The present invention relates to the compression moulding of performs (semi-finished pieces) intended for the subsequent formation (typically by blow-moulding) of synthetic resin containers, the perform being moulded by inserting a punch (male mould element) under pressure into a hollow die (female mould part) loaded with a charge of solid, pasty or liquid material, in particular a thermoplastic resin, the preform comprising an upper neck provided with projections and a hollow body lying below the neck.
More precisely, the invention relates to a method and the relative apparatus having a plurality of dies for compression moulding preforms, each die comprising a first component for forming the outer surface of the hollow body, said first die components being driven and operated by inserting the mould punch under pressure, into the interior of each of them, to compression mould the preform.
The hollow body of the preform has an outer shape which is smooth and axial, in particular free from undercuts, and can hence be extracted by axially moving the relative first die component, which can therefore be advantageously made with a monolithic body, in particular a body the parts of which are not radially drawn apart for the extraction.
In contrast, the neck of the preform possesses projections which form undercuts preventing its extraction from the die by simple movement in an axial direction. This means that the second die component, that provided to form the neck, must be made in several separable sectors which must be manipulated, with consequent mechanical complications which lead to applying that entire mould part concerned with the neck (both the punch and the neck die component) on that apparatus part which inserts the punches into the dies.
Other technical complications arise in the case in which the material charge is not completely contained in the cavity of that die part concerned with the hollow body of the preform, whether inserted into the cavity in substantially liquid form or in the form of a more or less solid elongate cylinder.
In this second case, this cylinder necessarily presents a diameter less than the minimum cavity of the die to enable it to be quickly inserted therein; as a result, particularly for containers having a capacity less than about 0.3 litres, it happens that the (axial) length of the material charge is greater than the cavity of the first die component and that hence the material charge, inserted into said cavity, projects externally upwards.
This results in problems and/or complications in the fitting-together of the die components in the step following insertion of the material charge into the first die component (but prior to the insertion of the punch into the die cavity), caused by the fact that the material charge can project from the cavity not only upwards but also radially (especially if pasty and therefore is unable to fold back radially from outside the cavity), it hence being impossible to lower the second die component onto the first in an axial direction, because it would intercept the top of the material charge.
Similar obstacles and complications occur in the other case, in which the material charge is substantially liquid and the capacity of that part of the die concerned with the hollow body is insufficient to contain it.
An object of the invention is to generally solve said technical problems.
This and further objects are attained by the invention as characterised in the claims.
The method of the invention relates to a mould comprising a first die component arranged to form the outer surface of the hollow body, and a second die component arranged to form the outer surface of the neck, and is characterised in that during the step of inserting the charge into the die cavity the second die component is associated with the first die component, said second component being divided into at least two sectors able to be drawn apart to extract the preform.
According to a first embodiment of the method, the second die component remains constantly associated with the first die component during the entire moulding cycle.
According to another embodiment of the method, the second die component is withdrawn from the first die component during the step of extracting the preform from the die.
The apparatus according to the invention comprises a plurality of die units each comprising a first die component for forming the outer surface of the preform hollow body, and a second component for forming the outer surface of the neck and associated with and secured, at least during the step of inserting the charge (8) into the die cavity, to the first die component, which second component is divided into at least two sectors to be drawn apart to extract the preform.
According to another aspect of the invention, the apparatus comprises, for compression moulding the preforms, a plurality of mutually independent shuttles to be driven and operated by inserting the punch into each of them under pressure to compression mould the preform; each of said shuttles comprises said first die component and said second die component (22), this being associated with and secured to the shuttle, at least during the step of inserting the charge (8) into the die cavity (20a), and is movable together with it, said second component being divided into at least two sectors to be drawn apart to extract the preform.
The invention is described in detail hereinafter with the aid of the accompanying figures which illustrate one embodiment thereof by way of non-limiting example.
An example of a preform to be obtained according to the invention is shown in
Generally, the neck 91 is provided with projections defining for example a thread 93 projecting radially outwards to receive a usual screw cap.
The preform 9 is obtained by a compression moulding process in which a punch 15 (mould male element) is inserted under pressure into a hollow die (mould female part) loaded with a charge 8 of material (solid, paste or liquid), in particular a thermoplastic resin. The die cavity 20a shapes the outer surface of the preform while the outer surface of the punch 15 shapes the inner surface thereof.
The apparatus of the invention operates by means of a plurality of die units 10 which, in a preferred embodiment, are constrained, while secured rigidly together, to move along an operative path in a horizontal plane (for example by being fixed to the same rotating platform of a turntable) while being moved vertically independently of each other when required, each of said die units 10 comprising a main body 11 containing a first die component 21 and other members.
Alternatively, said die units 10 can be incorporated in shuttles movable independently of each other, each shuttle comprising a main body 11 containing the first die component 21 and the other members. These shuttles are mutually independent and are arranged to be driven and operated within the apparatus which, inter alia, inserts said mould punch under pressure into each of them to compression mould the preform.
Essentially, the die unit 10 of the invention comprises a main body 11 carrying and enclosing a first die component 21, the inner surface of which forms the outer surface of the hollow body 92 of the preform 9. The main body 11 can be separate from the first die component 21, in which case it acts only as a support therefore (as shown in the figures), or can be integral therewith.
(In the preferred embodiment, the bodies 11 are mutually rigid within the apparatus).
According to the invention, the die unit 10 comprises a second die component 22, which forms the outer surface of the neck and is permanently secured to the die unit 10, and is divided into at least two complementary sectors 23 (in the embodiment shown in the figures, these sectors are two in number), able to be drawn apart to enable the preform to be extracted; when in their closed condition, these sectors 23 intimately adhere to each other via two respective matching faces 23a (these faces are flat and perpendicular to the direction in which the two sectors 23 move towards and away from each other) and also mate with the upper end of the first component 21 to form the die cavity 20a which shapes the outer surface of the preform.
According to the embodiment shown in
In
The shuttles 10 are initially introduced to the apparatus 40 by a usual introduction star member 45 which inserts them into a feed turntable 41 pertaining to the apparatus 40, to rotate the shuttles 10 through a path slightly less than 360°.
(In the preferred embodiment, the bodies 11 are rigid with the turntable 41 and therefore rotate constantly with it, without abandoning it).
During the initial part of the path of the turntable 41, a respective charge 8 (solid, paste or liquid) is inserted into the cavity 20a of the shuttle 10 by a suitable dispenser device 51 (of known type). The apparatus 40 then inserts a respective punch 15 into each shuttle 10 while this advances together with the turntable 41. The punches 15 are not shown in
During the final part of the path, the shuttles 10 leave the turntable 41 via an extraction star member 46.
Initially, the punch 15 approaches a shuttle 10 by descending vertically aligned with the axis A of the cavity 20a of the die, which is formed from the two components 21 and 22 in which the sectors 23 forming the component 22 are in the closed position (see
This aspect is very important not only if the charge is substantially solid, but also if it is substantially liquid and has a volume greater than the volume of the cavity of the first component 21, as the charge has to be fed into a cavity (the cavity 20a) having a capacity such as to contain it completely.
During the nest step (
During a subsequent step in the moulding process (which may be relatively soon or long after the step of
During a further subsequent step, the sectors 23 are drawn apart and away from the preform 9, allowing this to be extracted in an axial direction from the cavity 20a (see
Alternatively the sector 23 can firstly be drawn apart to release the preform 9, which is extracted from the cavity 20a together with the punch 15, the said preform then being detached from the punch 15.
In the embodiment shown in
Each sector 23 is joined to a pair of sliders 24 in the form of parallelepiped blocks fixed to two opposing sides of the sector and constrained to slide along respective horizontal parallel guides in the form of rods passing through the blocks, to determine the direction of mutual approach and withdrawal of the two sectors 23.
To maintain the respective sectors 23 in adhering contact with the upper surface 11a of the main body 11, the pairs of guides 25 are constantly pulled in an axial direction downwards by a pair of vertical ties 27. In detail, the ties 27 are slidably inserted into vertical channels 28 provided in the main body 11 and have their upper ends joined to respective blocks 29, to each of which the ends of the two guides 25 are rigidly butt-joined; the ties 27 are pulled constantly downwards by precompressed springs 26.
Two pairs of elastic means 30 are applied to two opposing sides of the body 11 of each die unit 10 in the angular position in which the ties 27 lie, to elastically urge the sectors 23 into their closed position. Each elastic means 30 comprises a lever 31 having a hinge pin 31a of horizontal axis fixed to the main body 11, with one end connected by a connecting rod 32 to a slider 24 and its other end connected by a tie 32 to a pre-stretched spring 34. A pair of said means 30 is applied to each slider 24, to urge the sectors 23 towards the axis A. The purpose of the means 30 is to maintain the two sectors 23 urged against each other while feeding the charge 8 into the die cavity 20a.
In
During the step of compressing the charge 8 within the cavity 20a, the sectors 23 are locked in the closed position by means of known type comprising an upper body 14 associated with the punch 15 and movable vertically thereto, possessing a frusto-conical cavity 14′ surmounted by a cylindrical cavity, which matches the frusto-conical outer lateral surface 23b of the sectors 23 also surmounted by a cylindrical surface complementary to said cylindrical cavity (FIGS. from 5A to 5D), or by other means able to prevent the sectors being drawn apart due to the pressure produced within the cavity 20a.
The step of extracting the punch 15 from the preform 9 (shown in
Subsequently, during the further axial withdrawal of the punch 15 from the die, as shown in
During the preform extraction step, the two sectors 23 are gripped, by known means (indeterminate and not shown in the figures) which draws them apart by overcoming the thrust of the spring 34.
In the embodiment shown in
However, this version differs from the preceding in that said sectors 23 are also movable in a vertical direction relative to the first component 21. The main body 11 also defines at the upper end of the first die component 21 a concave upper surface 61a coaxial with the axis A and having its concavity, in particular of frusto-conical shape, facing upwards and converging downwards, to surround the upper end of the first component 21; at the same time the sectors 23 possess respective lower projections 63 the lateral surfaces of which mate with the concave upper surface 61a, and together form a geometrical figure substantially complementary to the concavity defined thereby so that, when the sectors 23 are in their closed position (with the matching faces 23a mutually adhering) said projections 63 are positioned to adheringly bear against the concave surface 61a; said projections 63 also mate with the upper end of the first component 21 to give rise, together therewith, to the die cavity 20a which shapes the outer surface of the preform.
Each pair of sectors 23 comprises means for pulling them downwards until they are in their closed position adhering on the concave surface 61a, and means to raise said sectors 23 in an axial direction.
In greater detail, each sector 23 is rigidly fixed to a bracket 64 positioned below it to surround the upper end part of the main body 11 of the die unit on three sides, said brackets 64 being constrained to slide along respective parallel horizontal guides 65 consisting of rods passing through the brackets, to determine the direction in which the two sectors 23 mutually approach and withdraw from each other horizontally. In the lower part of the main body 11, about the first component 21, there is provided a cylinder-piston comprising a closed annular cavity 66 having cylindrical lateral surfaces and containing an annular piston 67 which sealedly slides along the lateral walls of the cavity 66, within which two variable volume chambers 66a and 66b remain defined above and below the piston 67, of which at least the lower chamber is in communication with pressurized operative fluid feed means (not shown in the figures).
Inside the cavity 66 there are two vertical piston rods 68, positioned in a vertical plane passing through the axis A and coplanar with the matching faces 23a of the sectors 23 on one and the other side of the axis A, their upper ends emerging to the outside of the main body 11 where they are fixed to respective blocks 70, to each of which the ends of two guides 65 are butt-joined; said piston rods 68 are fixed to the piston 67 and are driven upwards by it as far as its upper end position, consequently vertically moving the guides 65 and with them the two brackets 64 and the sectors 23 joined to them.
The downward movement of said elements is instead produced by the action of two precompressed elastic springs 69 wound about the piston rods 68.
These springs 69 normally pull the piston rods 68 downwards so that the sectors 23 are also pulled downwards with the projections 63 adhering to the surface 61a, this action advantageously serving to urge the two sectors 23 against each other into their closed position during the step in which the charge 8 is fed into the die cavity 20a and to maintain the cavity formed by the two sectors 23 adjacent to the cavity of the first component 21.
In
During the step of compressing the charge 8 within the cavity 20a, the sectors 23 are locked in their closed position by said upper body 14 (of known type) associated with the punch 15, the frusto-conical cavity 14′ of which mates with the frusto-conical outer lateral surface 23′ of the sectors 23, or by other means able to prevent the sectors drawing apart because of the pressure produced within the cavity 20a.
During a subsequent step (which may be relatively soon or long after the step of
Pressurized fluid is then fed into the lower chamber 66a to overcome the action of the springs 69, so that the piston 67 is moved vertically upwards, and with it the two sectors 23 to release these latter from their bearing against the surface 61a (see
Alternatively the sectors 23 can firstly be drawn apart to release the preform 9, which is extracted from the cavity 20a together with the punch 15 on which it remains, the said preform then being detached from the punch 15.
FIGS. from 12A to 12H show a succession of steps during the formation of the preform and during the subsequent extraction of the perform, in the second embodiment of the method of the invention.
In this case, at the instant of inserting the charge 8 (
The cavity 20a is fed with a charge 8 which, even if it were to project upwards above the cavity of the first component 21, would however be completely contained within the cavity also defined by the two sectors 23 in their closed position.
During the step of extracting the preform from the mould, the punch 15 is firstly (
Subsequently (
Then as shown in
Finally, the sectors 23 are drawn apart and withdrawn from the preform 9 (
In the embodiment illustrated in FIGS. from 12A to 12H, the punch 15 is axially fixed while the other mould parts are movable, in particular the die components 21 and 23 and the upper body 14.
In contrast, in the preceding
What is important in the different embodiments is that the various mould 15 parts undergo axial movements relative to each other.
Numerous modifications of a practical and applicational nature can be made to the invention, but without leaving the scope of the inventive idea as claimed below.
Number | Date | Country | Kind |
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RE2003A000050 | May 2003 | IT | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP04/05276 | 5/17/2004 | WO | 11/10/2005 |