Plastic and nonmetallic article shaping or treating: processes – Mechanical shaping or molding to form or reform shaped article – To produce composite – plural part or multilayered article
Reexamination Certificate
1998-10-19
2001-04-03
Ortiz, Angela (Department: 1732)
Plastic and nonmetallic article shaping or treating: processes
Mechanical shaping or molding to form or reform shaped article
To produce composite, plural part or multilayered article
C264S263000, C264S267000, C264S297200, C264S297800
Reexamination Certificate
active
06210619
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the invention
The present invention is directed to a method and apparatus for injection molding a two-piece plastic assembly. More specifically, the present invention is directed to a method and apparatus that utilizes a linearly moving shuttle mold to simultaneously mold and join a plastic assembly.
2. Description of the Related Arts
U.S. Pat. No. 5,413,743, teaches a method of manufacturing a two-piece headlamp assembly using a rotary platen. The rotary platen utilizes at least two die sets (two pair of matched molds) to form a plastic article. A first die set is used to manufacture a transparent lens. A second die set is used to manufacture a reflector that mates with the lens. The lens is injection molded at a first location on the rotary platen. The reflector portion is molded at a second location on the rotary platen at the same time as the lens. The reflector and lens die sets are opened and the die portion containing the lens is mated with the die portion containing the reflector in a third location on the rotary platen. When the lens and reflector are brought together, they form a cavity. A plastic material is injected into this cavity to join the lens and reflector.
The invention described in U.S. Pat. No. 5,413,743 utilizes at a minimum two separate die sets (four dies) requiring movement between their molding position and their joining position. This movement is achieved through a rotary table.
It is desirable to utilize an injection molding apparatus that may injection mold the two plastic components and then join the components using a single die set. It is further desirable that a single injection molding press be used to mold the components and then create a joining bond therebetween. It is also desirable that each cycle of the molding apparatus both mold the components and create a joining bond between a previously molded pair of plastic components.
SUMMARY OF THE INVENTION
The present invention is directed to a method and apparatus for manufacturing a two-piece plastic assembly from a single die set comprising a series of steps. A molding apparatus having a first mold moveable between first and second positions and a second mold is utilized for manufacturing the plastic articles. The first mold has a first surface and a second surface. The second mold has a third surface and a fourth surface. The apparatus moves the first mold to the first position and then closes. The apparatus brings the first and second molds together causing the first and third mold surfaces to define a first article cavity and the second and fourth mold surfaces to define a second article cavity. A molten first plastic material is injected into the first article cavity. A second plastic material is injected into the second article cavity. After the first and second materials have cooled, they form a first and second article respectively. The apparatus is opened and the first mold is moved to a second position. The apparatus is closed and the first mold positions the first article juxtaposed to the second article and forms a joining cavity therebetween. A third plastic material is injected into the joining cavity and joins the first and second article to form the plastic assembly.
The invention may optionally include additional mold surfaces so that a second pair of first and second articles may be formed while a first pair of first and second articles are joined. These additional surfaces will receive molten plastic material to form another pair of first and second articles while the first pair of first and second articles are joined together.
The invention may be practiced using a linearly moving shuttle mold. The shuttle mold includes a stationary mold and a mold linearly moveable along a line perpendicular to the mold closing movement. The shuttle mold enables a single die set to be able to mold the first and second articles and retain the molded articles within the die set as the first mold is moved between a first and second position. The first and second articles are brought together and joined when the first mold is moved to the second position. The present invention enabled the molding and joining of the two-piece assembly using a single injection molding apparatus and a single pair of opposed molds (die sets). A completed molded article is produced with each cycling of the molding apparatus.
These and other objects, features, and advantages of the present invention will become more readily apparent when viewed in connection with the accompanying drawings wherein like reference numerals correspond to like components.
REFERENCES:
patent: 3287485 (1966-11-01), McCord
patent: 4155478 (1979-05-01), Ogi
patent: 4261947 (1981-04-01), Ogi
patent: 5008060 (1991-04-01), Kanai et al.
patent: 5116557 (1992-05-01), Debaes et al.
patent: 5413743 (1995-05-01), Prophet
patent: 5603792 (1997-02-01), Guala et al.
patent: 5626413 (1997-05-01), Ferrell
patent: 5885499 (1999-03-01), Aksberg
patent: 6042364 (2000-03-01), Nishida
Ford Motor Company
MacMillan Sobanski & Todd LLC
Ortiz Angela
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