Apparatus and method for blow moulding three dimensional objects

Abstract: Apparatus for blow-moulding an article curved in three dimensions comprises two horizontally movable mould parts (10,12) which, when in contact with each other, define a mould cavity (34) curved in three dimensions to match the required article. An extrusion head (68) extrudes a parison (80) of synthetic resin material into the cavity so that it descends towards the lower end thereof. During this process, a first air flow is fed through apertures (84,86) in a cover (70) and passes through the mould cavity around the outside of the parison (80) to ease the passage of the parison towards the lower end. In addition, a second air flow is fed through a nozzle (88) in the extrusion head (68) into the interior of the parison (80) so as to help it descend and also to prevent its distortion as it moves into the mould cavity (34). Thereafter, closure members (50,52,58 and 60), which are slidable on, but movable independently of, the main mould parts (10,12), close off the upper and lower ends of the mould cavity and pinch the parison (80) between them, their movements being controlled by respective actuators (54,56,62,64). Blow-moulding then takes place through the nozzle (88) in order to produce the required article. The mould parts (10,12) are then separated. The article remains suspended by the closure members (50,52,58,60) and can be grabbed by a manipulator arm or a robot arm and then removed after separation of the closure members (50,52,58,60).

Description: The invention relates to moulding apparatus for blow-moulding an article curved in three dimensions, comprising two mould parts mounted to be movable relative to each other between a first, mutually separated, position and a second, closed, position in which the two mould parts together define a mould cavity curved in three dimensions to match the shape of the article and having first and second longitudinally spaced ends at least the first of which is open, extrusion means for extruding a parison of synthetic resin material into the cavity through the first end thereof, closure means movable independently of movement of the mould parts for closing the or each end of the mould cavity when the parison is in position therein, blow-moulding means for blow-moulding the parison in the cavity to form the said article, and flow means for providing a flow of air or other gas between the outside of the parison and the wall of the mould cavity as the parison passes into and along the mould cavity whereby to facilitate the passage of the parison into and along the mould cavity. Such apparatus is known from WO-A-89/04755. Here, the extrusion means is positioned above the first end of the mould cavity with a clear space between it and the mould parts so that the first end of the mould cavity is fully exposed to the surrounding atmosphere. The flow of air through the mould cavity and around the outside of the parison is achieved by suction applied to the second end of the mould cavity which draws air from the atmosphere through the first end thereof. Such an arrangement leaves the first end of the mould cavity substantially unprotected and is without any direct interconnection between the extrusion means and the mould parts. Also known from EP-A-0 301 694 is moulding apparatus as first set forth above except that, in this known apparatus, the flow of air or other gas into the mould cavity enters through the side wall of the cavity at bends or corners therein and thus has only a partial effect in facilitating the passage of the parison into the mould cavity. According to the invention, the apparatus as first set forth above is characterised by cover means for defining an enclosure around the extrusion means and the first end of the mould cavity, and in that the flow means comprises for supplying air or other gas into the enclosure and thence into the mould cavity through its first end, the air or other gas flowing through the cavity towards the second end thereof. Mounting apparatus according to the invention, which will be described in more detail below by way of example only, enables the blow-moulding of parts bent or curved in three dimensions. Such parts may, for example, be in the form of hoses or pipes having a pre-formed curved or bent configuration such as for use in the cooling, heating or air conditioning systems of motor vehicles. However, such parts may have other applications instead. Further embodiments of the invention are defined in the dependent claims. Moulding apparatus embodying the invention will now be described, by way of example only, with reference to the accompanying diagrammatic drawings in which: Figure 1 is a cross-section through part of one form of the moulding apparatus in its initial setting; Figure 2 corresponds to Figure 1 but shows the apparatus in a working configuration; Figure 3 is a section on the line III-III of Figure 1; Moulding apparatus and moulding methods according to the invention will now be described, by way of example only, with reference to the accompanying diagrammatic drawings in which: Figure 1 is a cross-section through part of one form of the moulding apparatus in an initial setting; Figure 2 corresponds to Figure 1 but shows the apparatus in a working configuration; Figure 3 is a section on the line III-III of Figure 1; Figure 4 is a cross-section of part of a modified form of the apparatus of Figures 1 to 3 during an early stage in the moulding method; Figure 5 corresponds to Figure 4 but shows a later stage in the method; Figure 6 is a cross-section through part of a further modified form of the apparatus of Figures 1 to 3; Figure 7 is a cross-section through another modified form of the apparatus of Figures 1 to 3; and Figure 8 shows part of the apparatus of Figure 7 at a later stage in the moulding method. Referring to Figure 1, the apparatus is mounted on a base 5 between two upright stanchions 6 and 8. These stanchions support two main mould parts 10 and 12. Mould half 10 is supported by and rigidly attached to a plate 14 supported by a horizontal arm 16 (see Figure 2) slidably extending through the stanchion 6 and connected to an actuator 18. The actuator 18 may be of any suitable form, such as a hydraulic actuator. It can be activated so as to move the arm 14 in the direction of the arrow A, thus moving the mould part 10 towards and away from the mould part 12. The mould half 12 is mounted in the same way. Thus, it is rigid with a plate 20 carried by a support arm 22 which is slidable in the stanchion 8 and connected to an actuator 24 for moving the arm 22 in the direction of the arrow B. Thus, the actuator 24 can be operated to move the mould part 12 towards and away from the mould part 10. The facing surfaces 26,28 of the mould parts 10,12 are respectively formed with respective halves 30,32 (see Figures 2 and 3) of a mould cavity 34. Each half of the mould cavity 34 is curved in three dimensions (see Figure 3). The two main mould parts 10,12 can be moved towards each other so that their faces 26,28 come into contact with each other as shown in Figure 3. The two halves 30,32 of the mould cavity are thus closed together to define the complete mould cavity 34. This mould cavity is shaped to match the outside surface of the article to be moulded. The apparatus also includes lower and upper pairs of closure members. The lower closure members are shown at 50 and 52. They are respectively slidably mounted on the lower surfaces of the main mould parts 10 and 12, such as by a key and keyway arrangement (not shown), so as to be slidable in the direction of the arrows C. This sliding movement is under the control of actuators 54 and 56 mounted on the stanchions 6 and 8. The upper closure members are shown at 58 and 60. These members are slidably mounted on the upper surfaces of the main mould parts 10,12 such as by a key and keyway arrangement. They are slidable in the direction of the arrows D under control of actuators 62 and 64 which are supported on the stanchions 6 and 8. In its upper region, the apparatus includes an extrusion head 68 and a cover plate 70. The extrusion head 68 and the cover plate 70 are supported directly or indirectly from the stanchions 6,8 by means not shown. The lower surface of the cover 70 makes sealing contact with the upper faces of the main mould parts 10,12 but in a manner which enables the mould parts to slide horizontally relative to the cover 70. The operation of the moulding apparatus will now be described. The initial positions of the main mould parts 10,12 and the lower and upper closure members 50,52,58,60 are shown in Figure 1. When a moulding operation is to take place, the main mould parts 10,12 are caused to move towards each other by operation of the actuators 18,24, until their surfaces 26,28 come into contact with each other as shown in Figure 3, thus forming the mould cavity 34. The lower and upper closure members 50,52,58,60 initially remain in the positions illustrated in Figures 1 and 2. The extrusion head 68 is now activated and extrudes a parison of synthetic resin 80 through an extrusion die 82, directing the parison downwardly into the mould cavity 34. As this process begins, a flow of air (or other suitable gas) is directed into the cavity 34 from a suitable source through apertures 84,86 leading into the interior 87 under the cover 70 and hence into the mould cavity 34. This air flow, indicated by the arrows, flows into the mould cavity and downwardly therethrough, around the outside of the parison 80 as it is extruded into the cavity, thus guiding the parison and keeping it clear of the internal wall of the mould cavity. Simultaneously with this process, a further air or gas flow is injected into the interior of the parison 80 through a nozzle 88 which is mounted centrally within the extrusion head 68. This air flow into the interior of the parison helps to ensure that the parison maintains a desired shape and does not become damaged or distorted or partially collapsed by the extrusion process and by the process of feeding it into and through the mould cavity. It will be understood that the parameters of the exterior and interior air flows (pressure, temperature, flow rate) can be regulated to facilitate the extrusion process and (for example) to prevent the material of the parison from becoming over-cool or partially solidified. When the parison 80 has become fully inserted into the mould cavity 34 (which may be detected by a suitable detector not shown), an inner part 90 of the extrusion head 68 moves downwardly relative to the outer part 92 and thus closes the extrusion die 82. The air flows through the holes 84 and 86 and through the nozzle 88 are cut off. Actuators 62 and 64 are then activated and the two closure members 58 and 60 are moved towards each other so as to close off the upper end of the mould cavity 34. The meeting faces of the closure members 58,60 are shaped with concave ends shown at 93 and 94 so as to surround the lower end of the nozzle 88. At the same time, actuators 54 and 56 are activated and move the closure members 50 and 52 towards each other so as to close off the lower end of the mould cavity 34. The blow-moulding operation now takes place, the blow-moulding air supply being fed into the interior of the parison through the nozzle 88. The closure members of each pair pinch the parison between them. At the end of the blow-moulding operation, the two main mould parts 10,12 are withdrawn away from each other into the position shown in Figure 1. This process is carried out by means of the actuators 18 and 24. When the two mould parts are withdrawn away from each other in this manner, the moulded article will be held in a fixed position with its two ends being respectively supported by the closed pairs of closure members 50,52 and 58,60. A manipulating arm or other automatic system such as a robot arm then grabs the parison. The closure members 50,52 and 58,60 are then withdrawn away from each other by means of their respective actuators. The moulded article is then removed. Figures 1 and 2 also show a modification in which two (in this example) additional airways 96 and 98 are formed through the main mould parts 10,12, connecting particular regions within the two halves of the mould cavity 34 to the upper faces of the main mould parts. When the main mould parts 10,12 are moved into contact with each other, as shown in Figure 2, these airways 96,98 become connected to the interior under the cover 70. Instead, however, they can be supplied with air from another source. In this way, the airways 96,98 conduct additional flows of air into the mould cavity to supplement the flow of air into the mould cavity from its top and flowing round the exterior of the parison. These supplementary air flows assist the downward movement of the parison. They are particularly useful when the mould cavity is sharply curved or of significant length. The outlets of the airways 96,98 are thus appropriately positioned according to the shape of the mould cavity. There may of course be more than two such airways. For example, there could be a plurality of such airways having their outlets all lying in the same horizontal plane. Instead, or in addition, there could be airways having outlets lying in different horizontal planes. The outlet of each airway, where it connects with the mould cavity, is provided with a one-way valve, lying in the local plane of the wall of the cavity, to close off the airway when air flow stops and moulding begins. Figure 4 and 5 shows a modification to the upper part of the apparatus of Figures 1 to 3 and parts in Figures 4 and 5 corresponding to those in the previous Figures are similarly referenced. In the modification of Figures 4 and 5, the functions of the cover 70 and the closure members 58 and 60 of Figures 1 to 3 are combined together. As shown in Figure 4, modified closure members 100 and 102 are used instead of the closure members 58 and 60 and the cover member 70 of the previous Figures. The closure members 100 and 102 are connected to be moved in the direction of the arrows D by the actuators 62 and 64 (see Figures 1 to 3). During the initial process, in which the parison 80 is fed into the mould cavity (after the two main mould parts 10,12 have been moved into contact with each other - see Figure 2), the closure members 100,102 are in the closed position as shown in Figure 4. As indicated, they are in contact with the end of the extrusion head 68, thus forming a closed chamber 104 corresponding to the closed cavity chamber 87 of Figures 1 to 3. As before, the parison 80 is extruded from the extrusion head 68 through the die 82 and through this chamber 104 and into the mould cavity. As before, this process is facilitated by a flow of air into the mould cavity 34 and around the outside of the parison 80, this flow of air entering the chamber 104 through apertures 106 and 108. In addition, a flow of air is fed into the interior of the parison through the nozzle 88 as the parison is fed into the mould cavity. When the parison has become fully inserted into the mould cavity, the lower end of the mould cavity is closed off by the closure members 50,52 (see Figure 2) in the manner already explained. The extrusion head 68 is then activated to close off the die 82, and blow-moulding takes place under the effect of the blow-moulding air which is blown into the interior of the parison through the nozzle 88. During the moulding operation, the closed chamber 104 forms a continuation of the mould cavity 34 and is thus of course appropriately shaped according to the desired shape of the corresponding end of the article to be moulded. Upon completion of the moulding operation, the main mould parts 10,12 are separated in the manner already described. As shown in Figure 5, the moulded article 80 is thus held supported at its upper end by the closure members 100 and 102 and at its lower end by the closed closure members 50,52 (see Fig. 2). As before, the moulded article can thus be grabbed by a manipulated arm or a robot arm. The closure members 100,102 are then withdrawn away from each other by the actuators 60,64 and the lower closure members 50,52 are also separated. The moulded article can then be removed. Figure 6 shows a further modification. Figure 6 illustrates the lower portions of the main mould parts 10,12 which, in the modification shown in Figure 6, have a modified shape at the lower end of the mould cavity. As shown in Figure 6, the closure members 50,52 are not used in this modification. Instead, the two main mould parts 10,12 are formed at 112 and 114 so that, when the main mould parts are in contact with each other, they themselves form a closure for the lower end of the mould cavity 34. In addition, though, an airway 116 is formed within the mould part 12 (or mould part 10) and connects with the lower end of the mould cavity 34 via an orifice 118 which is formed by grooves respectively cut in the facing surfaces of the portions 112 and 114 of the mould parts. By means of this airway 116, air can be drawn from the lower end of the mould cavity 34 so as to flow around the outside surface of the descending parison. This air flow can replace or supplement the air flow supplied through the holes 84,86 (Figures 1 to 3) or holes 106,108 (Figures 4 and 5). The airway 116 can be connected in any suitable way to a source of air pressure or suction. The moulding operation is otherwise as already described. Figures 7 and 8 show a further modification. Parts in Figures 7 and 8 corresponding to those in Figures 1 to 3 are correspondingly referenced. As shown in Figure 7, this modified form of the apparatus does not have the lower and upper closure members 50,52,58 and 60 for their respective actuators. Instead, a vertically movable closure member 120 is mounted on the base plate 5 and can be moved vertically by an actuator 122 in a manner to be explained. In addition, the assembly comprising the extrusion head 68 and the cover plate 70 is mounted on an arm 124 or other suitable mechanism by means of which they can be swung away from the mould parts 10,12. Initially, after the two mould parts 10,12 have been moved into contact with each other as already explained in conjunction with Figure 2, the apparatus has the configuration shown in Figure 7. As before, the parison 80 is extruded into the moulded cavity 34 and, simultaneously, air is blown around the outside of the parison through the holes 84 and 86 and into the interior of the parison through the nozzle 88, all to aid its descent into the mould cavity in the manner already explained. When the parison reaches the lower end of the mould cavity, the extrusion is stopped. The lower closure member 120 is then raised by the actuator 122 so as to enter into and close off the lower end of the mould cavity as shown in Figure 8. At the same time, the arm 124 removes the assembly comprising the extrusion head 68 and the cover plate 70 away from the top of the mould cavity. A combined upper closure member and blow-moulding head 126 is then lowered into the upper end of the mould cavity by means of an arm 128 so as to close off this upper end. Figure 8 shows that the lower and upper closure members 120 and 126 are shaped so as to provide the desired shapes for the ends of the article to be moulded and grip the ends 80A and 80B of the parison. Blow-moulding air is then blown into the parison through the member 126 via a nozzle 130 so as to carry out the moulding operation. Thereafter, the two main mould parts 10,12 are moved apart so as to leave the moulded article held suspended between the upper and lower members 120,126. As before, it can be grabbed by a manipulating arm or robot arm which then removes the moulded article after the closure members 120 and 126 have been moved in respective vertical directions away from the mould cavity. In a modification, the cover plate 70 and the extrusion head 68 and the associated mechanism are not movably supported on the arm 124 but are fixed. Instead, the mould parts 10,12, and their associated mechanism, together with the closure member 120, are arranged to be movable sideways away from the cover plate 70 and the extrusion head 68 and into alignment with the closure member 126. Any other suitable gas, instead of air, may be used for flowing around the outside of, and for blowing into the interior of, the parison during the injection process and also during the blow-moulding operation.

Claims: Moulding apparatus for blow-moulding an article curved in three dimensions, comprising two mould parts (10,12) mounted to be movable relative to each other between a first, mutually separated, position and a second, closed, position in which the two mould parts (10,12) together define a mould cavity (34) curved in three dimensions to match the shape of the article and having first and second longitudinally spaced ends at least the first of which is open, extrusion means (68) for extruding a parison (80) of synthetic resin material into the cavity (34) through the first end thereof, closure means (58,60;50,52) movable independently of movement of the mould parts (10,12) for closing the or each end of the mould cavity (34) when the parison (80) is in position therein, blow-moulding means (88) for blow-moulding the parison (80) in the cavity (34) to form the said article, and flow means (84,86) for providing a flow of air or other gas into the first end of the cavity (34) between the outside of the parison (80) and the wall of the mould cavity (34) and thence along the cavity (34) towards its second end as the parison (80) passes into and along the mould cavity (34) whereby to facilitate the passage of the parison (80) into and along the mould cavity (34), characterised by cover means for defining an enclosure (70,104) around the extrusion means (68) and the first end of the mould cavity (34), and in that the flow means comprises means (84,86) for supplying the flow of air or other gas into the enclosure (70) and thence into the mould cavity (34) through its first end. Apparatus according to claim 1, characterised by additional flow means for providing a flow of air or other gas into the interior of the parison (80) as it passes into the mould cavity (34). Apparatus according to claim 1, characterised by additional flow means mounted on the extrusion means (68) for supplying a flow of air or other gas into the interior of the parison (80) as it passes into the mould cavity (34). Apparatus according to any preceding claim, characterised by supply means (96,98) for supplying air or other gas into the mould cavity (34) through its wall at one or more positions intermediate its ends. Apparatus according to claim 4, characterised in that the supply means comprises one or more airways (96,98) formed in one or both of the mould parts (10,12). Apparatus according to any preceding claim, characterised by suction means for applying suction to the mould cavity (34) through its second end. Apparatus according to any preceding claim, characterised by regulating means for controlling one or more of the following parameters of the or each flow of air or other gas: flow rate, pressure and temperature. Apparatus according to claim 3, characterised in that the blow-moulding means includes means (88) for supplying blow-moulding air or gas into the interior of the parison (80) through the additional flow means on the extrusion means (68). Apparatus according to any preceding claim, characterised in that the closure means comprises a pair of closure members (50,52;58,60;100,102) mounted adjacent to the or each open end of the mould cavity (34), each said closure member (50,52;58,60) being slidably mounted on a respective one of the two mould parts (10,12) whereby the two closure members (50,52;58,60) of the or each said pair are movable towards each other to a closed position so as to close off the respective end of the mould cavity (34) and away from each other to an open position so as to open the respective end of the cavity (34). Apparatus according to claim 9, characterised in that the closure members (50,52;58,60;100,102) in moving towards each other to close off the end of the cavity (34), pinch the parison (80) between them and close it, whereby, upon movement of the mould parts (10,12) into the separated position, the corresponding end of the blow-moulded article is supported by and between the closure members (50,52;58,60). Apparatus according to claim 9 or 10, characterised in that the closure members (100,102) at the first end of the mould cavity (34) are shaped to define between them, when in their closed position, the enclosure (104) around the extrusion means (68) and the first end of the mould cavity (34). Apparatus according to any one of claims 9 to 11, characterised by respective actuator means (54,56;62,64) connected to each closure member (50,52;58,60;100,102) for moving the closure members of each said pair between the open and closed position. Apparatus according to any one of claims 1 to 8, characterised in that the closure means comprises, for the or each open end of the mould cavity (34), a closure member (120,126) movably mounted relative to the two mould parts (10,12) so as to be movable in a direction substantially perpendicular to their directions of movement and between an open position in which it is clear of the respective end of the mould cavity (34) and a closed position in which it closes that end. Apparatus according to claim 13, characterised in that, upon movement of the mould parts into the separated position, the corresponding end of the blow-moulded article is supported by the respective closure member (120,126). Apparatus according to claim 13 or 14, characterised in that the blow-moulding means comprises means (130) for supplying blow-moulding air or gas into the interior of the parison (80) through the closure member (126) at the said first end of the mould cavity (34).

Inventors: RENZO BERNARD, ROBINAULT MICHEL, RENZO, BERNARD, ROBINAULT, MICHEL
Applicants: DRAFTEX IND LTD, DRAFTEX INDUSTRIES LIMITED
Application year: 1995
Main classification: B29C49
IPC codes: B29B11, B29C49