Portable clean molding apparatus and method of use

A portable clean molding apparatus for receipt of molded articles ejected from a mold machine. The apparatus includes a receiving chamber having a first interior space and a selectively openable first door, a secondary chamber joined to the receiving chamber and having a second interior space and a selectively openable second door, and an air filtration cover unit installed over the receiving and secondary chambers so as to provide a low-particulate, positive airflow into the first and second interior spaces. The apparatus further includes at least one vent communicating with the second interior space so as to allow the airflow to exit the secondary chamber and at least one chute communicating with the first interior space so as to allow the airflow to exit the receiving chamber, the chute being located adjacent to the mold machine for the transfer of molded articles to the receiving chamber.

INCORPORATION BY REFERENCE

Applicants hereby incorporate herein by reference any and all U.S. patents and U.S. patent applications cited or referred to in this application.

BACKGROUND OF THE INVENTION

1. Field of the Invention

An aspect of this invention relates generally to clean environments, and more particularly to portable clean environments employed in the field of molding.

2. Description of Related Art

In the molding field, it is often desirable to mold parts in a low particulate count environment. This is particularly true for medical and optical molded parts, for example. Typically, such low particulate count molding is accomplished by locating the entire mold machine within a clean environment, such as a class 100,000 clean room. However, it is generally costly to maintain such a clean room, much less a lower particulate count permanent environment on the order of class 100, and the molder is often also then limited to the particular mold machine that is installed within the clean room, creating potential problems in production scheduling and in the event of machine downtime.

To address some of these concerns common to locating a mold machine in a permanent clean room, temporary clean rooms and other portable clean environments have been developed in the art. These temporary and portable clean environments are also relatively expensive to operate and/or are generally not capable of maintaining a low particulate count environment on the order of class 100 independent of a larger clean room within which they are designed to operate.

The following art defines the present state of this field:

U.S. Pat. No. 4,723,480 to Yagi et al. is directed to a manufacturing apparatus equipped with product transfer means arranged along the flow of products and provided with an air cleaning device. A partition panel is provided on the downstream side of the clean air blow-off vent of the air cleaning device so as to form a clean air passageway and prevent dust from penetrating into the passageway, so that goods are manufactured and transferred in the cleaned air passageway.

U.S. Pat. No. 4,981,634 to Maus et al. is directed to an injection molding process that creates a micro-cleanroom environment inside a mold cavity which can stay closed to airborne contaminants while ejecting and transferring the molded part out. The molded part is formed and solidified at a parting-line plane within the mold cavity, then is carried rearward on the movable mold insert to a second plane where it is stripped off and transferred out through a discharge aperture which is open when the mold cavity is in the second plane but closed off when in the first plane. The aperture faces substantially downward to prevent entry by upwelling thermal air currents. External supplied filtered gas can provide positive pressure through vents within the moldset's internal space. This maximizes mold and part cleanliness while speeding up “mold-open” cycle and may eliminate HEPA filters/enclosures and robots. Optical disks, lenses, food packaging and medical parts are suggested uses.

U.S. Pat. No. 5,139,459 to Takahashi et al. is directed to a clean transfer method capable of safely transferring a semiconductor or the like to various apparatuses for treating the semiconductor while keeping the environment clean. In the method, the semiconductor is transferred between a vacuum clean box arranged in a clean room and kept at the degree of vacuum of 1 Torr or less and a vacuum chamber arranged in a maintenance room while transfer ports of the vacuum clean box and vacuum chamber are kept air-tightly connected to each other. The vacuum clean box is movably arranged.

U.S. Pat. No. 5,316,560 to Krone-Schmidt et al. is directed to an apparatus for controlling the environment of an enclosed space. The apparatus includes a workspace compartment within a gas-tight chamber, a mechanism for circulating dehumidified gas in true laminar flow through the workspace compartment, and a highly efficient filtering component for removing contaminants from the gas.

U.S. Pat. No. 5,401,212 to Marvell et al. is directed to an environmental control system including a modular isolation chamber. Together with associated atmospheric regulatory equipment, the connectable modular chambers provide a smaller, cost-effective alternative to the traditional clean rooms utilized for fabricating or processing semiconductors and other products. Because the work pieces and processing or other machinery are isolated from the remainder of the rooms in which they are located, decontamination of much of each room is not required. Use of the portable, modular chambers of the present invention also permits increased control over particulate contaminates smaller than heretofore satisfactorily regulated and individualized regulation of differing processing environments within a single room.

U.S. Pat. No. 5,425,793 to Mori et al. is directed to chamber units are sequentially coupled with each other to thereby provide a volume of clean space, and whereby different environments can be maintained in the different chamber units. An air blowhole or door is provided at an opening section of each chamber unit. Moreover, a space section can be defined at the coupling part of the chamber units, and a suction pump and a suction hose can be provided in the space section, so as to prevent the environments of the different chambers from influencing one another.

U.S. Pat. No. 5,464,475 to Sikes et al. is directed to an improved machine for performing a manufacturing process on a workpiece. The machine includes a cabinet defining an interior workspace for performing the manufacturing process. The workpiece is placed in the workspace by an operator. The cabinet is coupled with a gas source for receiving a flow of gas from the gas source. The improvement comprises a first aperture in the cabinet providing access to an interior chamber within the cabinet. The interior chamber has an interior surface and an open end aligned with the first aperture for storing a work-in-process unit. The interior chamber is accessible to the operator for transferring the work-in-process unit between the interior chamber and the workspace. The improvement further comprises a second aperture in the interior surface of the interior chamber, the second aperture admitting the flow of gas from the gas source to establish a laminar flow of the gas in the chamber intermediate the first aperture and the second aperture.

U.S. Pat. Nos. 5,687,542, 5,953,884 and 6,145,277 to Lawecki et al. are directed to an apparatus and method for manufacturing articles, such as syringe barrels, substantially free from contaminants. The apparatus is an enclosure defining at least a class 100 and MCB-3 environment, and includes a molding isolation module and a packaging isolation module. Any contaminants that may exist within the enclosure are removed by the use of horizontal and vertical laminar airflows directed into air filter units. Further, the molding temperature may be selected such that it renders the fabricated articles substantially free from contaminants. The molding isolation module and packaging isolation module keep the fabricated articles substantially free from contaminants from the time the articles are molded to the time the articles are placed in sealed containers for shipment.

U.S. Pat. No. 5,833,726 to Kinkead et al. is directed to a scheme for defining, inside a processing facility, a storage environment that is substantially free of a targeted molecular contaminant and in which one or more substrates are to be stored for a period of time before or after a substrate processing step; the scheme including: an air blower for providing a flow of air within a storage environment defined inside a processing facility; a substrate support for holding one or more substrates inside the storage environment; and a molecular air filter having an input face positioned to receive air from the blower and having an output face for providing a flow of filtered air inside the storage environment, the molecular air filter being constructed and arranged to remove an airborne molecular contaminant from air flowing into the storage environment to achieve a concentration level of the molecular contaminant inside the storage environment suitable for storing one or more substrates therein for a sit time corresponding to the time before a subsequent substrate processing step; wherein the storage environment is substantially free of the targeted airborne molecular contaminant. Schemes for defining substrate storage environments for semiconductor device fabrication processes are also disclosed.

U.S. Pat. No. 5,997,399 to Szatmary is directed to an apparatus for providing a clean working environment including an isolation booth, a worker booth, and an access device arranged to enable a worker in the worker booth to handle material in an isolation chamber formed in the isolation booth. A pressure generator is positioned to communicate with the isolation chamber to generate an air pressure therein that is less than the air pressure of an air curtain passing through the worker booth so that air is drawn from the air curtain in the worker booth into the isolation chamber through any air leak opening that develops in and around the access device so as to block outflow of air in the isolation chamber to the worker booth through the air leak opening.

U.S. Pat. No. 6,010,400 to Krainiak et al. is directed to an isolation work station comprising an enclosure and an air circulation system and high efficiency air filter for generating a downwardly directed laminar air flow through the enclosure. Periodic sterilization of the enclosure may be accomplished by adding a sterilant, such as vaporized hydrogen peroxide, to the airstream, and the filter is impregnated with a catalyst for degrading the vaporized hydrogen peroxide during the purge cycle and wherein the airstream is circulated at a relatively low speed so as to increase the residence time in the filter.

U.S. Pat. No. 6,238,283 to Matsuyama et al. is directed to a work conveying and transferring apparatus having a trolley having a casing defining a hermetically sealed space, and a support portion provided on the trolley for placing at least one container containing a cassette carrying works. A container opening device is provided on the trolley to open the container placed on the support portion, and a cassette transferring device is provided for transferring the cassette from the trolley to a treating apparatus, with the container placed on the support portion opened. The support portion is provided in the sealed space, and works can be double sealed by the sealed space and the container.

U.S. Pat. No. 6,623,538 to Thakur et al. is directed to a compact, portable, lightweight, low power consuming, convenient, versatile and sterile laminar airflow device, useful in obtaining a workspace substantially devoid of airborne particulate contaminants, said device having a body divided into upper and lower chambers; the upper chamber housing one or more pre-filtration members, a motor driving a fan, and one or more filters located below the motor; and the lower chamber provided with a slidable front panel, a removable platform located at the lower portion of the chamber and a perforated plane placed on the removable platform.

The prior art described above teaches a manufacturing apparatus with an air cleaning device, an injection molding process operating without opening the mold to airborne contaminants, a clean transfer method and system therefor, an environment control apparatus, an environmental control system, a coupling-type clean space apparatus, a work-in-process storage pod, an isolation module for molding and packaging articles substantially free from contaminants, storing substrates between process steps within a processing facility, an isolation chamber air curtain apparatus, an isolation workstation, a double-sealed work conveying and transferring apparatus and container inspecting method, and a sterile laminar airflow device, but does not teach a portable clean molding apparatus and method providing for the receipt of parts molded in a mold machine, manipulating such parts in a low particulate count environment, and passing the manipulated parts out of the portable clean molding apparatus without compromising its low particulate count environment, and wherein the portable clean molding apparatus and the mold machine are both not located in a clean room. Aspects of the present invention fulfill these needs and provide further related advantages as described in the following summary.

SUMMARY OF THE INVENTION

The present invention is generally directed to a portable clean molding apparatus for receipt of molded articles ejected from a mold machine, comprising a receiving chamber having a first interior space and a first side including a selectively openable first door, a secondary chamber joined to the receiving chamber substantially along the first side and having a second interior space and a second side including a selectively openable second door, and an air filtration cover unit installed over the receiving and secondary chambers so as to provide a low-particulate, positive airflow into the first and second interior spaces. The apparatus further comprises at least one vent intersecting the secondary chamber so as to communicate with the second interior space and allow the airflow to exit the secondary chamber and at least one chute intersecting the receiving chamber at a first end so as to communicate with the first interior space and allow the airflow to exit the receiving chamber, the chute being located adjacent to the mold machine at a second end, whereby the molded articles ejected from the mold machine pass through the chute into the receiving chamber, are there sealably packaged, are then passed into the secondary chamber through the selectively openable first door, and, after the first door has been closed, are next passed out of the secondary chamber through the selectively openable second door.

DETAILED DESCRIPTION OF THE INVENTION

The above described drawing figures illustrate aspects of the invention in at least one of its exemplary embodiments, which are further defined in detail in the following description.

The present invention is directed to a portable clean molding apparatus10for receipt of molded articles110ejected from a mold machine100. The apparatus10, which is located generally adjacent to the mold machine100, comprises a receiving chamber20having a first interior space22and a first side24including a selectively openable first door26; a secondary chamber40joined to the receiving chamber20substantially along the first side24and having a second interior space42and a second side44including a selectively openable second door46; an air filtration cover unit60installed over the receiving and secondary chambers20,40so as to provide a low-particulate, positive airflow70into the first and second interior spaces22,42; at least one vent80intersecting the secondary chamber40so as to communicate with the second interior space42and allow the airflow70to exit the secondary chamber40; and at least one chute90intersecting the receiving chamber20at a first end92so as to communicate with the first interior space22and allow the airflow70to exit the receiving chamber20and attached to the mold machine100at a second end94, whereby the molded articles110ejected from the mold machine100pass through the chute90into the receiving chamber20, are there sealably packaged, are then passed into the secondary chamber40through the selectively openable first door26, and, after the first door26has been closed, are next passed out of the secondary chamber40through the selectively openable second door46, as explained in more detail below. It will be appreciated by those skilled in the art that by packaging the molded articles110in the low-particulate count environment of the receiving chamber20, then passing the packaged molded articles110into the second low-particulate count environment of the secondary chamber40, and again closing the receiving chamber20before accessing the articles110in the secondary chamber40, the receiving chamber20, and thus the molded articles110themselves, remain essentially uncompromised while allowing the articles110to be packaged and ultimately passed out of the clean molding apparatus10for shipment. Moreover, the stand-alone operation and portability of the clean molding apparatus10of the present invention allows for tremendous economy and versatility in molding a variety of articles110in a number of mold machines100, none of which must be located in a dedicated clean room or other such clean environment.

InFIG. 1there is shown an exemplary embodiment of the portable clean molding apparatus10of the present invention. The receiving chamber20and secondary chamber40are integrally formed on a single substantially rectangular base12having four legs14substantially at the four corners of the base12. The legs14may include rigid or adjustable-height feet, wheels, coasters, or any other suitable support contacts now known or later developed in the art. The construction of the base and side frame members16is preferably of square-cross-section aluminum tubing, while the side panels18themselves are preferably of ¼″ clear Lexan for visibility into the receiving and secondary chambers20,40. In the exemplary embodiment, the first interior space22is approximately double the second interior space42, the receiving chamber20measuring roughly 32″×24″×23″ and the secondary chamber measuring roughly 16″×24″×23″. It will be appreciated by those skilled in the art that a number of other materials and configurations for forming the receiving and secondary chambers20,40of the clean molding apparatus10are possible and that the present embodiment is merely exemplary. Specifically, while the portable clean molding apparatus10is shown and described as being an integral unit having the receiving and secondary chambers20,40formed on a single base12, it is entirely possible that the chambers20,40could be separable units removably joined along the receiving chamber's first side24so as to allow communication between them through the selectively openable first door26, as explained below. The receiving chamber20may be formed with one or more hand access ports28for accessing the first interior space22when the clean molding apparatus10is in operation, as when molded articles110ejected from the mold machine100are to be packaged and then passed through the first door26and into the secondary chamber40, as also described in detail below. The receiving chamber20may be further formed with a front access door28for accessing the first interior space22when the clean molding apparatus10is not in operation so as to perform cleaning, maintenance, setup and other such functions. Though an access door30having two gloved hand access ports28is shown in the exemplary embodiment as the front side of the receiving chamber20, those skilled in the art will appreciate that a variety of other means, both now known and later developed, can be employed in the present invention for accessing the receiving chamber's first interior space22, both when the clean molding apparatus is operating and when it isn't. With the receiving and secondary chambers20,40adjacently located as shown, the air filtration cover unit60is installed over both chambers so as to selectively blow a low-particulate, positive airflow70into the first and second interior spaces22,42. In the exemplary embodiment of the clean molding apparatus10, the cover unit60is a 2′×4′ Kydex housing, room-side control HEPA (“high efficiency particle arresting”) filter unit as manufactured by Airguard of Louisville, Ky. The HEPA filter operates at 99.99% minimum efficiency at 0.3 microns particulate size and flow rates of 70 to 120 ft/min±20% measured six inches from the filter face. Based on the numerous other possible configurations and parameters of the portable clean molding apparatus10, it will be appreciated that filtration units of various other sizes and performance levels may be employed without departing from the spirit and scope of the present invention. Moreover, air filtration devices other than the HEPA filter, both now known and later developed, may be utilized in the clean molding apparatus10.

Turning toFIGS. 2-5, in the exemplary embodiment of the portable clean molding apparatus10of the present invention, the chute90intersects the receiving chamber20at a first end92so as to communicate with the first interior space22and is located adjacent to the mold machine100at a second end94such that during use the molded articles110ejected from the adjacent mold machine100pass through the chute90and into the receiving chamber20. The chute90may be stabilized at its first end92within an opening32formed in the receiving chamber20using a gasket or the like (not shown), though it is to be understood that an airtight fit or seal is not required. Likewise, the chute90can be positioned with its second end94proximal to and slightly spaced apart from the mold (not shown) of the mold machine100or attached to the mold through a tie bar sleeve (not shown) as is known and used in the art. An exemplary such tie bar sleeve is a black neoprene, high-temperature sleeve with an approximately 2½″ diameter and 20″ mold open capacity manufactured and sold under part number TBS2.520 by Molding Automation Concepts of Woodstock, Ill. The positioning of the chute90's second end94adjacent to the mold as being attached or only proximal to the mold may be dictated by considerations including the size and configuration of the mold and the orientation of its parting line. In the exemplary embodiment, the chute90is substantially tubular and itself has a diameter of approximately six inches, yielding a projected area98into the receiving chamber of roughly 28.3 in2. As explained in more detail below, the chute90serves to also allow the airflow70to exit the receiving chamber20and, thus, the chute projected area98is one variable affecting the overall flow of air through and performance of the clean molding apparatus10. Those skilled in the art will appreciate that the chute90can take on a variety of sizes and configurations as needed based on the configuration of the mold machine100, including the mold itself (not shown) and its required opening (or the orientation of its parting line), and the size and shape of the molded articles110. As such, the chute90shown and described is merely exemplary. Relatedly, the secondary chamber40is equipped with a vent80to allow the airflow70to exit the secondary chamber40. Therefore, the vent projected area88is another variable affecting the airflow and performance of the clean molding apparatus10. In the exemplary embodiment, the vent80is configured as a substantially circular opening82having a perforated cover84over the opening82. The cover may have a number of roughly ⅜″ diameter holes86overlapping the opening82so as to allow air to flow therethrough. In one embodiment, there are a total of thirty-two such holes86for a total vent projected area88into the secondary chamber40of approximately 3.5 in2. It will be appreciated that a number of other vent configurations are possible in the present invention and that the vent80shown and described is only exemplary. Also in the exemplary embodiment, the selectively openable second door46of the secondary chamber40has dimensions of roughly 16″×23″, resulting in a second door projected area48into the secondary chamber40of approximately 368 in2. The relationship of these various projected areas to the projected areas into the respective receiving and secondary chambers20,40of the cover unit60's filter and the effect of these relationships on airflow and performance of the portable clean molding apparatus10of the present invention are discussed below. With continued reference toFIGS. 2-5, there is shown the selectively openable first door26located on the first side24of the receiving chamber20and allowing for transfer of molded articles110into the secondary chamber40, as also described below. While both the first and second doors26,46are shown as hinged doors pivoting about a vertical axis so as to selectively expose the opening in which each is situated, it will be appreciated by those skilled in the art that a number of other doors, curtains and other such barriers may be employed without departing from the spirit and scope of the present invention. In addition to the cover unit60room-side fan speed access control (not shown), the portable clean molding apparatus10may be further equipped with power and lighting controls and units (not shown) for the convenient and effective operation of the apparatus10. Within the clean molding apparatus10there may also be provided pressure gauges or manometers and flow meters (not shown) to monitor the pressure and air flow in both chambers20,40when the apparatus10is in operation.

Referring now toFIGS. 6-8, the airflow70through the clean molding apparatus10during the different stages of operation is shown schematically. Because the air supplied by the HEPA filter cover unit60is at a relatively low flow rate and, hence, a relatively low pressure in view of the sizes of the exit orifices in this control volume context, the flows are assumed incompressible in applying the Bernoulli and continuity equations. In the first stage, then, as shown inFIG. 6, the apparatus10is operating at steady state with the first door26between the receiving and secondary chambers20,40closed so that the airflow70entering the receiving chamber20exits through the chute90and the airflow70entering the secondary chamber40exits through the vent80. It is desirable that no non-negligible pressure differential, or pressure build-up in the secondary chamber40, be created, so that when the first door26is opened in order to pass packaged molded articles110into the secondary chamber40(seeFIG. 7), the airflow70will continue in its steady state pattern or, if anything, move through the receiving chamber20toward the secondary chamber40. In this way, ultimately, there will be no effective cross-contamination or compromise of the receiving chamber20even when temporarily opened to the secondary chamber40. Applying the continuity equation to this context, for there to be equal or greater pressure build-up, even if low, in the receiving chamber20as compared to the secondary chamber40, it follows that the airflow70must leave the secondary chamber40through the vent80at a rate equal to the rate at which the airflow70leaves the receiving chamber20through the chute90. Per the continuity equation, this would be accomplished so long as the ratio of the secondary chamber filter projected area64(As) to the vent projected area88(Av) is the same as or less than the ratio of the receiving chamber filter projected area62(Ar) to the chute projected area98(Ac).
(As/Av)≦(Ar/Ac)

As set forth above, in the exemplary embodiment of the present invention, the chute projected area98(Ac) is 28.3 in2, the receiving chamber filter projected area62(Ar) is 768 in2(32″×24″), and the secondary chamber filter projected area64(As) is 384 in2(16″×24″). Solving for the optimized vent projected area88(Av) as the chute projected area98multiplied by the secondary chamber filter projected area64divided by the receiving chamber filter projected area62, or multiplied by the filter ratio, results in a vent projected area88of greater than or equal to 14.2 in2, or roughly one-half the chute projected area98, as would be expected considering that the ratio of the filter projected areas62,64and of the volumes of the respective receiving and secondary chambers20,40are also 1:2. Similarly, applying the Bernoulli equation accounting for pressure and flow rate and assuming that the velocities of the air entering and exiting the receiving chamber20are to be equivalent to those entering and exiting the secondary chamber40, it follows that the velocity of air exiting the receiving chamber20(vr,exit) equals the velocity of air exiting the secondary chamber (vs,exit) equals the flow rate into the secondary chamber (Qs) divided by the vent projected area88(Av).
vr,exit=vs,exit=(Qs/Av)

Assuming that the flow rate generated by the HEPA cover unit60is 750 ft3/min, the flow rate into the receiving chamber20(Qr) is two-thirds of the total flow rate, or 500 ft3/min, and the flow rate into the secondary chamber (Qs) is one-third of the total flow rate, or 250 ft3/min. It follows that the velocity of air exiting the receiving chamber20(vr,exit) is the flow rate into the receiving chamber20(Qr) divided by the chute projected area98(Ac), which works out to 2,500 ft/min. Solving again for the vent projected area88(Av), it is once more determined to be approximately 14.2 in2, or roughly one-half the chute projected area98. However, a further means of optimizing the vent projected area88, and thus the vent size, is to consider that at the flow rates and pressures involved, some pressure build-up in the secondary chamber40will be negligible and, hence, not cause cross-contamination of the receiving chamber20when the first door26between the chambers20,40is opened. It has been determined empirically that the vent projected area88can be at least as low as 25% of the filter ratio multiplied by the chute projected area98for the clean molding apparatus10to still function as intended. That is, in the exemplary embodiment of the apparatus10, the actual vent projected area88is 3.5 in2, or roughly one-fourth of the 14.2 in2determined to be the minimum vent projected area88needed to produce no pressure build-up. Thus, the pressure that is built up at this reduced vent size is effectively negligible, as a clean molding apparatus10configured and operating as in the exemplary embodiment has been tested and certified to class 100.

As also shown inFIG. 6, a molded article110molded in the adjacent mold machine100′ (FIG. 5) has passed through the chute90and is located in the low-particulate, controlled environment of the receiving chamber20. Moving now toFIG. 7, there is shown one or more such molded articles110sealably packaged and passed through the opened first door26into the secondary chamber40. Again, this packaging operation can be accomplished by an operator accessing the first interior space22of the receiving chamber20through the hand access ports28(FIG. 1) or through any other such access means now known or later developed. Where the packaging step is at least in part a manual operation, the same means for accessing the molded articles110may also be employed in operating the selectively openable first door26effectively from within the receiving chamber20. Though the first door26is shown as a vertically hinged door, or barrier, selectively covering the first opening34between the receiving and secondary chambers20,40and opening into the receiving chamber20, it will be appreciated that a number of other barrier configurations and opening modes may be employed without departing from the spirit and scope of the invention, such as roll-up doors, sliding doors, accordion doors, and a variety of curtains and other such barriers. Moreover, with any such door configuration, it is also possible that the operation of the door can be accomplished in an automated fashion or otherwise through external controls as is known in the art, which would be particularly advantageous where the packaging step is automated and access to the first interior space22of the receiving chamber20during operation of the clean molding apparatus10is generally unnecessary. As with the attachment of the chute90to the receiving chamber20, it is not necessary that the first door26be airtight or positively sealed, but only that, when closed, it cause the steady state flows within each of the chambers20,40as described above in connection withFIG. 6. Essentially, at the relatively low flows and pressures associated with the clean molding apparatus10and the resulting substantially equivalent pressures in the two chambers20,40during operation, the airflow70entering each of the chambers20,40will take the path of least resistance out through the respective chute90and vent80. Therefore, at this stage of operation wherein the first door26between the receiving and secondary chambers20,40is temporarily opened, because the vent80is configured to allow the airflow70to exit at a rate effectively equal to or greater than that exiting the chute90, it follows that even when the door26is open, the airflow70continues substantially in its steady-state pattern or, if anything, some of the airflow70entering the receiving chamber20passes through the open first door26and into the secondary chamber40before exiting through the vent80. It will be appreciated by those skilled in the art that in this way effectively no air moves from the secondary chamber40into the receiving chamber20when the door26between them is opened, thereby preventing cross-contamination or compromise of the clean environment of the receiving chamber20as the packaged molded articles110are passed out of the receiving chamber20into the secondary chamber40. Once the articles110are passed through the opening34into the secondary chamber40, the first door26is again closed, returning the clean molding apparatus10to its steady state operation depicted schematically inFIG. 6.

Next turning toFIG. 8, there is shown the packaged molded articles110passed through the opened second door46and out of the secondary chamber40. As with the first door26, though the second door46is shown as a vertically hinged door opening away from the secondary chamber40, again, a number of other barrier configurations now known and later developed can be employed in the present invention in selectively covering the second opening54formed in the secondary chamber40for the purpose of accessing the second interior space42and retrieving therefrom packaged molded articles110passed into the secondary chamber40from the receiving chamber20through the selectively openable first door26. Based on the airflow70steady state continuity principles discussed above, the relationships between the various projected areas within the secondary chamber40can also be understood. Specifically, it will be appreciated that in order to minimize contamination in even the secondary chamber40, it is important that when the second door46is opened, the airflow70entering the secondary chamber40tend to exit through the second door46at a rate greater than or equal to that exiting through the vent80. In this way, outside air that has not passed through the HEPA filter cover unit60will effectively be prevented from entering the secondary chamber40through the open second door46, as the airflow70out will be greater. In contrast, were the airflow70to tend to exit through the vent80at a rate greater than that exiting the opened second door46, the result would be that outside air would be pulled into the secondary chamber40through the second door46. Taking into consideration the effect of projected area on flow rate, as explained above, it follows that a first desirable relationship for features of the secondary chamber40is for the second door projected area48(Ad), or the projected area into the secondary chamber40of the second opening54, to be greater than or equal to the vent projected area88(Av).
Ad≧Av

It is further desirable that the airflow70entering the secondary chamber40be greater than or equal to the airflow70exiting through both the opened second door46and the vent80combined, again, so that air will continue to move out away from the secondary chamber40even when the second door46is open and effectively no outside, unfiltered air will be pulled into the secondary chamber40, whether through the open second door46or the vent80. It follows, then, that the secondary chamber filter projected area64(As) is to be greater than or equal to the second door projected area48(Ad) and the vent projected area88(Av) combined.
As≧(Ad+Av)

Once the articles110are passed out of the secondary chamber40through the opening54, the second door46is again closed, once more returning the clean molding apparatus10to its steady state operation depicted schematically inFIG. 6. Those skilled in the art will thus appreciate that by packaging the molded articles110in the low-particulate count environment of the receiving chamber20, then passing the packaged molded articles110into the low-particulate count environment of the secondary chamber40, and closing the first door26between the chambers20,40before accessing the articles110in the secondary chamber40through the second door46, the receiving chamber20, and thus the molded articles110themselves, remain essentially uncompromised while allowing the articles110to be packaged and ultimately passed out of the clean molding apparatus10for shipment.

As stated previously, the chute90can take on a variety of sizes and configurations as needed based on the configuration of the mold machine100and the size and shape of the molded articles110. Beyond the gravity-feed, enclosed, tubular slide shown, the chute90may be an enclosed conveyor, ramp, elevator or other such part-mover now know or later developed. For purpose of the airflow70through the clean molding apparatus10, it is the resulting variance of the chute projected area98into the receiving chamber20that is to be accounted for. Under the continuity principles, it may be preferable to have the vent80change in size accordingly so that the relative projected areas remain at roughly the same proportion and the performance of the overall clean molding apparatus10continue generally as described above. Thus, in this embodiment, it is desirable to form the vent80such that its effective projected area88can be easily varied. There are a number of means by which the size and/or configuration of the vent80can be modified, both now known and later developed in the art. An exemplary adjustable opening is shown inFIGS. 9a-d, wherein the vent80is again configured as a substantially circular opening82, but now having a slotted frame83around three sides of the opening82for removable receipt of covers84,84′ of varying patterns and sizes of holes86,86′. As such, one cover is easily replaced with another by sliding them in and out of the slotted frame83to quickly and conveniently vary the effective vent projected area. Thus, as shown inFIG. 9a, a first cover84is in position within the frame83over the vent opening82so as to create a first vent projected area. InFIG. 9b, the first cover84is partially removed from the slotted frame83, as when it is to be replaced by a different cover84′ so as to vary the vent projected area. Next, inFIG. 9c, the first cover84is completely removed and a different second cover84′ is in position to be inserted in the slotted frame83. Finally, inFIG. 9d, the second cover84′ is fully inserted in the frame83over the opening82so as to yield a second vent projected area. Again, numerous other such means for varying the vent projected area88are possible without departing from the spirit and scope of the invention, including pivoting louvers, slidable overlapping openings, etc., whereby the removable covers84,84′ shown and described are merely exemplary. Alternatively, the vent80may be configured to be sufficiently large to accommodate the full anticipated range of chute90sizes, in which case the desired relationship of the exit flow rate from the secondary chamber40through the vent80being effectively greater than or equal to the exit flow rate from the receiving chamber20through the chute90would always be satisfied.

In use, the portable clean molding apparatus10of the present invention is first positioned adjacent to a mold machine100from which molded articles110are to be ejected for packaging and shipment. The clean molding apparatus10is a stand-alone unit that is relatively small in size, constructed of relatively lightweight materials, and configured with sliding or rolling feet so that locating the apparatus10in various positions adjacent to a variety of mold machines100is a simple maneuver. As explained previously, the clean molding apparatus10has in an exemplary embodiment a parts chute90that is positioned proximal to the mold machine100's mold (not shown) or connected at its free end94to the mold itself using tie bar sleeves or the like (not shown), so that once the apparatus10is in position, it is effectively rendered operable by plugging the unit into a 115-volt power source (not shown). Cleaning and maintenance of the apparatus10can be performed right on location; specifically, in the receiving chamber20through the front access door30and in the secondary chamber40through the second door46. The front access door30may also be used to supply the receiving chamber20with a parts container and the necessary packaging supplies (not shown), for example. With the apparatus10in position and supplied with power and the receiving and secondary chambers20,40cleaned and prepared for use, the HEPA filter cover unit60may be operated so as to blow a low-particulate, positive airflow70into the chambers20,40, as described above. Again, the airflow70entering the receiving and secondary chambers20,40is exhausted through the chute90and the vent80, respectively. After the filtered air has been forced through the clean molding apparatus10for a few minutes to reach a low-particulate, steady state flow as depicted schematically inFIG. 6, the apparatus10is ready for use. As articles110are molded in the mold machine100and ejected from the mold itself (not shown), they pass through the chute90into the first interior space22of the receiving chamber20. There, the molded articles110may be inspected, deburred, etc., as necessary, and then packaged, either through automated processes or manually by an operator accessing the first interior space22through the glove access ports28installed in the front access door30of the receiving chamber20. Once the desired number of molded articles110are so packaged, with the second door46of the secondary chamber40remaining closed, the first door26between the receiving and secondary chambers20,40is opened and the packaged molded articles110are passed into the second interior space42of the secondary chamber40. Then, the first door26is closed so as to again isolate the receiving chamber20from the secondary chamber40. The packaged molded articles110are next passed out of the secondary chamber40through the selectively openable second door46and are boxed or otherwise prepared for shipment. In an alternative use, it is possible that parts so packaged may be later returned to the same or another clean molding apparatus10for subsequent inspection and sorting. In this case, the apparatus10would not require a chute90for receipt of the molded articles110from a mold machine100. Accordingly, the opening32in the receiving chamber20through which the chute90was inserted may serve as a ventilation hole in much the same way as the vent80of the secondary chamber40. In this way, the so configured clean molding apparatus10may be placed in any convenient location and, again, rendered operable by simply plugging the unit into a 115-volt power source (not shown). Then, to return previously packaged molded articles110to the receiving chamber20for inspection or sorting, essentially the reverse steps would be followed as described above for moving packaged parts out of the clean molding apparatus10. That is, with the first door26between the receiving and secondary chambers20,40closed, the second door46is opened and the articles110are passed into the secondary chamber40. Once the second door46is again closed, the first door26is then opened and the parts moved from the secondary chamber40back into the receiving chamber20, with the first door26once again closed afterward. Now the molded articles110can be removed from their packaging and inspected and sorted as necessary in the uncompromised receiving chamber20through the glove access ports28or other such means. Removing the subsequently inspected, sorted and repackaged molded articles110from the clean molding apparatus10is then as before. It will be appreciated by those skilled in the art that the portable clean molding apparatus and method of the present invention is thus economical and versatile in operation by effectively creating a portable mini-clean room environment outside of a mold machine, in which molded parts may be received and manipulated and then passed out of without compromising its low particulate count environment, thereby eliminating the need for a larger and more costly clean room and the associated logistical drawbacks due to the then limited number of mold machines that can be employed in clean molding applications.

While aspects of the invention have been described with reference to at least one exemplary embodiment, it is to be clearly understood by those skilled in the art that the invention is not limited thereto. Rather, the scope of the invention is to be interpreted only in conjunction with the appended claims and it is made clear, here, that the inventor(s) believe that the claimed subject matter is the invention.