features, advantages, and objects of the present invention will be made apparent from the following detailed description and any appended drawings.
One or more preferred exemplary embodiments of the invention are illustrated in the accompanying drawings in which like reference numerals represent like parts throughout and in which:
Before explaining one or more embodiments of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of the components set forth in the following description or illustrated in any appended drawings. The invention is capable of other embodiments, which can be practiced or carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein is for the purpose of description and should not be regarded as limiting.
With reference to
With continued reference to
To facilitate mounting of the male lock half 28, the male lock half 28 has one or more fastener-receiving mounting through bores 36 that extend completely through a base 38 of the lock half 28 that extends along a bottom 40 or outer edge 42 of the lock half 28. To facilitate mounting of the female lock half 32, the female lock half 32 has one or more fastener-receiving mounting through bores 44 that extend completely through a base 46 of the lock 32 that extends along a bottom 48 or outer edge 50 of the lock 32. Where used on a mold, one of the lock halves 28 or 32 of the interlock assembly 26 is mounted to one of the mold halves and the other one of the lock halves 28 or 32 of the interlock assembly 26 is mounted to the other one of the mold halves with the interlock assembly 26 guiding the mold halves into alignment as the head 30 of the male lock half 28 is received in the receptacle 34 formed in the female lock half 32 as the mold halves come together during cycling of the mold.
When used to align mold halves of a plastic injection mold, the male and female lock halves 28 and 32 of such an interlock assembly 26, preferably mold parting line lock or interlock 24, can be and preferably are mounted to respective opposed mold halves of a plastic injection mold in the manner such as shown and disclosed in commonly owned U.S. Pat. No. 7,862,326, the entirety of which is hereby expressly incorporated by reference herein. A plurality of interlock assemblies 26, each preferably a mold parting line lock or interlock 24, preferably is used with each pair of mold halves of the plastic injection mold, with a preferred embodiment employing four such interlock assemblies 26, each preferably a mold parting line lock or interlock 24, which are spaced apart and disposed along each side of the mold halves of the mold in the manner also shown and disclosed in U.S. Pat. No. 7,862,326. In such an arrangement, the male lock half 28 of each one of the four interlocks 26, preferably mold parting line locks or interlocks 24, is mounted to one of the mold halves and the female lock half 32 of each one of the four interlocks 26, preferably mold parting line locks or interlocks 24 in such a manner like that further depicted and described in U.S. Pat. No. 7,862,326.
The female lock half 32 shown in more detail in
With continued reference to
In one preferred embodiment, the upper or outer corner 74 of each misalignment tolerant male lock head receptacle entry facilitating profile 72 is generally planar, tapered and/or inclined in a manner that narrows the width of the receptacle 34 from at or adjacent the mouth 70 of the receptacle 34 the farther back or deeper into the receptacle 34 the generally planar, tapered and/or inclined corner 74 extends. In another preferred embodiment, the upper or outer corner 74 of each misalignment tolerant male lock head receptacle entry facilitating profile 72 is a generally convexly or outwardly radiused corner 74 that is curved and/or inclined in a manner that narrows the width of the receptacle 34 from at or adjacent the mouth 70 of the receptacle 34 the farther back or deeper into the receptacle 34 the radiused or curved corner 74 extends.
With continued reference to
Formed in the bottom corners of the receptacle 34 are diagonally outwardly extending corner reliefs 78 and 80 spaced apart by bottom surface 66 and receptacle endwall 68 with each corner relief 78 and 80 providing a debris repository well 82 and 84 and which can also serve as a lubricant reservoir 86 and 88 during use and operation of interlock assembly 20 that preferably is configured for use as a mold parting line interlock 24. As shown in
With additional reference to
With continued reference to
The male lock head 30 is further defined by a pair of spaced apart, generally parallel and generally planar sidewalls 98 and 100 and by a pair of front and rear walls 102 and 104. The head sidewalls 98 and 100 are respectively defined by female lock engagement surfaces 106 and 108, which preferably are generally flat or substantially planar, one surface 106 or 108 of which preferably makes sliding engagement or contact with corresponding surface 58 or 60 of respective receptacle sidewall 62 or 64 during male lock head 30 insertion into or removal from the female lock receptacle 34. The sidewalls 98 and 100 and front and rear walls 102 and 104 of the head 30 extend generally perpendicular relative to the female lock arm abutments 90 of the male lock base 38 and outwardly from the base 38 to or adjacent the end wall 96 of the head 30. The head end wall 96 is generally perpendicular to the head sidewalls 98 and 100 and is also generally perpendicular to the head front and rear walls 102 and 104.
With reference once again to
A male lock head 30 configured with a preferred misalignment tolerant interlock engagement facilitating lead-in profile 110 in accordance with the present invention has convexly outwardly rounded or radiused outer corners 112 to help prevent the end of the head 30 at or adjacent the corresponding corner 112 contacting part of the female lock half 32 from sticking, binding, clashing or otherwise interfering with head 30 being able to move into the receptacle 34 during alignment interlocking or alignment lockup during mold closing. Such a male lock half 28 made with a head 30 configured with such lead-in profiles 110 coming in contact with an adjacent one of the outer receptacle corners 74 advantageously slides off and/or around it into the receptacle 34 as the rounded or radiused exterior of the lead-in profile 110, i.e., corresponding rounded or radiused outer corner 112, helps prevent binding, sticking, clashing or other interference therebetween. Where the outer corners 74 of the receptacle 34 of the female lock half 32 are also configured with an outwardly tapered male lock head receptacle entry facilitating profile 72, the misalignment tolerant interlock engagement facilitating lead-in profile 110 and outwardly tapered male lock head receptacle entry facilitating profile 72 advantageously operatively cooperate with one another when they come into contact with each during alignment interlocking or alignment lockup of the lock halves 28 and 32 during mold closing while accommodating angular misalignment of at least ±5° and as much as ±10°.
Each lead-in profile 110 of the head 30 is provided or defined by a respective convexly outwardly rounded or radiused outer corner 112 of the head 30. Entry of the head 30 into the receptacle 34 during mold closing can also be facilitated by a recessed concavely rounded relief 118 disposed adjacent to but downstream of outer corner 112 of profile 110. As is best shown in
Each convexly outwardly rounded or radiused outer corner 112 of the head 30 is elongate and generally parallel to the other convexly outwardly rounded or radiused outer corner 112 of the head 30 with one outer corner 112 formed in one of the receptacle wall contacting sidewalls 98 of the head 30 being generally oppositely outwardly extending and parallel to the other outer corner formed in the other one of the receptacle wall contacting sidewalls 100 of the head 30. As such, head 30 is equipped with a pair of oppositely outwardly projecting, generally parallel and elongate convexly outwardly rounded or radiused outer corners 112 each of which is or defines an elongate convexly outwardly rounded or radiused lead-in profile rib 115. The elongate convexly outwardly rounded or radiused lead-in profile ribs 115 are generally parallel with one another with one of the ribs 115 formed of the outer corner 112 of one of the head sidewalls 98 and the other one of the ribs 115 formed of the outer corner 112 of the other one of the head sidewalls 98.
The head 30 preferably also has a pair of the recessed reliefs 118 that are parallel with one another and disposed on opposite sides of the head 30 with one of the reliefs 118 preferably formed in one of the receptacle sidewall contacting head sidewalls 98 and the other one of the reliefs 118 preferably formed in the other one of the receptacle sidewall contacting head sidewalls 100. Like the smoothly rounded or radiused outer corners 112 or outer lead-in profile ribs 115 of the male lock head lead-in profiles 72, each recessed relief 118 also is smoothly concavely radiused or continuously smoothly rounded with no sharp corners, ridges or any other interruptions to facilitate smooth relative motion between the head 30 and an adjacent contacting outer receptacle corner 74 that comes into contact therewith during insertion of the head 30 into the receptacle 34.
Each recessed concavely rounded or concavely radiused relief 118 can be configured to help accommodate angular misalignment between the head 30 and receptacle 34 by providing clearance in which part of the outer receptacle corner 74 can pass, and even rotate, during relative motion between the head 30 and outer receptacle corner 74 during insertion of the head 30 into the receptacle 34. In the preferred male lock embodiment shown in
Even where one or both of the male lock head reliefs 118 does not provide nor is configured to provide angular misalignment compensation, each relief 118 provides a debris repository well 120 in the head 30 which receives debris wiped or scraped from adjacent corresponding surface 106 or 108 of respective head sidewall 98 or 100 during insertion of the head 30 into the receptacle 34 and/or removal of the head 30 from the receptacle 34. Each one of the debris repository well 120 defined by corresponding relief 118 preferably is elongate, extends substantially the entire width of the head sidewall 98 and/or 100 in which it is formed and are generally parallel with each other with one well 120 formed in one head sidewall 98 and the other well 120 formed in the other head sidewall 100.
During at least one of insertion of the head 30 into the receptacle 34 and removal of the head 30 from the receptacle 34, sliding point contact between surface 106 or 108 of respective head sidewall 98 or 100 and corresponding surface 58 or 60 of the receptacle sidewall 62 or 64 wipes or scrapes debris that has accumulated on one or both contacting sidewall surfaces 98 or 100 and/or 58 or 60 into respective adjacent debris deposit repository well 120. During at least one of insertion and removal, contact between surface 106 or 108 of respective head sidewall 98 or 100 and corresponding surface 58 or 60 of the receptacle sidewall 62 or 64 preferably is line contact that more efficiently wipes or scrapes debris into respective adjacent debris deposit repository well 120 by wiping or scraping each one of the contacting surfaces 98 or 100 and/or 58 or 60 across substantially the entire width of the contacting surfaces 98 or 100 and/or 58 or 60. Depending on the orientation of the head 30 of the male lock half 28 and the receptacle 34 of the female lock half 32 relative to gravity, each relief 118 or debris deposit repository well 120 can also be a recessed lubricant well 122 (
The male lock half 28 can have and preferably also does have a recessed relief 124 at the root of the head 30 at or adjacent where each head sidewall 98 and 100 intersects the base 38 of the male lock half 28. In at least one preferred male lock embodiment, the recessed lock head root relief 124 defines a debris-receiving repository well 126 in which debris wiped or scraped from contacting surfaces 98 or 100 and/or 58 or 60 of the head 30 and/or receptacle 34 during at least one of insertion of the head 30 into the receptacle 34 and removal of the head 30 from the receptacle 34. In at least one other preferred male lock embodiment, the recessed lock head root relief 124 defines a lubricating reservoir 128 from which lubricant flows via gravity along surfaces 98 or 100 and/or 58 or 60 of the head 30 and/or receptacle 34 re-lubricating one or more of the surfaces 98 or 100 and/or 58 or 60 of the head 30 and/or receptacle 34 during alignment interlock assembly operation preferably including during at least one of insertion of the head 30 into the receptacle 34 and removal of the head 30 from the receptacle 34.
At least one of the receptacle-contacting sidewall surfaces of the head 30 of the male lock half 28 and/or at least one of the head-contacting sidewall surfaces that define or otherwise form part of the receptacle 34 of the female lock half 32 is configured with an engagement surface having a microscopically three-dimensionally contoured lubricant film retaining region 130 which is shown formed in the outer surface 108 of the sidewall 100 of the head 30 of the male lock half 28 illustrated in
Each debris repository well 82, 84, 120 and 126 has a depth at least a plurality of times, preferably at least a plurality of pairs, i.e., at least three, of times the maximum depth of the recesses 132 to ensure that debris squeegeed or wiped from the lubricant film retaining region 130 into a well 82, 84, 120 and 126 stays in the well 82, 84, 120 and 126. In a preferred embodiment, each well 82, 84, 120 and 126 has a depth that is at least five times and preferably at least ten times the depth of the recesses 132 that define the lubricant film retaining region 130 so that debris from shed from the recesses 132 during wiping of the engagement surface during mold lock engagement and disengagement is retained in the well 82, 84, 120 and 126 thus reducing, minimizing and preferably substantially completely preventing abrasive wear. In addition, each well 82, 84, 120 and 126 can and preferably does define or serve as a gravity feed lubricant reservoir 86, 88, and 128 that returns lubricant swept with debris into the well 82, 84, 120, and 126 back to the lubricant film retaining region 130 of the corresponding engagement surface to help re-lubricate the engagement surface and help maintain the lubricant film 130 in or on the lubricant film retaining region 130.
As is shown in
The male lock half 28 and female lock half 32 preferably are made of a metal, such as an alloyed steel, preferably A2 high speed steel, K340 steel, such as BOHLER K340 ECOSTAR and/or ISODUR steel, or D2 tool steel, with the outer surfaces 58, 60, 106 and/or 108 of the male lock head and receptacle sidewalls treated, preferably heat treated and/or plasma treated to a hardness of at least a 55 Rockwell C hardness, preferably at least a 58 Rockwell C hardness, and more preferably at least a 60 Rockwell C hardness. These surfaces of one or both lock halves 28 and/or 32 can be hardened, preferably via a cryogenic treatment after an initial hardening treatment step, such as after being heat treated and/or plasma treated, to achieve such a high Rockwell C hardness of at least 55 Rockwell C hardness, preferably at least a 58 Rockwell C hardness, and more preferably at least a 60 Rockwell C hardness. Such a combination of recess or pocket depth, density, spacing, surface hardness and steel material choice advantageously work synergistically to produce an extremely long life lower male lock half 28 and female lock half 32 of the present invention that lasts even longer when lubricated with a petroleum-based high temperature extreme pressure grease lubricant that preferably is comprised of a lithium complex and which meets or exceeds NLGI 2 grade requirements.
In another preferred embodiment, at least one of the receptacle-contacting sidewall surfaces of the head 30 of the male lock half 28 and/or at least one of the head-contacting sidewall surfaces that define or otherwise form part of the receptacle 34 of the female lock half 32 is configured with such a microscopically three-dimensionally contoured lubricant film retaining region 130 like that formed in the outer surface 108 of the sidewall 100 of the head 30 of the male lock half 28 illustrated in
At least one of the receptacle-contacting sidewall surfaces of the head 30 of the male lock half 28 and/or at least one of the head-contacting sidewall surfaces that define or otherwise form part of the receptacle 34 of the female lock half 32 is configured with a microscopically three-dimensionally contoured lubricant film retaining region 130 which is shown formed in the outer surface 108 of the sidewall 100 of the head 30 of the male lock half 28 illustrated in
As is shown in
With continued reference to
With reference to
A mold alignment interlock assembly of the present invention includes a generally T-shaped male mold lock that is slidably guided into a receptacle formed in a generally U-shaped female mold lock bringing the male and female mold locks into alignment with one another and the mold halves being brought together. The mold interlock assembly is configured to wipe debris from shallow nano-recesses or nano-pockets shallow enough to shed debris when wiped therefrom during sliding line contact between a surface of at least one of the male lock head sidewalls and/or at least one of the female-lock receptacle defining sidewalls with such pockets laser etched therein deep enough to retain lubricant therein even after having debris cleared or wiped therefrom. A preferred embodiment employs an array of rows and columns of such nano-pockets having a depth no greater than 15 microns and preferably between 10-12 microns which can overlap one another and which form a hydrodynamic bearing from the lubricant film produced by high temperature high pressure lithium containing petroleum based grease retained in each pocket even after repeated debris cleanings or wiping occur during mold cycling. Such a mold interlock assembly can also have one or more reliefs formed in the head of the male lock and/or the receptacle of the female lock which are debris repositories in which debris self-cleaned from the head and receptacle sidewall surfaces during head insertion and/or removal from the receptacle and which can also serve as lubricant reservoirs which re-lubricate one of more of the head and/or receptacle sidewall surfaces during mold cycling.
The present invention is directed to an alignment lock assembly, preferably a mold lock or bar lock, for facilitating alignment of one component of a reciprocating machine relative to another component of the reciprocating machine during relative reciprocation thereof, the lock assembly that has a male lock half carried by one component, the male lock half comprised of an engagement surface, a female lock half carried by the another component, the female lock half comprised of an engagement surface opposed to the engagement surface of the male lock half during reciprocation of the one component relative to the another component, and wherein the engagement surface of at least one of the male and female lock halves is configured to reduce wear during reciprocation of the one component relative to the another component. At least one of the engagement surfaces is comprised of a three-dimensionally contoured lubricant film retaining region configured to retain a film of lubricant thereon, the three-dimensionally contoured lubricant film retaining region comprised of at least a plurality of pairs of lubricant-retaining recesses formed in the at least one of the engagement surfaces. Each lubricant-retaining recess has a depth no greater than 25 microns and configured to shed debris therefrom during contact between adjacent and opposed engagement surfaces of the male and female lock half during relative movement therebetween during reciprocation of the one component relative to the other component.
At least 40% of the surface area of the at least one of the engagement surfaces is comprised of the lubricant-retaining recesses as this ensures that a more uniform lubricant film is produced or formed thereon and that re-lubrication of lubricant from the lubricant-retaining recesses also is more uniform further helping to ensure that a more uniform lubricant film is produced. As a result, wear is reduced and preferably minimized through more uniform coverage and re-lubrication of lubricant along substantially the entire surface of the engagement surfaces of the male and female lock halves.
In one embodiment, each lubricant-retaining recess has a depth of no greater than 25 microns. Each lubricant-retaining recess has a sidewall and a bottom wall that is generally flat to facilitate debris shedding or removal during wiping action caused by the slidable contact between the engagement surfaces of the male and female lock halves. Each one of the lubricant-retaining recesses can be and preferably is in the form of a round, oval or oblong debris-shedding lubricant-retaining pocket. Each one of the lubricant-retaining recesses is comprised of a round, oval or oblong debris-shedding lubricant-retaining pocket. Each debris-shedding lubricant-retaining pocket preferably is laser etched or laser cut.
In an embodiment, each lubricant-retaining recess is formed of or by a recessed debris-shedding lubricant-retaining pocket formed in the at least one of the engagement surfaces having a depth no greater than about 25 microns. Each debris-shedding lubricant-retaining pocket has a sidewall bounding a generally flat bottom wall that preferably is a substantially flat bottom wall. In addition, at least 40% of the surface area of the at least one of the engagement surfaces is comprised of the debris-shedding lubricant-retaining pockets.
The engagement surface of at least one of the male and female lock halves is formed of at least a plurality of pairs of rows and at least a plurality of pairs of columns of uniformly spaced apart lubricant-retaining recesses, wherein the at least a plurality of pairs of rows of the lubricant-retaining recesses are uniformly spaced apart, and wherein the at least a plurality of pairs of columns of the lubricant-retaining recesses are uniformly spaced apart. At least 40% of the surface area of the engagement surface of at least one of the male and female lock halves is covered with the lubricant-retaining recesses. Each lubricant-retaining recess has a sidewall and a bottom wall that is substantially flat. Each lubricant-retaining recess has a depth of no greater than 25 microns. The substantially flat bottom wall of each lubricant-retaining recess preferably is disposed at a depth of no lower than 25 microns.
In at least one such embodiment, the lubricant-retaining recesses of each one of the rows are staggered relative to the lubricant-retaining recesses of each adjacent one of the rows, and the lubricant-retaining recesses of each one of the columns are staggered relative to the lubricant-retaining recesses of each adjacent one of the columns. Each one of the lubricant-retaining recesses of each one of the rows overlaps in a transverse direction relative to the one of the rows at least 25% of an adjacent one of the lubricant-retaining recesses of each adjacent one of the rows. Each lubricant-retaining recess has a depth of no greater than 25 microns. Each lubricant-retaining recess can be formed with a sidewall and a bottom wall that is generally flat. Each lubricant-retaining recess can be formed with a bottom wall that is substantially flat.
In one embodiment, each lubricant-retaining recess is a round, oval or oblong debris-shedding lubricant-retaining pocket recessed into the engagement surface of at least one of the male and female lock halves and which has a maximum depth no greater than about 25 microns. Each debris-shedding lubricant-retaining pocket has a bottom wall that is substantially flat and a sidewall substantially completely bounding the bottom wall. Each debris-shedding lubricant-retaining pocket can be and preferably is laser etched or laser cut.
In addition, at least one of the engagement surfaces can and preferably does have a debris repository well that is disposed adjacent the lubricant film retaining region that has a depth greater than the maximum depth of the lubricant-retaining recesses of the lubricant film retaining region. At least one of the engagement surfaces has a pair of debris repository wells that on opposite sides of the lubricant film retaining region, each debris repository well having a depth greater than the maximum depth of the lubricant-retaining recesses of the lubricant film retaining region. Each one of these debris repository wells also can and preferably does serve or function as a lubricant supply reservoir that gravity feeds lubricant wiped into the wells with debris back to the recesses or pockets of the lubricant-film retaining region of the engagement surface(s), including during re-lubrication during reciprocating machine cycling.
Each one of the lubricant-receiving recesses has a width or diameter of no more than about five millimeters, and a depth of no more than about 25 microns. Each one of the recesses is defined by a generally flat bottom wall having a depth of no more than about 25 microns. Each one of the recesses preferably is in the form of a generally round, circular, oval or oblong pocket formed by laser etching or laser cutting in the engagement surface of the male lock half and/or female lock half. Each one of the pockets has a bottom wall that preferably is generally flat and which is bounded by an upraised sidewall. In addition to being debris-shedding lubricant-retaining pockets, the pockets also provide a visual wear indicator, a bearing wear indicator, which visually shows a smooth surface lacking pockets when replacement due to wear is indicated
In a preferred embodiment, each one of the engagement surfaces of the male and female lock halves is comprised of a three-dimensionally contoured lubricant film retaining region formed of at least a plurality of pairs of spaced apart lubricant-retaining recesses formed therein having a maximum depth no greater than about 25 microns. The male lock half and female lock half preferably form one of a mold lock and bar lock.
The present invention also is directed to an alignment lock assembly, such as a mold lock or bar lock, for aligning or facilitating alignment of one component of a reciprocating machine, e.g., a molding machine, relative to another component of the reciprocating machine during relative reciprocation thereof, the lock assembly that includes a male lock half with an outwardly extending alignment head, and female lock half having a receptacle in which the alignment head of the male lock is removably received causing alignment of the male lock and female lock during receipt of the head of the male lock in the receptacle. The male lock half and female lock half each have at least one engagement surface that come into slidable moving contact with one another during reciprocating of one component, e.g., one mold half, of the reciprocating machine relative to another component, e.g., another mold half, of the reciprocating machine. The head of the male lock half is defined by a pair of spaced apart walls, at least one of which has an engagement surface. The receptacle of the female lock half is defined by a pair of spaced apart walls at least one of the walls having an engagement surface. At least one of the engagement surfaces is three-dimensionally contoured with at least a plurality of pairs of lubricant-retaining recesses, each of which is deep enough to hold lubricant but shallow enough to allow shedding of debris therefrom.
In one preferred embodiment, one of the head of the male lock half and the receptacle formed in the female lock half are defined by complementary engagement surfaces that contact one another during receipt of the head of the male lock half in the receptacle in the female lock half during alignment interlocking therewith or during removal of the male lock half from the receptacle in the female lock half during separation of the male lock half from the female lock half. At least one of the engagement surfaces of the one of the male lock half and female lock half has a bearing surface, in the form of a three-dimensionally contoured lubricant-retaining region, comprised of spaced apart hydrodynamic bearing layer forming lubricant-holding recesses formed therein that not only retain lubricant therein but which also form a hydrodynamic bearing layer along the bearing surface when lubricant is received in the lubricant-holding recesses.
Each one of the lubricant-receiving recesses is deep enough to hold a lubricant therein but shallow enough for debris accumulated therein to be removed therefrom by contact with the other one of the engagement surfaces of the other one of the male lock half and female lock half during one of insertion of the head of the male lock half into the receptacle in the female lock half and removal of the head of the male lock half from the receptacle in the female lock half. Contact between the engagement surfaces of the one of the male lock half and female lock half during insertion of the head of the male lock half into the receptacle in the female lock half is slidable wiping contact that self-cleans debris accumulated in the lubricant-receiving recesses during insertion of the head of the male lock half into the receptacle in the female lock half. The contact between the engagement surfaces of the one of the male lock half and female lock half during removal of the head of the male lock half from the receptacle in the female lock half is slidable wiping contact that self-cleans debris accumulated in the lubricant-receiving recesses during removal of the head of the male lock half from the receptacle in the female lock half.
Each one of the lubricant-receiving recesses has a width or diameter of no more than about five millimeters, and a depth of no more than about 25 microns. Each one of the recesses is defined by a generally flat bottom wall having a depth of no more than about 25 microns. Each one of the recesses preferably is in the form of a generally round, circular, oval or oblong pocket formed by laser etching or laser cutting in the engagement surface of the male lock half and/or female lock half. Each one of the pockets has a bottom wall that preferably is generally flat and which is bounded by an upraised sidewall. In addition to being debris-shedding lubricant-retaining pockets, the pockets also provide a visual wear indicator, a bearing wear indicator, which visually shows a smooth surface lacking pockets when replacement due to wear is indicated.
The head of the male lock has a three-dimensionally contoured profile that not only facilitates insertion of the head into the receptacle in the female lock, but which also has a debris catcher in which debris wiped from the lubricant-dispensing packets accumulates. The profile of the head of the male lock is configured to make wiping contact during one of insertion of the head of the male lock into the receptacle in the female lock and removal of the head of the male lock from the receptacle in the female lock. The head has a generally rectangular cross-section with an outwardly extending grease-spreading and debris-clearing wiping surface at or adjacent a free end of the head and a necked down relief that serves a debris collecting relief formed in the head of the male lock. The receptacle formed in the female lock half is defined by a pair of generally parallel generally planar sidewalls extending oppositely and toward one another from an open mouth at one end of the receptacle to an endwall at an opposite end of the receptacle, and wherein the open end has an inwardly tapering lead in profile contour that defines a cross-section width of the receptacle at the mouth that is greater than a cross-sectional width of the receptacle downstream of the mouth facilitating misaligned entry of the head of the male lock into the receptacle. Contact between the engagement regions of the one of the male lock half and female lock half during removal of the head of the male lock half from the receptacle in the female lock half is slidable wiping contact that self-cleans debris accumulated in the lubricant-receiving recesses during removal of the head of the male lock half from the receptacle in the female lock half.
Understandably, the present invention has been described above in terms of one or more preferred embodiments and methods. It is recognized that various alternatives and modifications may be made to these embodiments and methods that are within the scope of the present invention. It is also to be understood that, although the foregoing description and drawings describe and illustrate in detail one or more preferred embodiments of the present invention, to those skilled in the art to which the present invention relates, the present disclosure will suggest many modifications and constructions as well as widely differing embodiments and applications without thereby departing from the spirit and scope of the invention. The present invention, therefore, is intended to be limited only by the scope of the appended claims.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2018/018866 | 2/20/2018 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62460145 | Feb 2017 | US |
