Plastic Tube Screen Fill Injection Mold

The present invention involves a fabrication of plastic-tube-screen-fill (PTSF) injection mold fabricating PTSFs using molten plastics injection molding machine. The PTSFs replace PVC-film-fills currently using in water evaporative cooling towers. The PTSFs have a higher water cooling efficiency compared to the efficiency of the PVC-film-fills and therefore the PTSFs reduce the operation and construction expenses of the cooling tower, and also the PTSFs reduce the production of plastic wastes due to the utilizing of high cooling efficient media in the cooling towers. In order to commercialize the PTSFs, a manufacturing tool of the PTSFs to fabricate a low-cost plastic-tube-screen-fill is needed. To achieve this end, the PTSF injection mold is invented by comprising four partial-molds, which is operated in three dimensional disassembling and reassembling processes using a vertical injection molding machine.

BACKGROUND OF THE INVENTION

Field of the Invention

This invention relates to an injection mold for fabricating of using an injection molding machine. More specifically, the injection mold of the present invention for fabricating of the plastic-tube-screen-fill is concerned with articulated molds comprising multiple piece partial-molds that cooperate together to define a complete mold, and then disassemble to release the finished molding.

Description of the Related Art

The plastic-tube-screen-fill (PTSF) is schematically drawn inFIG.2and patented, U.S. Pat. No. 10,046,502 B2, by the present inventor. The PTSF has the same function and process of evaporative water cooling with those of a current PVC film fill in the shape of thin plate. The PVC film fills are used for fabrication of PVC film fill packs, used in current water cooling towers, which are made up of by assembling side by side of a plurality of PVC film fills. But, the PVC film fills have drawbacks such as a lower efficiency of water cooling and more consumption of materials for their fabrication, compared with those of the PTSF. The PVC film fill is fabricated using a common double pieces molding process which employs two partial-molds, one for each side of the film fill plate. On the other hand, the previous fabrication method of PTSF presented by the present inventor is to fabricate the PTSF through multiple fabrication steps, namely,6steps including three fabrication steps including one tube fabrication step and two PTSF frame fabrication steps, and three assembling steps of those three components of tube and two frames. The detailed fabrication process of the PTSF is referred to the patent given above. The multiple-pieces PTSF to be fabricated through the multiple fabrication steps definitely induces causes of cost-ineffectiveness and low competitiveness of the PTSF. Consequently, the fabrication method of the PTSF provided in the patent given above has a serious drawback of the multi-step fabrication method which cannot strengthen the market competitiveness of the PTSF. Therefore, a new fabrication method of the PTSF able to be making the fabrication cost of the PTSF to be extremely low is demanded and presented in the present invention.

SUMMARY OF THE INVENTION

The PTSF injection mold of the present invention fabricates the plastic-tube-screen-fill, invented by the present inventor, by a single shot of the molten plastics into the PTSF injection mold using the molten plastics injection machine. The PTSF injection mold is shown inFIG.1, which comprises upper and lower partial-molds, a cavity partial-mold placed between the upper and lower partial-molds, and an ejector system assembly attached beneath the lower partial-mold. The cavity partial-mold comprises a top frame partial-mold and metal-rod-filled-tubes (this type tubes are explained in the section of <Cooling Process of Molded PTSF>) bottom frame partial-mold. The top frame partial-mold comprises a plurality of partial circular plates surrounding circles provided on an inner surface along the axis of the frame as shown inFIGS.5-2,5-4and5-5. The metal-rod-filled-tubes attached bottom frame partial-mold is made up of a plurality of metal-rod-filled-tubes whose larger ends are attached over every circles provided on the inner surface along the axis of the same structured frame with the top frame of the top frame partial-mold as illustrated inFIGS.5-1,5-3and5-6. Thus, the cavity partial-mold is in two components of the top frame partial-mold and the metal-rod-filled-tubes attached bottom frame partial-mold and therefore the PTSF injection mold comprises four partial-molds, which allows the PTSF injection mold to be used in a vertical injection molding machine for disassembling of the PTSF injection mold to eject the product PTSF. The PTSF comprises three components of plastic-tube-screen, top frame, and bottom frame, which are in one structure and in the shape of a rectangular plastic tube screen attached between top and bottom frames as shown inFIG.2. The PTSF has an unique design of the end-side-lengths of the top and bottom frames of the PTSF as the tube being near the left edge of the frame is apart from the edge of the frame by ¾ tube-regular-spacing (long end-side-length, tube-regular-spacing is an interval of axis between the adjacent tubes placed on along the axis of the frame), while the tube near the right edge is apart by ¼ tube-regular-spacing (short end-side-length) and the tubes in the middle of the PTSF are apart from each other at the tube-regular-spacing as shown inFIG.2. Such arrangement of the tubes in the PTSF pack is described in the third paragraph of <Upper and Lower Partial-Molds>.

Since the PTSF is in a single structure and has partial circular holes on the top and bottom frames and the tubes of the PTSF are not solid tubes as shown inFIG.2, the PTSF cannot be fabricated using a double piece injection mold. So, the single structure of PTSF is necessary to be changed into two pieces which are horizontally separable from each other. To achieve this end, the plastic tubes of the PTSF are replaced with metal tubes whose internal spaces are filled with metal rods, namely, metal-rod-filled-tubes, because plastics and air pocket are not allowable in the mold. The PTSF used for fabrication of the injection mold is replaced with Metal-Rod-filled-tube-Screen-Fill (MRSF) and then the one structured PTSF can be divided into two structured components of the top frame and the Metal-Rod-filled-tube-Screen (MRS) attached bottom frame (MRS bottom frame) made up by attaching MRS on the bottom frame to be in one single structure as shown inFIGS.5-1and5-3. Hence, the one structured PTSF comprises the top frame and MRS bottom frame partial-molds so that the PTSF injection mold comprises four components of the upper and lower partial-molds, and the top frame and MRS bottom frame partial-molds. The metal tubes used for fabrication of the injection mold are slightly in cone shapes and their large-side outer diameters are same with inner diameters of the plastic tubes of the PTSF. The cone-shaped tubes help for the MRS to be easily pulled out from the molded PTSF by a mechanical machine after molding of the PTSF formed surrounding the MRSF within the PTSF injection mold.

The formation of the PTSF cavity within the PTSF injection mold is accomplished by covering the cavity partial-mold with the inner surfaces of the upper and lower partial-molds to define a pair of complete PTSF cavity (including tube screen cavities, top and bottom frame cavities) formed surrounding the MRSF within the cavity partial-mold when the upper and lower partial-molds are brought together over the cavity partial-mold. Now, the single structured PTSF is fabricated by a single shot of molten plastics into the PTSF cavity formed surrounding the entire surface of the MRSF within the cavity partial-mold of the PTSF injection mold by using the injection molding machine and then the PTSF injection mold is disassembled to release the finished molding of PTSF as shown inFIG.2after cooling and setting of the formed PTSF surrounding the surface of the MRSF within the cavity partial mold. The PTSF injection mold, placing upright on its bottom side with the lower and upper partial-molds at the left and right side of the cavity partial-mold as shown inFIG.1-2, is disassembled into three parts, lower partial-mold, cavity partial-mold, and upper partial-mold placed as shown inFIGS.3-3,3-1, and3-2, respectively.FIGS.3-2and3-3show the same inner surfaces of the upper and lower partial-molds, comprising imaginary top and bottom frames including a plenty of male and female push-button producers near the end sides of the both imaginary frames and a plurality of hollowed-out tube cavity halves of the PTSF cavity between the imaginary top and bottom frames, which are showing the components provided on the inner surfaces of the upper and lower partial molds are in the same layout of positions and configurations to each other.FIG.3-1shows a schematic drawing of the cavity partial mold comprising the top frame partial-mold and the metal-rod-filled-tubes attached bottom frame partial-mold of which top and bottom frames comprise multiple female and male push-buttons. The top frame comprises the female push-button producer on the left end-surface of the frame and the male push-button producers on both end-side top surface of the frame. The bottom frame comprises the female push-button producer on the left end-surface of the frame and the female push-button producers on both end-side bottom surface of the frame, and multiple gas venting channels made on the upper surfaces of top and bottom frame base plates of the cavity partial mold by connecting one end of the gas venting lines to the top and bottom frame producers.

In order to supply the molten plastics into the PTSF cavity of the PTSF injection mold, a runner system comprising a sprue, main runners, bridge runners, and gates is set up within the upper partial-mold as shown inFIGS.6-1and6-2. The molten plastics is transported from the injection machine nozzle to the runner system through the sprue and then flows through the main and bridge runners to reach the gates as shown inFIG.6-1.FIG.6-2illustrates the cross section view X-X of the PTSF injection mold shown inFIG.1, showing a side view of the runner system of main and bridge runners reaching to the gates. Passing the gates, the molten plastic fills the entire PTSF cavity. As a total length of the runners from the sprue to the gates is relatively long, it is necessary to keep the molten plastics in a required molten state while flowing through the long runner. The runner system is, therefore, heated through the heated manifold provided surrounding the runner system and an insulator is covered over the outside surface of the upper partial-mold to prevent heat loss through the surface of the injection mold as shown inFIGS.6-1and6-2.

The assembling of the upper and lower partial-molds and the cavity partial-mold builds the PTSF injection mold forming the PTSF cavity in the core of the PTSF injection mold. The PTSF cavity is full of air or gas. Hence, when the molten plastics is injected into the PTSF cavity to fabricate the PTSF, the gas is vented out of the cavity at the same time. If the gas is slowly or not vented out, the molten plastics is slowly or cannot be fully entered the cavities because the gas pushes back the molten plastics. Consequently, the gas venting lines are necessary for the gas in the cavities to be smoothly vented out of the PTSF injection mold. So, multiple gas venting lines are made on both upper side base plates of the cavity partial-mold, jointing area between the upper surfaces of top and bottom frame base plates of the cavity partial-mold and the surfaces of top and bottom frame-side base plates of the upper partial-mold as shown inFIGS.4-1and4-3.

For quickly cooling and setting of the molten plastics of the molded PTSF in the core of the PTSF injection mold, the water is supplied adjacent to the tubes, top frame, and bottom frame of the molded PTSF. To cool the molded tubes, the U-shape cooling loops are built inside the metal-rod-filled-tubes of the MRSF within the cavity partial-mold as shown inFIGS.6-1,8-1and8-2. To cool the molded bottom frame, the inlet and outlet cooling loops connected to each of the U-shape cooling loops within the metal-rod-filled-tubes of the MRSF are placed adjacently along the outside surface of the bottom frame of the cavity partial-mold and built in the base plate of the bottom frame as shown inFIGS.6-2and7. Also, as shown inFIG.7, to cool the molded top frame of the PTSF cavity partial-mold, a single U-shape cooling loop is built in the base plate and adjacent along to the outside surface of the top frame and the inlet and outlet ports of the all cooling loops are connected to the water supply and collection manifold. A cooling process of the molded PTSF allows the molded PTSF to harden and become dimensionally stable for ejection of the product, PTSF, and is uniformly and entirely progressed over the whole body of the molded PTSF. For such a cooling process of the molded PTSF to successfully progress, the heat transferred into the molded PTSF from the molten plastics is carried away by a coolant which circulates through the cooling loops provided adjacently to the inner surfaces of the plastic tubes of the PTSF formed within the cavity partial-mold as shown inFIG.6-2,8-1and8-2. Since the temperature and flowing rate of the coolant determine the efficiency of the heat removal from the molded PTSF and also the temperature difference of the inlet and outlet coolants is kept under a temperature required in the molten plastics injection molding machine, the long cooling loop of the present cooling system is grouped into four small-groups of cooling loops as shown inFIG.7in order to accurately control the temperature and flow rate of the coolant.

For ejecting of the molded PTSF, the disassembling of the tour partial-molds comprised in the PTSF injection mold needs twice of disassembling processes such as horizontally removing process of the cavity partial-mold and vertically lifting-up process of the upper partial-mold. To satisfactorily accomplish such processes, a vertical injection molding machine performing such a three dimensional disassembling and assembling process of the PTSF injection mold is employed for fabricating of the PTSF. Another reason to employ the vertical injection molding machine is based on the following reason. The PTSF cavity formed surrounding the MRSF within the cavity partial-mold is in the shape of the wide and flat plate so that the PTSF cavity is necessary to be placed on a horizontal flat place, considering a gravitational force evenly affecting the movement of the molten plastics throughout the entire PTSF cavity (tube cavities, top and bottom frame cavities) placed on the horizontal flat place. Thus, taking account of three dimensional loading and unloading processes and the wide and flat plate-shape of the PTSF cavity, a vertical injection molding machine is a right machine for fabrication of the PTSF. The PTSF injection mold is mounted on the workbench of the vertical injection molding machine and the molten plastics is injected and cooled in the mold. When the molded PTSF is ready for ejection, the ejection process starts by removing the cavity partial-mold from the PTSF injection mold by simultaneously pulling out the top frame and MRS bottom frame partial-molds in the opposite directions against each other, and then, the metal-rod-filled-tubes are pulled out from the molded plastic tubes along with pulling-out of the MRS bottom frame partial-mold at the same time. Consequently, the molded PTSF remains alone within the PTSF injection mold without the cavity partial-mold. Next, the upper partial-mold is removed to leave the molded PTSF on the lower partial-mold. Finally, the ejector pins of the ejector system assembly shown inFIG.1are moved upward to push the molded PTSF off from the lower partial-mold.

DESCRIPTION OF NUMBER IN THE DRAWINGS

1PTSF injection mold,2upper partial-mold,2-1imaginary upper partial-mold,3lower partial-mold,3-1imaginary lower partial-mold,4cavity partial-mold,5bottom frame side of cavity partial-mold,6bottom frame side of upper partial-mold,7bottom frame side of lower partial-mold,8bottom side of PTSF injection mold,9cold water inlet port,10warm water inlet port,11nozzle supporter,12mold parting line,13ejector system assembly,14top frame partial-mold,15top frame cavity (top frame imaginary line, imaginary top frame),16MRS bottom frame partial-mold,16-1MRS bottom frame,17bottom frame cavity (bottom frame imaginary line, imaginary bottom frame),17-1MRS bottom frame cavity,18top frame base plate,19bottom frame base plate,20mold base plate,21U-shape cooling loop,21-1U-shape hollowed-out line,21-2inlet port of U-shape cooling loop,21-3outlet port of U-shape cooling loop,22metal-rod-screen (metal-rod-filled-tube-screen, MRS),22-1U-shape-cooling-loop embedded metal-rod-filled-tubes (UMRS, U-shape-cooling-loop embedded Metal-Rod-filled-tubes Screen),23cone-shape metal tube (cone-shape metal-rod-filled-tube, metal-rod-filled-tube, metal-rod-filled-metal-tube, metal tube),24U-shape cooling loop embedded metal rod (metal solid rod),25tube cavity (tube producer, molded tube),25-1lowest tube cavity surface,26imaginary top and bottom frames of cavity partial-mold,27figure reduction gap,28imaginary contact surface between upper and lower partial-mold,28-1PTSF cavity (cavity),29PTSF (plastic-tube-screen-fill, MRSF),29-1plastic-tube-screen (plastic tube),30top frame (top frame body),31bottom frame (bottom frame body),32plugged tube end (gray circle),33partial circular hole,34male push-button,35tube holder,36corrugate line,37corrugate tube (tube),38open tube end (not shown inFIG.2),39female push-button,40I-I cross section view inFIG.1,41partial circular dark plate hole producer (partial circular plates, dark parts),42plugged end of metal tube (end-surface),43hollowed-out PTSF cavity half,43-1long rectangular gray-part (hollowed-out tube cavity half),44carved corrugated spiral line (slanted line),44-1imaginary carved corrugated spiral line,45female push-button producer (black spot),46imaginary bottom frame half (long narrow square dot line),46-1bottom frame side,47un-carved inner surface,47-1inner surface of the upper and lower partial mold,48male push-button producer (white spot),48-1hollowed-out male push-button producer half49imaginary top frame half (long narrow square dot line),49-1top frame side,50gas venting line (gas venting channel),51top frame white square box (top frame half producer space to be occupied with top frame cavity half of the PTSF cavity),52bottom frame white square box (bottom frame half producer space o be occupied with bottom frame cavity half of the PTSF cavity),53upper and lower mold halves hollowed-out of tube cavity halves of PTSF cavity halves,54tube holder cavity,55plugged tube-end producer (gray circle),56water entering end of U-shaped cooling loop embedded metal-rod-filled-tube (dark circle),57heat insulator,58hot runner system,59bridge runner system,60injection machine nozzle,61sprue,61-1sprue bushing,62molten plastic passage (runners),63heated manifold,64main hot runner,65bridge hot runner,65-1cold-slug-well,66nozzle,67direct gate (gate),68end loop of each group cooling loop,69inlet port of 1stgroup cooling loop,70cold water inlet coolant loop,71warm water outlet coolant loop,72outlet port of 1stgroup cooling loop,73coolant loop reduction gap,74return spring,75ejector guide pin,76ejector pin bushing,77ejector associate pin (ejector pin gap),78outlet and79inlet ports of 4thgroup cooling loop,80ejector bar,81ejector back plate,82ejector system assembly,83ejector pin plate,84back plate stopper,85ejector stopper,86inlet/outlet outside coolant loop connected to coolant supply/collection manifold,871stgroup cooling loop,882ndgroup cooling loop,893rdgroup cooling loop,904thgroup cooling loop,91bottom side of PTSF injection mold,92inlet coolant loop,93zigzag outlet coolant loop,94right side of PTSF injection mold,95imaginary bottom frame of cavity partial-mold,96imaginary MRSF including 4 groups of metal-rod-filled tubes,97imaginary top frame of cavity partial-mold,985thgroup cooling loop,99left side of PTSF injection mold,100inlet outside coolant loop,101zigzag-returning outlet outside coolant loop,102inlet port of cold water (inlet port),103outlet port of warm water (outlet port),104bottom frame outside surface,105cooling system,106coolant supply and collection manifold.

DESCRIPTION OF SPECIFIC TERMS USED

Plastic-tube-screen-fill (PTSF)29: a plurality of tubes are vertically arranged in the shape of a rectangular string screen between the top and bottom ring-shaped holes perforated frames by attaching their both ends on the inner circles of the ring-shaped holes provided on the inner surfaces along the axes of the frames at a tube-regular-spacing between the adjacent tubes on the frames.

Cavity partial-mold4: cavity partial-mold allows for PTSF cavity to be formed surrounding the cavity partial-mold by covering the upper and lower cavity partial-mold halves with the hollowed-out PTSF cavity halves on the inner surfaces of the upper and lower partial molds.

Tube cavity25: tube-shape space formed surrounding the metal-rod-filled-tube surface by covering the upper and lower metal-rod-filled-tube halves with hollowed-out tube cavity halves on the inner surfaces of the upper and lower partial-molds.

Metal-rod-filled-tube23: tube is filled with metal rod.

PTSF cavity28-1: PTSF-shape space formed surrounding the MRSF within the cavity partial-mold.

MRS bottom frame16-1: Metal-Rod-filled-tube-Screen (MRS) attached bottom frame made up by attaching MRS on the bottom frame to be in one single structure as shown inFIG.5-1

MRS bottom frame cavity17-1: partial PTSF cavity without top frame cavity comprising cavity surrounding the MRS and bottom frame cavity shown inFIG.1-1.

MRSF29: Metal-Rod-filled-tube-Screen-Fill comprising top and bottom frames and metal-rod-tube-screen between them.

Hollowed-out tube cavity halves43-1: tube cavity halves are hollowed-out on the inner surfaces of the molds, which are provided between the imaginary top and bottom frames.

Hollowed-out PTSF cavity half43: plastic-tube-screen-fill cavity half is hollowed out on the inner surface of the mold.

Hollowed-out inner surfaces: Inner surface hollowed-out of the PTSF cavity halves on upper and lower partial-molds.

Upper and lower mold halves hollowed-out of tube cavity halves of PTSF cavity halves53: upper and lower mold halves on which tube cavity halves of PTSF cavity halves are hollowed-out on upper and lower mold halves.

Female and male push-button producers45,48: female and male push-button producers make their counterpart male and female push-buttons on the top and bottom frame of PTSF, respectively.

Imaginary top and bottom frame26: long rectangular shape dot line marked adjacent to the tube-screen cavity half hollowed-out on the inner surface of the upper or lower partial-mold.

Tube-regular-spacing: an interval between the longitudinal axes of the adjacent tubes along the axes of the top and bottom frames.

Metal-rod-filled-tube23: tube is filled with metal rod.

Metal-rod-filled-tube-screen (MRS)22: a rectangular shape screen is made up of metal-rod-filled-tubes.

Metal-rod-filled-tubes attached bottom frame partial-mold: bottom frame partial-mold with metal-rod-filled-tubes attached on the inner surface of the bottom frame of the bottom frame partial mold.

Top and bottom frame base plates18,19: base molds supporting top and bottom frame producers of the top and bottom frame partial-molds.

U-shape cooling loop embedded metal-rod-filled-metal-tube22-1: metal-tube filled with metal-rod having U-shape cooling loop embedded over both side rod-surfaces along the axes of the metal rod.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The PTSF injection mold1of the present invention for fabricating of the PTSF29using to an evaporative cooling tower comprises the upper2and lower partial-molds3whose inner surfaces are contacted to each other at the mold parting line12located between the upper2and lower partial-molds3and the cavity partial-mold4placed between the upper2and lower partial-molds3as shown inFIG.1. The upper2and lower partial-molds3comprise their inner surfaces hollowed-out of the PTSF cavity halves43of the tube-screen-fill cavity28-1and the male48and female push-button producers45provided on the imaginary top49and bottom frame46of the hollowed-out PTSF cavity half43. The cavity partial-mold4comprises top frame partial-mold14and MRS bottom frame partial-mold16. Namely, the PTSF injection mold1comprises the four partial-molds of the upper2and lower partial-molds3, and the top frame14and MRS bottom frame partial-mold16, and therefore the disassembling of the four partial-molds comprised in the PTSF injection mold1needs twice of disassembling processes such as horizontally and simultaneously removing process of the top frame14and MRS bottom frame partial-molds16in the opposite directions against each other and vertically lifting-up process of the upper partial-mold2without moving the lower partial-mold3. The assembling process of the four partial-molds to build the PTSF injection mold1is accomplished by building the cavity partial-mold4on the lower partial-mold3on the workbench of the injection machine by combining the top frame14and MRS bottom frame partial-molds16which are horizontally and simultaneously brought back in the opposite directions against each other, and then the upper partial-mold2vertically lays down on the cavity partial-mold4. Such a three dimensional assembling and disassembling processes of the PTSF injection mold1can be handled without any problems under the mechanical operation of a vertical injection molding machine which is employed for fabrication of the PTSF1.

By assembling the four partial-molds to build the PTSF injection mold1, the PTSF cavity28-1is formed surrounding the cavity partial-mold4(built by combining the top frame14and MRS bottom frame partial-molds16) in the core of the PTSF injection mold1. When the upper2and lower partial-molds3are brought together in contiguous relation to cover the upper and lower halves of the cavity partial-mold4, the upper and lower PTSF cavity halves43hollowed-out on the inner surfaces of the upper3and lower partial-molds4join together to define the PTSF cavity28-1surrounding the MRSF29of the cavity partial-mold4, shown inFIGS.1-1and1-2, previously built over the parting line12of the PTSF injection mold1shown inFIG.1. The PTSF cavity28-1formed surrounding the MRSF29in the core of the PTSF injection mold1is in the same configuration of the PTSF29shown inFIG.2.

Based on the disassembling and reassembling of the PTSF injection mold1described above, the ejection of the molded PTSF29from the PTSF injection mold1is described by using an automatic ejection operation of the vertical injection molding machine, which starts from the setting of the PTSF injection mold1on the workbench of the vertical injection molding machine as follows.

Firstly, a setting up of the PTSF injection mold1on the workbench of the vertical injection molding machine starts by placing the lower partial-mold3with its inner surface facing up over the workbench of the injection molding machine, pointing its top frame49-1and bottom frame sides46-1to be respectively in accord with the left and right sides of the workbench;

Secondly, each of the top frame partial-mold14and the MRS bottom frame partial-mold16is horizontally moving inward to the center of the workbench from the left and right outside of the workbench in opposite directions against each other to be respectively in accord with the left and right sides of the workbench and being combined by attaching each of the plugged tube end producers55on the top frame partial-mold14on every plugged ends of the metal tubes42of the MRS bottom frame partial-mold16to create the cavity partial-mold4;

Thirdly, the cavity partial-mold4is placed4over the lower partial mold3previously placed over the workbench, whose top frame49-1and bottom frame sides46-1are respectively in accord with the left and right side of the workbench, to create the lower PTSF cavity28-1half between the lower partial-mold3and the cavity partial-mold4by joining the hollowed-out inner surface of the lower partial-mold3and the lower MRSF half of the cavity partial-mold4together in contiguous relation;

Fourthly, the upper partial-mold2with its inner surface facing down is placed over the lower partial-mold3with the upper MRSF half of the cavity partial-mold4protrudent on the inner surface of the lower partial-mold3. Then, the PTSF cavity halves43hollowed-out on the inner surfaces of the upper2and lower partial-molds3and the MRSF29of the cavity partial-mold4cooperate to form the PTSF cavity28-1surrounding the MRSF29of the cavity partial-mold4in the core of the PTSF injection mold1. The formed PTSF cavity28-1includes the top15and bottom frame cavities17and a plurality of tube cavities25between the top15and bottom frame cavities17. The formed PTSF cavity28-1in the core of the PTSF injection mold1is in the same configuration with the PTSF29shown inFIG.2.

Finally, disassembling of the PTSF injection mold1on the workbench of the vertical injection molding machine to release the molded PTSF29out of the PTSF injection mold1starts by removing the cavity partial-mold4from the PTSF injection mold1. The cavity partial-mold4is removed by horizontally pulling the top frame partial-mold14and the MRS bottom frame partial-mold16at the same time out of the PTSF injection mold1in the opposite directions against each other. Such a removing of the cavity partial-mold4is accomplished by horizontally pulling the metal-rod-filled-tubes23out of the molded tubes of the PTSF cavity28-1along with the MRS bottom frame partial-mold16at the same time and leaves the molded PTSF29alone in the core of the PTSF injection mold1. And next, by lifting up the upper partial-mold2from the PTSF injection mold1, the product PTSF29is left alone over the lower partial-mold3and pushed off from the lower partial-mold3by ejecting operation of the ejector pin plate83and ejector associate pins77of the ejector system assembly82attached beneath the PTSF injection mold1shown inFIG.1.

Upper and Lower Partial-Molds

As the inner surfaces of the upper2and lower partial-molds3are in the same configurations of the components necessary to form the PTSF cavity28-1within the PTSF injection mold1as shown inFIGS.3-2and3-3, the same configured upper and lower partial-molds are fabricated as shown inFIGS.4-1to4-6.FIG.4-1shows the schematic picture of the inner surface of the partial-mold, used for the upper2and lower partial-molds3, which comprises a plurality of long rectangular gray-parts43-1with slanted lines44showing the hollowed-out MRS cavity half43of the PTSF cavity28-1, long narrow square dot lines49,46attached on the top and bottom sides of the hollowed-out MRS cavity half43showing the imaginary frames49,46of the top and bottom frame halves of the PTSF cavity28-1, and alsoFIG.4-1shows multiple female45and male48push-button producers made respectively near the left and right end-sides of the both imaginary frames49,46and hollowed-out male push-button producer halves48-1made on the right ends of the long square dot lines49,46.FIGS.4-3and4-4show respectively the side views of the cross sections of line VI-VI and VII-VII of the top frame49and bottom frame halves46of the PTSF cavity28-1shown inFIG.4-1. The top frame51and bottom frame white square boxes52shown inFIGS.4-3and4-4are filled with each of the top and bottom frame halves49,46of the PTSF cavity28-1when the upper and lower side halves of the cavity partial-mold4shown inFIG.3-1are covered with the upper2and lower partial-mold3shown inFIGS.4-1,3-2, and3-3.FIG.4-2illustrates the V-V cross section view of the hollowed-out PTSF cavity halves43on the inner surfaces of the upper2and lower partial-molds3. The dark53and gray parts20shown inFIG.4-2are the hollowed-out PTSF cavity mold half and mold base plate, respectively, and the half-circle-carved white parts are hollowed-out MRS cavity halves43with carved corrugated spiral line producers44.FIGS.4-3and4-4respectively show the female45and male push-button producers48,48-1making the male34and female push-buttons39on the both sides of top30and bottom frames31of the PTSF29shown inFIG.2, and also they show the male push-button producers48-1making male push-buttons on the right end-surfaces of the top and bottom frames.FIGS.4-5and4-6respectively show the lowest height (lower surface of tube cavity half) and highest height (inner surface line of the lower partial-mold) of the mold cross sections along the axis of the hollowed-out tube cavity half taken along the lines VIII-VIII and IX-IX shown inFIG.4-1. The slanted lines44shown inFIG.4-1are in the same configurations on the inner surfaces of the upper2and lower partial-mold3as shown inFIGS.3-2and3-3. The slanted lines44are the carved corrugated spiral lines44on the surfaces of the hollowed-out tube cavity half43-1to produce protrudent spiral lines44on the surface of the corrugate tubes37. The slanted directions of the carved corrugated spiral lines44on the inner surfaces of the upper2and lower partial-molds3are in same directions as shown inFIGS.3-2,3-3, and4-1. Such carved corrugated spiral lines44are arranged to form continuously-linked corrugated spiral line cavities44-1over the tube cavity25formed surrounding the metal-rod-filled-tube23of the cavity partial-mold4as shown inFIGS.4-7and4-8when the upper2and lower partial-molds3are brought together.

FIGS.4-7and4-8show schematic configuration pictures of assembled upper and lower partial-molds obtained by combining each of the molds shown inFIGS.4-5and4-6and their upside-down molds.FIG.4-8is obtained by touching each other of the inner surfaces47-1of the lower partial-mold3shown inFIG.4-5and its upside-down mold at the parting line12such as the inner surfaces of the upper2and lower partial-molds3are contacted at the parting line12of the PTSF injection mold1.FIG.4-7is also obtained by assembling together the mold shown inFIG.4-5and its upside down mold by adjusting the figure height shown inFIG.4-7to be same with the height of the figure shown inFIG.4-8. The dot lines shown inFIG.4-7are the imaginary mold (upper partial-mold) combined with the true mold (lower partial-mold) shown inFIG.4-5and the imaginary tube cavity25created between the imaginary upper partial-mold2and true lower partial-mold3, which shows how to explicitly use the simple true mold (lower partial-mold) shown inFIGS.4-5and4-6in the PTSF injection mold1.

The hollowed-out tube cavity halves43-1are arranged on the inner surfaces47-1of the upper2and lower partial-molds3by placing the hollowed-out tube cavity half43-1on the left end-side of the PTSF cavity28-1half to be apart from left edges of the imaginary top49and bottom frames46shown inFIG.4-1by ¾ tube-regular-spacing (an interval between the longitudinal center lines (axes) of the adjacent tubes provided along the axis of the frame of PTSF), while that on the right end-side of the PTSF cavity28-1half by ¼ tube-regular-spacing from the right edges of the imaginary top49and bottom frames46. Such an arrangement of the tubes37of the fabricated PTSF29allows the tubes37packed in the PTSF pack to be arranged in a zigzag configuration, when the PTSFs29are assembled to fabricate the PTSF pack by assembling side by side of the PTSFs29by horizontally rotating of every other PTSF29by180degree. To assemble the PTSFs29for fabrication of the PTSF pack by following the assembling procedure described above, multiple male push-button producers48are made on the both end sides of the imaginary top49and bottom frames46by an equal space between adjacent male push-button producers48along the axes of the imaginary frames15,17at the same distances from both edges of the imaginary frames15,17as shown inFIG.4-1, and also a same number of female push-button producers45are made on the other both end sides of the imaginary frames46,49in the same way as done for the opposite end sides. In case of joining of the PTSF packs side by side, the push-buttons34,39on the end-sides or end-surfaces of the top30and bottom frames31of the outermost PTSF29of the PTSF pack are joined with the counterpart push-buttons39,34of the PTSF pack to be attached and the piling of one pack on the other pack is achieved by aligning and inserting of the female push-buttons39on the bottom of the upper pack to be piled into the counterpart male push-buttons34on the top of the pack. Since the PTSF cavity halves43hollowed-out inner surfaces of the upper2and lower partial-molds3are same in their configuration and positions, one of the upper2and lower partial molds3is fabricated and used for the both partial-molds.

When both upper and lower surface halves of the cavity partial-mold4within the PTSF injection mold1positioned as shown inFIG.1are covered with the upper2and lower partial-molds3, the upper and lower MRSF29halves of the cavity partial-mold4are covered with each of the inner surfaces47-1of the upper2and lower partial-molds3, containing the imaginary top49and bottom frame lines46and a plurality of hollowed-out tube cavity halves43-1, to create the PTSF cavity28-1formed surrounding the surface of the MRSF29within the cavity partial-mold4. Thus, the molten plastics is injected into the PTSF cavity28-1through the injection molding machine and the PTSF is formed surrounding the PTSF cavity. After cooling and setting of the molten PTSF29, the molded PTSF29is ejected from the PTSF injection mold1. The both left end-sides of the top30and bottom frames31of the fabricated PTSF29have multiple male push-buttons34, which are placed at the same distances from the both edges of the frame and arranged by an equal space between adjacent push-buttons along the axis of the frame. The other both end-sides of the top30and bottom frames31have the same number of female push-buttons39arranged in the same configuration as arranged on the opposite sides of the frames as shown inFIGS.2,2-1, and2-2. Such arrangements of the male34and female push-buttons39on both end-sides along the axes of the top30and bottom frames31allow the PTSFs29to be assembled by aligning and pressing the male34and female push-buttons39on the previous PTSF29over their counterpart female39and male34push-buttons on the present PTSF29horizontally rotated by180degree as described above.

The schematic picture of the cavity partial-mold4is shown inFIGS.1-1and3-1.FIG.1-1shows the cavity partial-mold4placing in the core and on the cross section I-I of the PTSF injection mold shown inFIG.1.FIG.3-1illustrates the schematic drawing of the cavity partial-mold4comprising the top frame14and MRS bottom frame partial-molds16which is made up of by joining the top frame partial-mold14shown inFIGS.5-2and5-4and MRS bottom frame partial-mold16shown inFIGS.5-1and5-3.FIGS.5-1to5-6explicitly show the schematic pictures of two components of the top frame14and MRS bottom frame partial-molds16separated from the cavity partial-mold4.FIGS.5-2,5-4, and5-5show the schematic pictures of the front, side, and inner surface views of the top frame partial-mold14, respectively.FIGS.5-1,5-3, and5-6illustrate the pictures of the MRS bottom frame partial-mold16showing the front, side, and top views of the MRS22attached on the inner surface along the axis of the bottom frame, respectively. As shown inFIGS.5-5and5-6, the top view of the MRS bottom flame partial-mold16is in a same shape with that of the inner surface of the top frame partial-mold14except for dark circles56with black dots21showing water-inlet-ends of U-shaped cooling loop embedded metal-rod-filled-tubes24of MRS22and white spots48on the both end-side bottom frame base plate18of the top frame partial-mold14. The counterparts of the dark circles56are the gray circles55on the inner surface of the top fame partial-mold18which are the plugged ends42of the tubes24of the MRS22, making the plugged tube ends32shown on the top frame30of the PTSF29shown inFIG.2. The counterparts of the white spots48are the black spots45on both end-side bottom frame base plate19of the bottom frame partial-mold16which are the hollowed-out male push-button producers making the male push-buttons34on the left- and right-side top surfaces of the top frame30of the PTSF29as shown inFIG.2. The black spots45made on the left end-surfaces of the top and bottom frames of the top14and MRS bottom frame partial molds16are female push-button producers making female push-buttons39on the left end-surfaces of the top and bottom frames of the PTSF29shown inFIGS.2-1and2-2. As shown inFIGS.5-1and5-2, the top15and bottom frame imaginary lines17produce the top30and bottom frames31of the PTSF2shown inFIG.2and their top views are schematically drawn as shown inFIGS.5-5and5-6comprising a plenty of partial circular dark plate hole producers41and tube holders54surrounding the white circle tube producers25formed surrounding the metal tubes23with the plugged tube end producers55inside the white circles25provided along the axis of the frame.FIGS.5-2and5-4show a plurality of groups of protrudent dark plate hole producers41attached along the axis of the top frame imaginary line15. The protrudent dark plate hole producers41shown inFIG.5-2are side views of the partial circular dark plate hole producers41attached on the top frame base plate18of the top frame partial-mold14shown inFIG.5-2.FIG.5-4shows the left side view of the top frame partial-mold14. The dark protrudent plate hole producers41make the partial circular holes33on the top30and bottom dark frames31of the PTSF29shown inFIG.2. The white parts54in the top and bottom frame imaginary line15shown inFIGS.5-1and5-2make the tube holders35and frame bodies of the top and bottom dark frames30,31of the PTSF29shown inFIG.2. Likewise, when the molten plastics is injected into the top15and bottom frame imaginary lines17, top and bottom frame cavity, of the cavity partial mold4shown inFIG.3-1, each of the dark41and white parts54in the top15and bottom frame imaginary lines17makes the partial circular holes33and the top30and bottom frame bodies31, including the plugged tube ends32and tube holders35, of the PTSF29shown inFIG.2.

Since the cavity partial mold4comprises two structured components of the top frame14and MRS bottom frame partial molds16as described in the second paragraph of Summary of the Invention, the cavity partial mold4can be separated into the top frame14and MRS bottom frame partial molds16by pulling out the top frame partial mold14and the MRS bottom frame partial mold16horizontally against each other from the cavity partial mold4. When the molten plastics is injected into the PTSF injection mold1to fabricate the PTSF29, the molten plastics fills the PTSF cavity28-1comprising the top frame15and MRS bottom frame cavities17-1respectively formed surrounding the imaginary top frame15and MRS22attached on the imaginary bottom frame17of the MRS bottom frame16-1. After cooling and setting of the molten plastic PTSF formed within the PTSF cavity28-1surrounding the cavity partial-mold, the top frame partial-mold14and the MRS bottom frame partial-mold16are removed out of the formed PTSF29. The removing of the top frame partial-mold14is to remove the partial circular plate hole producers41, hollowed-out male push-button producers48, and female push-button producers45out of the formed plastic top frame30and the removing of the MRS bottom frame partial-mold16to remove the MRS22, partial circular plate hole producers41, and female push-button producers45out of the formed plastic-tube-screen29and formed plastic bottom frame31of the formed PTSF29. Such removal processes of the top frame15and MRS bottom frame16-1are achieved by pulling out the top frame partial mold and the MRS bottom frame partial-mold horizontally against each other.

Runner System for Supplying of Molten Plastics into PTSF Cavity

The PTSF29is in a complex structure comprising the plastic-tube-screen29-1made with a plurality of corrugate tubes37as shown inFIG.2and the formed PTSF cavity28-1within the PTSF injection mold1has a large volume necessary to be filled with a large amount of molten plastics, so that a plurality of gates67are necessary to manage the large amount of molten plastics to pass all gates67to fully fill the PTSF cavity28-1at the same time and within as short time as possible before the molten plastics loses its required viscosity. To achieve this end, the layout of the bridge runners and gate locations is designed for the runners and gates to be symmetrically and equidistantly placed surrounding the longitudinal center line of the PTSF for the molten plastics to fill the cavities in uniform velocity.

Two gates67are made on each of upper tube cavity halves53of the PTSF cavity28-1half hollowed-out on the inner surface47-1of the upper partial mold2. Their locations on the hollowed-out tube cavity half43-1are respectively made at the same distance from the both ends of the hollowed-out tube cavity half43-1. For supplying of the molten plastics uniformly to all gates67, an H-type bridge runner system59is known to be suitable. Hence, the H-type bridge runner system59is employed as shown inFIGS.6-1and6-2. The H-type runner system59supplying of the molten plastics to all gates67needs a long runner62and also the molten plastics should be kept in a required molten state while flowing through the long runner62. To achieve this, the temperature surrounding the runners62should be kept in an equal or higher temperature than required temperature. If not, the required rapid and steady flowing of the molten plastics through the runners62is disturbed to stop the processing of molding, due to degrading the viscosity of the molten plastics into a low viscosity. To keep the temperature of the molten plastics flowing through the runners62in the required operational conditions of the molten plastics, the runners62are maintained under the same or higher temperature by heating the runners with a heated manifold63provided surrounding the runners62, so-called, hot runner system58embedding the runners62as shown inFIGS.6-1and6-2. Consequently, the heat of the hot runner system58is controlled by the heated manifold63and then the heat of the H-type runners59is consecutively controlled to keep the rapid and steady flowing of the molten plastics through the runners62. To conserve the heat inside the upper partial-mold2, the outside surface of the upper partial-mold2is covered with an insulator to prevent a loss of heating through the wall.

The hot runner system comprises sprue61, main hot runners64, bridge hot runners65, nozzles66, and gates67as shown inFIGS.6-1and6-2. To permit a rapid and steady flowing of the molten plastics through the runners62to reach the gate areas67, the cross-sectional area of the sprue61is provided as large enough as passing the large amount of molten plastics to fill all the PTSF cavity28-1within a required time and the cross-sectional area of the main hot runner64is a little smaller than that of the sprue61, and also the cross-sectional areas of the bridge hot runners65are smaller than the main hot runner64cross-sectional area. Additionally, all runner intersections have cold-slug-wells65-1to help the smooth steady flow of the molten plastics through the runners62as shown inFIGS.6-1and6-2. The nozzles66attached on the ends of the bridge hot runners65have the same cross-sectional area with those of the bridge hot runners65in order to keep the same flowing rates of the molten plastics through the runners62for compensating a drawback of a large amount of molten plastics required due to a plurality of long tube cavities25. The gates67attached on the nozzles66are made with relatively wide cross-sectional areas, compared with conventional narrow gate area, since it is necessary for the long PTSF cavity28-1to be quickly filled with molten plastics to prevent a slowly filling of the cavities due to a low viscosity of the molten plastics.

Setting of Gas Venting Lines

By assembling of the upper2and lower partial-molds3and the cavity partial-mold4, the PTSF cavity28-1is formed surrounding the cavity partial-mold4in the core of the PTSF injection mold1. The PTSF cavity28-1is full of air or gas. Hence, if the molten plastics is injected into the PTSF cavity28-1to fabricate the PTSF29, then the gas vents out of the mold through the gap of the parting line12between the jointed inner surfaces47-1of the upper2and lower partial-molds3and ejector pin gaps77provided in the base plates20of the lower partial-mold3as shown inFIGS.6-1and6-2when other gas venting channels50are not provided. But those gaps are not enough to unresistingly and quickly vent a large amount of gas out of the PTSF cavity28-1within a short time. If the gas slowly vent out, the molten plastics cannot quickly fill all cavities owing to a back pressure of the gas developed by pressing the gas remaining in the cavity28-1due to flowing pressure of the molten plastics. To eliminate such problems of the gap-venting of gas, multiple gas venting channels50are made on the upper surfaces of top18and bottom frame base plates19of the cavity partial mold4by connecting one end of the gas venting lines50to the top15and bottom frame producers17as shown inFIG.3-1.

Cooling Process of Molded PTSF

The cooling system106embedded within the PTSF injection mold1of the present invention is designed to intensively and effectively cool the molded PTSF29formed in the PTSF cavity28-1surrounding the cavity partial-mold4in the core of the PTSF injection mold1as shown inFIGS.6-1,6-2, and7. As shown inFIG.7, the cooling system106provided within the cavity partial-mold4comprises four groups of U-shape cooling loops21built in the metal solid rods24of the MRS22within the cavity partial-mold4and a single U-shape cooling loop21in the top frame base plate18of the top frame partial-mold14to cool the molded top frame30of the molded PTSF29. The first87and fourth groups90of U-shape cooling loops21shown inFIG.7are grouped by connecting six of U-shape cooling loops21and the second88and third groups89by connecting five of U-shape cooling loops21. The connection of each of the U-shape cooling loops21with other U-shape cooling loops21is accomplished by connecting the inlet102and outlet ports103of the current U-shape cooling loop21to the outlet port103of the previous one and to the inlet port102of the next cooling loop, respectively, as shown inFIG.7. The inlet port102of the first U-shape cooling loop21and the outlet port103of the last U-shape cooling loop21within each group are connected respectively to the inlet outside coolant loop100and the zigzag-returning outlet outside coolant loop101, which are provided in the bottom frame base plate19and adjacent to the outside surface of the bottom frame cavity17of the cavity partial-mold4to cool the molded bottom frame31as shown inFIGS.6-2and7. Such patterns of connecting the U-shape cooling loops21are continued to the fourth group cooling loop90. To cool the molded top frame30of the molded PTSF, the single U-shape cooling loop98is placed adjacently along the outside surface of the top frame cavity15and in the top frame base plate18of the cavity partial-mold4as shown inFIGS.6-1and7. The inlet100and outlet outside coolant loops101connected to each group of U-shape cooling loops21are connected to the water-supply-and-collection-manifold107and those of the single U-shape cooling loop21cooling the molded top frame30are directly connected to the water-supply-and-collection-manifold107as shown inFIG.7.

In order to build the U-shape-cooling loops21in the cone-shape metal rods24of the MRS22within the cavity partial-mold4, the cone shape metal rods24whose large end-side-diameters are slightly smaller than the internal diameters of the plastic tubes29-1of the plastic-tube-screen-fill are selected and then U-shape hollowed-out lines21-1are made on their surfaces along the axes of the rods24as shown inFIGS.8-1and8-2. The metal rods24with the U-shape hollowed-out lines21on their surfaces are inserted into the internal spaces of the metal tubes23by pushing up to the ends of the metal tubes23as shown inFIGS.8-1and8-2.FIG.8-1shows a schematic drawing of an axial cross section view of a metal tube23filled with metal rod24hollowed-out of U-shape cooling loop21embedded over the rod surface along the axis of rod24and a larger end-side view of the metal tube23and the picture shown inFIG.8-2shows the cross section and larger end-side views taken after rotating the metal tube23by 90 degree along the axis of the metal tube23. The U-shape cooling loops21are formed between the both side internal surfaces of the metal tubes23and the surfaces of the metal rods24filled in the metal tubes23due to tightly joining the internal surfaces of the metal tubes23and the U-shape hollowed-out line21-1surfaces of the metal rods24. Thus, the metal-rod-filled-tubes23of the MRS22of the cavity partial-mold4include the U-shape cooling loops21touched the internal surfaces of the metal tubes23. Namely, U-shape-cooling-loop embedded Metal-Rod-filled-tube-Screen (UMRS)22-1are developed, which has a dual-function of molding the plastic tubes29-1surrounding their surfaces and cooling them by circulating coolant through the U-shape cooling loops21. When the molded tubes25-1surrounding the UMRS22-1of the cavity partial-mold4in the PTSF injection mold1is cooled by circulating coolant through the U-shape cooling loops21, the heat absorbed in the molded tubes25-1formed surrounding the surfaces of the UMRS22-1is transferred into the coolant in the U-shaped cooing loops21in the UMRS22-1through the thin wall of the metal tubes23by thermal conduction mechanism, and then the heated coolant is carried away from the molded tubes25-1by circulating coolant through the U-shape cooling loops21embedded within the metal-rod-filled-tubes23of the UMRS22-1. The inlet69and outlet ports72are provided by attaching ports21-2,21-3to both ends of the hollowed-out U-shape cooling loops21made between the internal surface of the metal tube23and the surface of the metal rods24as shown inFIGS.8-1and8-2.

Ejecting Process of Molded PTSF from PTSF Injection Mold

The PTSF injection mold1is mounted on the horizontal workbench of the vertical injection molding machine and the molten plastics is injected into the PTSF cavity28-1in the core of the PTSF injection mold1through the injection machine to form the PTSF29within the cavity partial-mold4. The formed plastic PTSF29is cooled by coolant circulating surrounding the PTSF cavity28-1. When the molded PTSF29is properly cooled to be ejected, the ejection process of the molded PTSF29starts by removing the cavity partial-mold4in the core of the PTSF injection mold1. The cavity partial-mold4is removed simultaneously and horizontally pulling the top frame14and MRS bottom frame partial-molds16out of the PTSF injection mold1in the opposite directions against each other. At the same time, the metal-rod-filled-tubes (MRS)22within the molded plastic tubes29-1of the molded PTSF29are pulled out along with the MRS bottom frame partial-mold16because the MRS22is attached on the bottom frame31being in the single structure. Hence, the molded PTSF29remains alone in the core between the upper2and lower partial-molds3without the cavity partial mold4. Next, the upper partial-mold2is lifted-up and removed away to leave the molded PTSF29on the lower partial-mold3. Finally, the ejector pin plate83and ejector associate pins77are moved upward to push the molded PTSF29off from the lower partial-mold3under operation of the mold ejector controller of the ejector system assembly82shown inFIG.1. To fabricate the next PTSF29, the PTSF injection mold1is set up on the workbench of the injection molding machine. The setting of the PTSF injection mold1is accomplished by following the reverse unloading procedure of the top frame14and MRS bottom frame16, and upper partial-molds2. Namely, the top frame14and MRS bottom frame partial-molds16are simultaneously placed back over the lower partial-mold3on the workbench, and then the upper partial-mold2is placed over the top frame14and MRS bottom frame partial-molds16. Such loading and unloading of the all partial-molds are achieved by an automatic mechanical operation.

The PTSF injection mold1of the present invention fabricates PTSFs29, being able to replace PVC-film-fills using in water evaporative cooling towers, which have a higher water cooling efficiency compared with that of the PVC-film-fills, so that the PTSFs29reduce the operation and construction expenses of the cooling tower and the production of plastic wastes due to the utilizing of high cooling efficient media. In order to commercialize the PTSFs29, a manufacturing tool of the PTSFs29fabricating a low-cost PTSF29to overcome the extremely complex-structured PTSF29is needed. To achieve this end, the PTSF injection mold1, which can fabricate the PTSF29in one single shot of the molten plastics, is invented by comprising four partial-molds and operated in three dimensional disassembling and reassembling process using a vertical injection molding machine.

While only specific embodiments of the invention has been described and shown, this invention may be further modified and altered within the concept and scope of this disclosure. This application is therefore intended to cover any modifications, alterations, variations, adaptations, or use of the invention using its general principles. Further, it is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalent thereof.