Abstract:
In a modular mold assembly first and second mold frame halves used to define at least one aperture extending therethrough, the apertures cooperating to define a mold module cavity when said first and second halves are assembled. At least one mold module slidingly receivable in each of the apertures and can be locked therein securing the mold module within the mold cavity in response to the first and second halves being in engagement with one another. Upon separation of the mold halves, the modules are released and can be removed.

Description:
FIELD OF THE PRESENT INVENTION 
     The present invention is generally directed to molds used in injection molding machines, and is more specifically directed to a mold having cavities adapted to receive and retain mold inserts. 
     BACKGROUND OF THE PRESENT INVENTION 
     Molds used in injection molding machines generally include mold halves or sections which include portions that define the features of the items being molded. Since injection molding machines involve high temperatures and pressures, as well as mechanisms for cooling and ejecting molded components, the actual portion of the mold that defines the shape of the final product to be molded comprises only a small part of the entire mold assembly. As such it is beneficial to provide interchangeable mold modules that comprise that portion of the mold that defines the final molded product while maintaining a module support frame common to any number of these modules. 
     As such, molds used in the injection molding process often include a frame having one or more cavities therein each adapted to accept a mold module for producing the same or different molded parts. In general these mold modules are bolted in place and must be unbolted to remove the module from the mold. This is often time consuming and inconvenient as tools must be on hand to at least partially disassemble the mold. In addition, the bolts can be difficult to remove; sometimes resulting in stripped threads in the mold as well as in broken bolts. Moreover if a module must be changed quickly, the mold and module may be extremely hot further exacerbating the problem of mold removal. 
     Based on the foregoing, it is the general object of the present invention to provide a mold assembly that overcomes the problems associated with prior art molds. 
     SUMMARY OF THE PRESENT INVENTION 
     The present invention is directed in one aspect to a modular mold assembly comprising first and second mold frame halves, each defining at least one aperture extending therethrough. When the mold halves are assembled, these apertures cooperate to define a mold cavity. A mold module having a surface defining at least in part a portion of the item to be molded, is slidingly receivable in each of the apertures defined by the first and second mold frame halves. Once the mold modules are positioned within the apertures, locking means are employed to secure each mold module within its respective aperture in response to the first and second mold frame halves being brought into engagement with one another. The locking means also acts to release each mold module from a respective one of the first and second mold frame halves is response to the first and second mold frame halves being separated from one another. 
     In the preferred embodiment of the present invention, the locking means includes a first and second locking wedge; each with first locking wedges being coupled of the first and second mold frame halves and positioned in each apertures. The second locking wedges are slidingly coupled to the first locking wedges and are movable between a locked position wherein an outwardly facing surface defined by the second locking wedges thereby engages and securedly retains the mold module positioned in one of the mold frame half apertures, and an unlocked position wherein the outwardly facing surface is spaced away from the mold module, making the mold module freely removable from the respective first or second mold frame half. 
     In the preferred embodiment of the present invention, the first locking wedges each define a tapered surface slidingly engaged with a respective one of the second locking wedges. Accordingly, as the first and second mold frame halves are brought into engagement with one another, the tapered surface of the first locking wedges progressively engages the second locking wedge causing the outwardly facing surface to engage the mold module releasably retaining it within the mold cavity. Conversely, upon separation of the first and second mold frame halves, the tapered surface of the first locking wedges progressively disengages the second locking wedge causing the outwardly facing surface to move away from the mold module thereby allowing it to be freely removable from the aperture in either the first or second mold frame halves. 
     Preferably, a respective one of each of the second locking wedge and lacking wedges defines a dovetail-shaped groove with the other defining an outwardly projecting dovetail-shaped protrusion adapted to mate with the groove. It is also preferable that the surface of the second locking wedge engageable with the first locking wedge also be tapered. In this manner, small movements of the first locking wedge relative to the second locking wedge causes larger concomitant movement of the outwardly facing surface of the second locking wedge toward or away from the mold module. 
     The preferred embodiment of the present invention also includes a mold frame base upon which are positioned the first and second mold frame halves, one-on-top-of-the-other. A series of springs are positioned between the mold frame halves for urging the halves away from one another. During a molding operation the mold frame halves are pressed together and retained in that position be one or more clamps movable between a locked and unlocked position. 
     A mounting plate is coupled to the mold modules positioned within the apertures in the mold frame halves. A mounting member projects outwardly from the mounting plate and is adapted to frictionally engage a bushing positioned in an aperture defined by the mold frame base. The frictional force exerted between the mounting member and the bushing is sufficient to hold the mounting modules in place when the mold frame halves are separated to eject the molded items from the mold modules. The frictional force is not sufficient to overcome the force exerted by the springs, thereby allowing the first and second mold frame halves to separate when the clamp is released. 
     Preferably, the mounting member is in the form of a polymeric bushing threadedly attached to the mounting plate via a fastener. The polymeric bushing includes a tapered bore extending longitudinally therethrough and the fastener defines a tapered peripheral surface adapted to mate with the tapered bore so that subsequent tightening of the fastener causes an outer periphery defined by the polymeric bushing to expand, thereby providing the capability to set the desired amount of friction between the bushing in the mold frame base and the polymeric bushing. While a polymeric bushing has been described, the present invention is not limited in this regard as other materials such as metals or elastomers can be substituted without departing from the broader aspects of the present invention. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a cross-sectional front elevational view of a mold embodying the present invention. 
     FIG. 2 is a view of the mold of FIG. 1 taken along the line  2 — 2 . 
     FIG. 3 is a cross-sectional, view of the mold of FIG. 1 taken along the line  3 — 3 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     As shown in FIGS. 1 and 2, a mold incorporating the present invention is generally designated by the reference number  10  and includes first and second mold frame halves,  12  and  14  respectively. The first and second mold frame halves,  12  and  14 , are supported on a mold base assembly generally designated by the reference number  16 . A top plate  18  is positioned on an upper surface  19  of the first mold frame half  12  so that the first and second mold frame halves are interposed between the top plate and the mold base assembly  16 . 
     As best seen in FIG. 2, the four apertures  22  extend through the first mold frame half  12 . The apertures  22  are in turn approximately aligned with apertures  24  extending through the second mold frame half  14  there apertures also have approximately the same peripheral shape as the apertures  22 . Together the apertures  22  and  24  extending through the first and second mold frame halves,  12  and  14  respectively, cooperate to define mold cavities adapted to receive at least a pair of mold modules generally designated by the reference number  26  and positioned one on top of the other with the mating surfaces of the pair of mold modules coacting to define the geometry of a part to be molded. While four mold modules  26  have been shown and described, the present invention is not limited in this regard as any number of mold modules and corresponding cavities can be employed without departing from the broader aspects of the present invention. 
     As shown in FIG. 3, the top plate  18  and the first mold frame half  12 , each define a plurality of bores (only one shown),  27  and  28  respectively, extending partway therethrough with a bore  27  in the top plate being approximately aligned with a corresponding bore  28  in the first mold frame half. Likewise the second mold frame half  14  and a bottom plate  30  forming part of the mold base assembly  16  also each include a plurality of bores (only one shown),  32  and  34  respectively, extending partway therethrough with a bore  32  in the second mold frame half being approximately aligned with a corresponding bore  34  in the bottom plate. A spring, shown schematically in FIG. 3 as element  36 , is positioned in each of the cavities formed by the bores  27  and  28 , and  32  and  34 , for biasing the top plate  18  away from the first mold frame half  12 , and the second mold frame half  14  away from the bottom plate  30  when the mold is in an open position (the mold is shown in a closed position in FIG.  3 ). 
     Referring back to FIG. 1, a plurality of toggle clamp assemblies (four shown) generally designated by the reference number  38  are provided to hold the mold  10  in the closed position against the biasing force exerted by the springs  36 . Each toggle clamp assembly  38  includes a locking/release lever  40 , a clamping arm  42  coupled to the locking/release lever, and a clamping bracket  44 . During a clamping operation, the clamping arm  42  is engaged with the clamping bracket  44  and is moved to the locked position as shown in FIG.  1 . While toggle clamp assemblies have been shown and described, the present invention is not limited in this regard as other clamping or fastening mechanisms, such as bolts, quarter-turn fasteners, or C-type clamps may be substituted. 
     The first and second mold frame halves,  12  and  14  respectively, each define stepped bores  46 , only two shown in FIG. 1, extending therethrough. A shoulder screw  48  is positioned in each stepped bore  46  with one shoulder screw having an end threadedly engaged with the bottom plate  30 , and the other threadedly engaged with the top plate  18 . Each of the stepped bores  46  include a portion of sufficient size to slidingly receive a head portion  50  defined by each shoulder screw  48 . This portion of the stepped bores  46  have a length greater than the width “W” of the head portion. Accordingly, when the toggle clamp assemblies  38  are released, the springs  36 , FIG. 3, urge the top plate  18  and the second mold frame half  14  toward the open position. This causes the head portions  50  of the shoulder screw  48  engaged with the top plate  18  to move relative to the first mold frame half  12 . Concomitantly, the second mold frame half  14  moves relative to the head portions  50  of the shoulders screws threadedly engaged with the bottom plate  30 . The amount of movement of the top plate  18  and the second mold frame half  14  in moving from the closed to the open positions is limited by the heads  50  of the shoulder screws  48  contacting the first and second mold frame halves,  12  and  14  respectively, at the junctions  52  defined by the stepped bores  46 . 
     Still referring to FIG. 1, the preferred embodiment of the present invention includes locking mechanisms generally designated by the reference number  54  positioned in each of the apertures  22  and  24  defined by the first and second mold frame halves  12  and  14  respectively. The locking mechanisms  54  each include first and second locking wedges  56  and  58  respectively, with the first locking wedge being attached via a fastener to either the top plate  18  or the bottom plate  30 . The first locking wedge  56  defines a first tapered surface  60  slidingly engaged with a second tapered surface  62  defined by the second locking wedge  58 . Referring to FIG. 2 the first locking wedge also defines a dovetail/shaped protrusion  64  projecting outwardly from the tapered surface  60  and extending longitudinally therealong. The tapered surface  62  of the second locking wedge  58  defines a dovetail-shaped groove  66 ,extending longitudinally therealong and adapted to slidingly mate with the dovetail-shaped protrusion  64 . The second locking wedge  58  also includes a locking tab  68  projecting outwardly therefrom and adapted to engage a corresponding slot  70  defined by the mold module  26  positioned adjacent to the second locking wedge. 
     As the first and second mold frame halves,  12  and  14  respectively are moved from the open to the closed position, the movement of the top plate  18 , and the second mold frame half  14  causes the tapered surface  60  of the first locking wedge  56  to progressively and slidingly engage the tapered surface  62  of the second locking wedge  58 . This causes the locking tab  68  to engage the slot  70  thereby releasably securing the respective mold module  26  in place. Conversely, as the mold is moved from the closed to the open position the dovetail connection between the first and second locking wedges causes the locking tab  68  to move out of, and away from the slot  70  thereby allowing the respective mold module to be easily removed. 
     Referring to FIG. 3, in addition to the above-described locking wedges, the mold module  26  positioned in the second mold frame half  14  includes spacers  72  coupled thereto and extending to a mounting plate  74 . A generally cylindrical mounting member  76  is positioned within a recess  78  defined by the mounting plate  74  and includes a tapered bore  80  extending therethrough. A fastener  82  having a tapered outer surface complimentary in shape to the tapered bore  80  is positioned therein and threadedly engaged with the mounting plate. The mounting member  76  is slidably received in a bushing  84  that in turn is positioned in an aperture  86  defined by the mold frame base  16 . 
     Preferably, the mounting member is formed from a suitable type of material, such as, but not limited to a polymer, so that as the fastener  82  is tightened, the mounting member  76  expands causing it to frictionally engage the bushing  84 . Accordingly, when the first and second mold frame halves are moved to the open position so that the locking wedges disengage the mold modules  26  the friction between the mounting member  76  and the bushing  84  is insufficient to resist the force exerted by the springs, so that the mounting member slides relative to the bushing. However, the frictional force is sufficient to hold the mold module  26  in place to allow a molded part to be ejected. 
     Various modifications and substitutions may be made without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of example, and not by limitation.