Abstract:
A core assembly for an injection molding-machine. The assembly includes a movable mold half and a stationary mold half clamped onto each their platen of an injection molding-machine. It also includes an actuator for advancing and retracting during operation at least one core into and from a mold cavity in a mold. The actuator is connected to a core-carrier for carrying the at least one core. The core-carrier is slidingly mounted to and partly projecting from a guidance connected to one of the mold halves. A first hole is formed in the closed mold for slidingly receiving the projecting part of the core-carrier. The core assembly allows products to be continuously molded with an extremely high degree of accuracy, and it is simple, inexpensive and easy to mount and maintain while also allowing for positioning of cores at various angles relative to the mold.

Description:
This application is a 371 filing of International Patent Application PCT/EP2010/051402 filed Feb. 5, 2010. 
     BACKGROUND 
     The invention relates to a core assembly comprising an actuator for during operation advancing and retracting at least one core into and from a mould cavity in a mould consisting of two mould halves clamped onto each their platen of an injection moulding-machine, whereby the actuator is connected to a core-carrier for carrying the at least one core. 
     The invention also relates to an injection moulding-machine comprising said core assembly and a method of manufacturing moulded products by utilizing the moulding-machine. 
     Injection moulding is a popular and efficient technique to mass-produce plastic products for various applications. There are few limitations as to the shape and complexity of injection moulded products. Accordingly, recent decades have seen an ever-increasing number of custom-shaped moulded products. 
     Many of those products are formed with openings, undercuts or the like formed in the side of the products. Core assemblies therefore is required for imparting the cores to be moved to and fro into a direction forming an angle with the direction in which plastic is injected into the mould cavity in the mould. 
     A known core assembly of this kind comprises a cam pin arrangements where an angular pin disposed in the movable mould half is used for moving a cam slide carrying a core. Upon opening and closing of the mould, the angular movement of the cam pin translates into sliding motion of the cam slide and the attached core. 
     An inherent drawback of this approach is that it depends on an optimal fit of components including the mould halves, which often are subject to some compression and expansion during operation. Also, cam pins may be prone to deflection and displacement owing to the force component acting in the mould clamping direction. This may increase maintenance efforts and costs. Also, the motion of a cam slide sliding in a guideway formed in a mould half cannot be performed with the required accuracy. 
     Other known core assemblies of this kind are arranged for moving the cam slide independently of the clamping motion of the mould halves. These assemblies include actuators as e.g. hydraulic working cylinders attached to the cam slide and the mould for moving the slide with the core. It is however difficult to connect the actuators to both the cam slide and the mould. 
     An attempt to solve this problem is known from the PCT application WO 2008/015274 A1. The core assembly comprises also in this case a guideway and a slide, which slidingly is mounted onto the guideway and an actuator in form of a hydraulic working cylinder attached to the slide. The guideway is however attached to a clamping arrangement on the stationary platen of an injection moulding-machine whereby effectively is prevented that the hydraulic working cylinder need to be attached to the respective mold half. The guideway can however in this way not continuously be sufficiently exact orientated in relation to the required motion direction of the core resulting in that the product can be incorrectly moulded. 
     SUMMARY OF THE INVENTION 
     The above-mentioned disadvantages of the prior art core assemblies are according to the invention remedied by, 
     in a first aspect of the present invention providing a core assembly which continuously can mould a product with an extremely high degree of accuracy, 
     in a second aspect of the present invention providing a core assembly which continuously can operate with the required security, 
     in a third aspect of the present invention providing a durable core assembly, 
     in a fourth aspect of the present invention providing a simple and inexpensive core assembly, 
     in a fifth aspect of the present invention providing a core assembly which is easy to maintain, 
     in a sixth aspect of the present invention providing a core assembly which is easy to mount, 
     in a seventh aspect of the present invention providing a core assembly that is conveniently adaptable to a given mould, 
     in an eight aspect of the present invention providing a core assembly that allows for positioning of cores at various angles relative to the mould. 
     The novel and unique features of the invention consists in the fact that the core-carrier slidingly is mounted to and partly is projecting from a guidance, which preferable releasable is connected to one of the mould halves, and that a first hole is formed in the closed mould for slidable receiving the projecting part of the core-carrier. 
     Thereby is advantageously obtained a core assembly with a simple, inexpensive and durable construction, which is easy to mount and maintain and which during operation functions with the highest degree of accuracy. The core assembly can moreover conveniently be adapted to be mounted onto a given mould at various angles relative to the mould. 
     The guidance for the core-carrier can in a preferred embodiment of the guide assembly according to the invention be a guide bush with an end part received in a second hole formed in the mould being in its closed position whereby the first hole for receiving a part of the core-carrier is debouching into the second hole for receiving the end part of the guide bush while the second hole is debouching into an edge of the closed mould. 
     The end part of the guide bush can in an advantageous embodiment of the core assembly moreover be formed with a collar to be received in a complementary formed part of the second hole. 
     According to the invention can the guide bush in its mounted position in the second hole furthermore be connected to the stationary mould half by means of screws or the like through the collar. 
     The collar then secures the correct position in both the axial and transverse direction of the guide bush in relation to the mould cavity whereby advantageously is obtained that products with correct shapes continuously can be moulded during operation. 
     The actuator can in a preferred embodiment of the core assembly according to the invention be a pneumatic or hydraulic working cylinder with a piston and a piston rod. The actuator then can be connected to the guide bush by means of e.g. a flanged joint or a screw joint while the core-carrier is connected to the piston rod of the cylinder. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will be explained in greater details below, giving further advantageous features and technical effects and describing exemplary embodiments with reference to the drawing, in which 
         FIG. 1  is a side elevation, seen in axially cross section, of a first embodiment of a core-carrier unit of the core assembly according to the invention in retracted position, 
         FIG. 2  shows the same seen from without, 
         FIG. 3  shows the same, but in advanced position, 
         FIG. 4  is a side elevation, seen in axially cross section, of a second embodiment of a core-carrier unit of the core assembly according to the invention in retracted position, 
         FIG. 5  shows the same seen from without, 
         FIG. 6  shows the same, but in advanced position, 
         FIG. 7  shows, seen from in front, a mould half, which is clamped onto the stationary platen of an injection moulding-machine formed with a mould cavity and a first and second hole segment adapted for receiving a first and second core-carrier and parts of guide bushes for slidingly receiving the core-carriers, 
         FIG. 8  shows, seen from in front, the mould half, which is clamped onto the stationary platen of an injection moulding-machine mounted with fragments of a first and second embodiment of a core-carrier unit, both being in their advanced position, 
         FIG. 9  shows the same, but with the core-carrier units in retracted positions. 
         FIG. 10  is a cross section taken along the first embodiment of the core-carrier unit of the mould in closed position and with the core-carrier unit in advanced position being in process of moulding a product in the cavity in the mould, 
         FIG. 11  shows the same, but in open position of the mould and with the moulded product ejected from the cavity of the mould, 
         FIG. 12  is, shown in a larger scale, an exploded view of a cross section of a core-carrier unit and a fragment of the stationary mould half, and 
         FIG. 13  shows the same but in mounted position of the core-carrier unit. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The core assembly according to the invention is used in an injection moulding-machine (not shown) for repeatingly moulding products formed with e.g. holes or undercuts in the side of the products. For the sake of simplicity is the invention here described by means of a simple product in form of a square cup. The core assembly can of course be utilized also for moulding more complicated products. 
     The core assembly consists in the main of one or more core-carrying units and holes formed in the mould, seen in closed position, for at least partly receiving the core-carrying units. 
     The mould consists of two mould halves clamped onto a movable and a stationary platen (not shown) of the injection moulding-machine. In one or both mould halves is formed a mould cavity. 
       FIG. 1  shows a first embodiment  1  of a core-carrying unit according to the invention. In  FIG. 1  is the core-carrying unit shown in axial section and in a retracted position and in  FIG. 2  as well in retracted position but seen from without. In  FIG. 3  is the unit shown also from without but in an advanced position. 
     The core-carrying unit comprises a working cylinder  2 , a guide bush  3  and a core-carrier  4  carrying a first embodiment of a core  5 . The core of this first embodiment of the core-carrying unit has a square cross section. 
     The working cylinder  2  has a piston  6  attached to a piston rod  7  and connecting branches  8  and  9  for connecting the cylinder to a supply (not shown) of pressured air or oil. 
     The cylinder  2  and the bush  3  are connected to each other by means of a flange  10  on the cylinder and a flange  11  on the bush. E.g. a screw joint can be utilized instead. 
     The core-carrier  4  is connected to the piston rod  7  of the cylinder  2  by means of a screw joint (not seen). Other connections means can be utilized instead. 
     The bush  3  is formed with a circumferential collar  12  with two bores  13 . The collar can have any suitable shape, but is in this case a bead. The core-carrier is moreover formed with a square block  14 . 
     The purpose of the bead  12 , the bores  13  and the block  14  will be described later in more details. 
     A slide lining  15  is furthermore mounted in the guide bush  3 . The lining is made of an abrasion-resistant materiel with a low coefficient of friction whereby the core-carrying unit continuously can function effectively and at the same time can achieve a long lifetime. The materiel can be bronze. 
       FIG. 4  shows a second embodiment of a core-carrying unit  16  according to the invention. In  FIG. 4  is the core-carrying unit shown in axial section and in a retracted position and in  FIG. 5  as well in retracted position but seen from without. In  FIG. 6  is the unit shown also from without but in an advanced position. 
     The core-carrying unit comprises a working cylinder  17 , a guide bush  18  and a core-carrier  19  carrying a second embodiment of a core  20 . The core of this second embodiment of the core-carrying unit has a circular cross section. 
     The working cylinder  17  has a piston  21  attached to a piston rod  22  and connecting branches  23  and  24  for connecting the cylinder to a supply (not shown) of pressured air or oil. 
     The cylinder  17  and the bush  18  are connected to each other by means of a flange  25  on the cylinder and a flange  26  on the bush. E.g. a screw joint can be utilized instead. 
     The core-carrier  19  is connected to the piston rod  22  of the cylinder  17  by means of a screw joint (not seen). Other connections means can be utilized instead. 
     The bush  18  is formed with a circumferential collar  27  with two bores  28 . The collar can have any suitable shape, but is in this case a bead. 
     The purpose of the bead  27  and the bores  28  will later be closer explained. 
     A slide lining  29  is furthermore mounted in the guide bush  18 . The lining is made of an abrasion-resistant materiel with a low coefficient of friction whereby the core-carrying unit continuously functions effectively and at the same time achieves a long lifetime. The materiel can be bronze. 
     The core assembly consists, as mention above, of core-carrying units and holes formed in the mould, seen in closed position, for receiving the core-carrying units. The core assembly comprises in this case the core-carrying units  1  and  16 . 
       FIG. 7  shows, seen from in front, the stationary mould part  30  formed with a first hole segment  31  for receiving the first the core-carrying unit  1  and a second hole segment  32  for receiving the second core-carrying unit  16 . The term “segment” is here referring to that part of a receiving hole, which is formed in a mould half. 
     The first hole segment  31  has a first section  33  for wholly or partly receiving the guide bush  3  of the first core-carrying unit  1 , a second section  34  for slidingly receiving the core-carrier  4  and a third section  35  for slidingly receiving the core  5 . 
     The first hole segment section  33  is formed with a circumferential groove  36  for receiving the bead  12  and with two threaded holes  37 . 
     The first hole segment  31  moreover is formed with a square recess  38  for slidingly receiving the block  14  of the core-carrier  4 . 
     The second hole segment  32  has a first section  39  for wholly or partly receiving the guide bush  18  of the second core-carrying unit  16 , a second section  40  for slidingly receiving the core-carrier  19  and a third section  41  for slidingly receiving the core  20 . 
     The second hole segment section  39  is formed with a circumferential groove  42  for receiving the bead  27  and with two threaded holes  43 . 
     In the stationary mould half  30  is moreover formed a part of a mould cavity  44 . 
     The first core-carrying unit  1  has in  FIG. 8  been placed in the first hole segment  31  formed in the stationary mould half  30  while the second core-carrying unit  16  has been placed in the second hole segment  32 . 
     Both core-carriers have releasable been connected to the stationary mould half  30  by means of screws (not seen) which has been led through bores (not seen) formed in the beads and screwed into the threaded holes  37  and  43  in the stationary mould half. 
     The first, second and third sections of each hole segments are flush with each other whereby that advantage is achieved that the core-carriers automatically will be correctly orientated in relating to the mould cavity in the mould by simply attaching the core-carrying units to the stationary mould half. 
     The direction of the first hole segment  31  for the first core-carrying unit  1  is perpendicular to an edge of the stationary mould half while the direction of the second hole segment  32  for the second core-carrying unit  16  forms an angle with an edge of the stationary mould half. 
     The core carriers  1  and  16  have in  FIG. 8  by means of the working cylinders  2  and  17  been pushed forwards to their advanced positions where the cores  5  and  20  are engaging the mould cavity  44 . The core carriers now is in their moulding positions. 
       FIG. 9  shows the same as in  FIG. 8  but with the core-carriers pulled to their retracted position by means of the working cylinders  2  and  17 . The block  14  of the core-carrier  31  slides during the retracting operation along the square recess  38 . 
     The square block  14  and the square recess  38  constitute together a key and slot assembling which effectively prevents the first core carrier in turning so that the core always is placed exactly at the same place for each moulding operation and identical products therefore repeatingly can be produced. 
     Other key and slot assemblings can be used instead. For example a key and slot assembling (not shown), which has a key attached to the core-carrier and a slot formed in the guide bush. 
     The closed mould consisting of the stationary mould half  30  and the moving mould half  45  is in  FIG. 10  seen in a cross section taken along the axis of the first core-carrying unit  1  which in the figure is only fragmentarily shown. 
     The first core-carrying unit  1  is placed in the first hole segment  31  and is by means of screws  46 , which are led through bores  47  in the bead  12 , screwed into threaded holes  48  formed in the stationary mould half  30  for attaching the core-carrying unit to said mould half. 
     Thereby is in an easy and quick way achieved a firm and durable connection between the core-carrying unit and the mould half. The connection can easily be disconnected for maintenance of the core assembling. 
     The core-carrying unit is in  FIG. 10  in its advanced position where the core is protruding into the cavity  44 . During a moulding operation is hot plasticized plastic by means of an injector  49  injected into the cavity  44  through a nozzle  50  and an inlet channel  51  whereby the cavity is filled with the hot plasticized plastic  52  except in those areas of the cavity where the cores are. 
     The mould thereafter is cooled down to a temperature in which the plastic is sufficiently solid to be ejected. 
     This situation is seen in  FIG. 11  where the mould has been opened by retracting the movable mould half  45  away from the stationary mould half  30 . The product  53  has been ejected by means of an ejector pin  54 . 
     The product is in this case a simple cup, which has square cross section and a square hole complementary to the shape of the first core  5  of the first core-carrier  4 . 
     A round hole has likewise been formed in the wall of the product by means of the second core  20  of the second core-carrier  14 . This hole cannot be seen in  FIG. 11 . 
     The two halves of the cavity are in this case symmetrical, but can as well be asymmetrical and have different shapes. 
       FIG. 12  is an exploded view of a cross section of the bead  12  on the guide bush  3  and a fragment of the stationary mould half  30 . For the sake of simplicity is the guide bush in this case shown without slide lining. 
     The bead  12  is, as mentioned above, formed with bores  47  for screws  46  while the stationary mould half  30  is formed with threaded holes  48 , which fits to the outer thread of the screws  46 . Also seen is the groove  36  for receiving the bead  12 . 
     By mounting is the bead  3  placed in the groove  36  after which the screws  46  via the bores  47  in the bead  12  are screwed into the threaded holes  37  in the stationary mould half  30 . 
     The guide bush is, as seen in  FIG. 13 , now solid and securely connected with the stationary mould half. 
     The shape of the bead  12  is complementary to the shape of the groove  36  for receiving the bead. That implies that the guide bush effectively is secured against being displaced in either the axial or the transverse direction in relation to the cavity in the mould. 
     The orientation of the core in relation to the mould cavity is therefore precisely defined and securely maintained for each moulding operation. 
     For being able continuously to produce identical products it is important too that the core always will be advanced to exactly the same predetermined position in the mould half. 
     This feature is achieved by means of a stop for the carriage of the core. Such stop can e.g. be arranged in the working cylinder, the guide bush or the mould. 
     In a preferred embodiment according to the invention is the end stop the rearmost end edge in the hole segment, which serves for receiving the core-carrier and is formed in the mould halves. 
     The core-carrier being advanced will thereby automatically be stopped in exactly the same predetermined position each time a moulding operation is carried out. 
     In  FIGS. 7-11  is the end edge of the first whole segment  31  denoted  55  and in  FIGS. 7-9  is the end edge of the second hole segment  32  denoted  56 . 
     The core carrier of the invention is above described on basis of that the collar on the guide bushes is a circumferential bead. The collar can however have any other suitable shape and doesn&#39;t either need fully to extend over an angle of 360°. 
     Also, other means then collars can within the scope of the invention be used for securely attaching the guide bush to the stationary mould half. 
     Such other means can, by way of example, be a square bar which is protruding from the guide bush and fits into a complementary formed recess in the stationary mould half. 
     The actuator for moving the core-carrier to and fro between its advanced and retracted position is above described as a working cylinder. Any other suitable kind of actuators can however be used within the scope of the invention, e.g. a step motor, which furthermore advantageously can be adapted electronically to stop the core-carrier and thereby the core precisely in its advanced and retracted position. 
     The core-carrier described above and shown on the drawing is each mounted with only one core. Each core-carrier can however carry more cores. 
     The mould described above and shown on the drawing is equipped with two core-carrying units. A mould can however, within the scope of the invention, be equipped with more than two core-carrying units.