Abstract:
A method and apparatus for blow molding a case for housing an object, such as a tool, is disclosed generally comprising first and second mold portions located adjacent each other to create separate cavities for forming base and lid portions of a case and a punch for each portion corresponding to the outline of an object. In certain embodiments, the punch protrudes into the cavity during blow molding to create a sidewall to facilitate a press fit. In some embodiments, additional punches and/or recesses are provided to produce additional apertures or flanges in the walls of the tool case.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a divisional of U.S. patent application Ser. No. 10/958,824 filed Oct. 5, 2004, which is currently pending. 

   FIELD OF THE INVENTION 
   The present invention relates to a method and apparatus for creating blow molded cases. More specifically, the invention relates to a method and apparatus for creating double wall cases with a punched area for housing an object. 
   BACKGROUND OF THE INVENTION 
   The use of blow-molding as a method for manufacturing various sorts of articles is generally well known. Typically, this process involves the use of a mold consisting of two separate halves or portions having cavities of particularly desired shapes and sizes. Usually, one extrudes a large-diameter, sealed tube of molten material (commonly referred to as a “parison”), places the tube between the mold halves, and closes the mold around the tube. Fluid pressure is then introduced into the tube, forcing the molten tube against the walls of the cavities, conforming the tube to the shape thereof. The pressure is maintained until the molten material cools and solidifies. The pressure is then released, the mold halves are pulled apart, and the hardened article is ejected therefrom. 
   One such article that is commonly manufactured in this manner is double wall cases. By producing cases in this manner, one is able to produce a device that is capable of carrying and protecting tools placed inside the case that has a multitude of desirable physical characteristics—such as rigidity, scuff resistance, and impact absorption—yet that is relatively inexpensive to manufacture. Typically, these cases will be formed using the process described above, where one mold half forms the exterior of both the base and lid portions of the case, while the other mold half forms the interior of both base and lid portions. Usually, the mold half forming the exterior of the case forms a wall with a smooth, attractive shape, while the mold half that forms the interior of the case is often molded with compartments to hold specific contents, such as, for example, a pistol-type soldering iron and various tips therefore. In fact, a particular advantage of manufacturing cases in this way is that the walls formed by the two mold halves do not need to match, as the space between these walls is filled with air. 
   One disadvantage of these cases, however, as that, due to their double wall nature, they tend to be both heavy and cumbersome. Accordingly, it has been suggested to cut out sections of the interior walls of the case in order to utilize the wasted volume of space between the double walls. By doing so, the case can be made smaller in light of the fact that this previously unused space is now being used to house the tool. Moreover, by removing sections of the walls, the case also decreases significantly in weight. As a result, it is also much easier to mold the design of the interior of the case, as it is no longer necessary to create deep molded compartmentation, and fewer molding rejects also result. 
   An example of this approach is disclosed in U.S. Pat. No. 3,317,955 to Schurman, et al., which discloses the earliest known double wall case blow-molded case, illustrating a rectangular cutout of most of the inside wall of the base portion. Another example is disclosed in U.S. Pat. No. 3,327,841 to Shurman, et al., which illustrates a partial cutout shaped to accommodate the outline of a pistol-type soldering gun. The gun is further supported by a cradle molded in the outside wall of the base portion of the case, while the space under the uncut portion of the inside base is usable for storage of an electric cord, thereby maximizing the utilization of what was previously wasted unused space. 
   However, one problem with removing wall sections in blow-molded cases as shown in these disclosures is that, because the blow molding process involves the use of a parison with a continuous, unbroken surface, the mold itself cannot produce any holes in the blow-molded wall other than the hole or holes through which the fluid pressure is introduced. Therefore, removing these sections typically involves an additional manufacturing step, where these wall sections are cut or burned after the blow molding process is completed and the case has been ejected from the mold. For example, cutting the inner wall was often accomplished with the use of a small circular saw blade mounted to a router and guided by a molded vertical lip surrounding the area to be cut. The router was fixed and the case was moved around the router axis by hand or by mechanical means. Round holes are often cut with hole saws, or occasionally, are burned. Cutting or burning these holes after the blow molding process is completed, however, requires additional tooling and additional manufacturing steps, entailing further difficulty, time, and expense. Moreover, the process produces unwanted sawdust or charred material around the cutout lip. 
   Another disadvantage of removing the wall sections after the blow molding process is complete is that the blow-molding process itself takes an unnecessarily long time. Generally, when a double wall case is blow molded using injections of fluid through one or more needles, the amount of air that can be circulated within the case is severely limited. Accordingly, the amount of heat that can be removed from the inside plastic walls is also limited, and thus, because these walls must be cooled before the part can be ejected from the mold, the blow-molded cycle is slow. Similarly, draining the blowing fluid through one or more needle orifices at the end of the blowing cycle is a relatively slow process, and because the case cannot be ejected from the mold until he internal air pressure has returned nearly to atmospheric pressure, the process is somewhat slow. 
   What is desired, therefore, is a blow-molded case that is double walled, but is not heavy or cumbersome. What is also desired is a case that is easy and inexpensive to manufacture. What is further desired is a blow-molded case that does not produce residual sawdust and/or charred plastic. What is also desired is a case that does not require a long blow molding cycle. 
   SUMMARY OF THE INVENTION 
   Accordingly, it is an object of the present invention to provide a double wall case that utilizes the space between the walls of the case. 
   It is a further object of the present invention to provide a double wall case that does not require additional manufacturing steps after the blowing cycle. 
   It is yet another object of the present invention to provide a double wall case that does not require cutting or burning during manufacture. 
   It is still another object of the present invention to provide a double wall case that does not require a long time to cool the inside plastic walls of the case during manufacture. 
   It is yet another object of the present invention to provide a double wall case that does not require a long time to drain blowing fluid from the case during manufacture. 
   In order to overcome the deficiencies of the prior art and to achieve at least some of the objects and advantages listed, the invention comprises an apparatus for creating a blow-molded case for housing an object, including a mold comprising first and second mold portions that, when located adjacent each other, have first and second mold surfaces at least partially defining first and second cavities, the cavities having first and second cavity surfaces, respectively, against which first and second walls of the blow-molded case are blown, respectively, during blow molding, and a first punch having a punching surface at least part of which corresponds to at least part of the outline of the object, wherein, when the first punch is in an unactivated position, the first cavity surface includes the first mold surface and at least part of the first punch and, when the first punch is in an activated position, at least part of the first punch is extended past the first wall of the blow-molded case and inside the first cavity such that a first hole, at least part of which corresponds to at least part of the outline of the object, is created in the first wall of the blow-molded case. 
   In another embodiment, the invention comprises a method for creating a blow-molded case for housing an object, including providing a mold having first and second mold portions, providing a first punch, wherein the first punch has a punching surface at least part of which corresponds to at least part of the outline of the object, moving the first mold portion adjacent to the second mold portion, thereby at least partially enclosing first and second cavities having first and second cavity surfaces, respectively, blowing a first wall of the blow-molded case against the first cavity surface and a second wall of the blow-molded case against the second cavity surface, and extending at least part of the first punch through the first wall of the blow-molded case and into the first cavity, thereby creating a first hole in the first wall of the blow-molded case. 
   In yet another embodiment, the invention comprises a blow-molded case for housing an object, including a double wall base portion having a first cavity for housing at least part of the object, a double wall lid portion connected to the base portion, the lid portion having a second cavity for housing at least part of the object, and wherein one of the base and lid portions has a first punched hole at least part of which corresponds to at least part of the outline of the object for receiving the object. 
   In still another embodiment, the invention comprises a method for creating a blow-molded case for housing an object, including moving a first mold portion adjacent to a second mold portion, thereby creating first and second cavities, blowing first and second walls of the blow-molded case against the first and second cavities, respectively, and punching a hole, at least part of which corresponds to at least part of the outline of the object, in the first wall of the blow-molded case. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1A  is a perspective view of a tool case in the open position made in accordance with the invention. 
       FIG. 1B  is a perspective view of the tool case of  FIG. 1  in the closed position. 
       FIG. 2  is a perspective view of an apparatus in accordance with invention for making the tool case of  FIG. 1 . 
       FIG. 3A  is a side view of one embodiment of the apparatus of  FIG. 2  in an open position. 
       FIG. 3B  is a side view of the apparatus of  FIG. 3A  in a closed position. 
       FIG. 4A  is a cut-away, cross-sectional view of part of one embodiment of the apparatus of  FIG. 3B  where a punch is in an unactivated position. 
       FIG. 4B  is a cut-away, cross-sectional view of the apparatus of  FIG. 4A  where a punch is in an activated position. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   The basic components of one embodiment of a double wall blow molded tool case in accordance with the invention are illustrated in  FIG. 1A . As used in the description, the terms “top,” “bottom,” “above,” “below,” “over,” “under,” “above,” “beneath,” “on top,” “underneath,” “up,” “down,” “upper,” “lower,” “front,” “rear,” “back,” “forward” and “backward” refer to the objects referenced when in the orientation illustrated in the drawings, which orientation is not necessary for achieving the objects of the invention. 
   The case  10  includes a double wall base portion  12  and a double wall lid portion  14 . The base portion  12  has a punched hole  20  in its inner wall  22  that corresponds to the outline of an object, such as a tool, to be housed by the tool case  10 . Accordingly, the hole  20  and the space between the inner wall  22  and the outer wall  24  provide a cavity  26  in which the tool can be placed. 
   Similarly, the lid portion  14  includes a punched hole  30  in its inner wall  32 . Accordingly, the hole  30  and the space between the inner wall  32  and outer wall  34  provide a cavity  36  for accommodating the top of the tool when the tool case  10  is closed, as shown in  FIG. 1B . In certain advantageous embodiments, the hole  30 , like the hole  20 , corresponds to the outline of the tool to provide a more secure fit. 
   In some embodiments, a sidewall  40  substantially perpendicular to the plane of the punched hole  20  runs along the perimeter of the hole  20 , providing a press fit insertion of the tool into the cavity  26 . Additionally, in certain embodiments, an additional punched aperture  42 , which may be a through hole or a blind hole, is provided to permit accessories—such as, for example, drill bits, or, as another example, a power cord—to be stored therein. In some of these embodiments, a flange  44  is provided adjacent the hole  20  and aperture  42  in order to provide for greater rigidity. Also, in certain embodiments, at least one boss  46  in the outer wall  24  is provided to engage a particular shape or aperture in the tool, such as a handle. Depending on the particular embodiment and on the particular tool for which the tool case  10  is designed, one or more of the above-described features may be provided in the lid portion  14  in addition to, or in lieu of, the presence of these features in the base portion  12 . 
   As illustrated in  FIG. 2 , an apparatus for creating the tool case  10  of  FIG. 1  comprises a mold  50  including a first mold portion  52  and a second mold portion  54 . As shown in  FIGS. 3A-B , the first mold portion  52  includes first and second punches  56 ,  58  having first and second punching surfaces  66 ,  68 , respectively. When the first and second mold portions  52 ,  54  are separated, such as when a parison is being disposed in the mold  50 , the first and second punches  56 ,  58  are in an unactivated position, as shown in  FIG. 3A . As illustrated in  FIG. 3B , when the first and second mold portions  52 ,  54  are moved adjacent each other (i.e., when the mold  50  is closed), the first and second punches  56 ,  58  remain in the unactivated position while the parison is being injected with blowing fluid. Accordingly, portions of the first and second punches  56 ,  58  form part of the surfaces against which the walls of the blow molded case are blown. Later, when it is desired to punch holes in the walls of the blow molded case, the first and second punches  56 ,  58  are moved to an activated position, as shown in phantom in  FIG. 3B . 
   The operation of the mold portion  52 ,  54  and punches  56 ,  58  is illustrated in  FIGS. 4A-B . When the first mold portion  52  is adjacent the second mold portion, a cavity  70  is formed in each of the base and lid portions of the mold  50 . For example, referring to  FIG. 4A , when the punch  56  is in the unactivated position, the cavity  70  has a cavity surface  80  comprised of the mold surface  72  of the mold portions  52 ,  54  and part of the punch  56 . This cavity surface  80  defines the cavity  70 . When blowing fluid is injected into the parison, the wall of the blow molded case is blown against the cavity surface  80 . 
   After a predetermined time interval, the punch  56  is moved from an unactivated position to an activated position, as illustrated in  FIG. 4B . When this occurs, the punch  56  is extended past the wall of the blow molded case and into the cavity  70 , thereby creating a hole in the wall of the blow molded case. The punch  56  has a punching surface  76  corresponding to the outline of the tool to be housed in the tool case  10 , and thus, a hole in the shape of the tool is created in the wall of the blow molded case  10 . In certain advantageous embodiments, the punching surfaces of both punches  56  and  58  correspond to the outline of the tool. By removing a large section of the walls of the blow molded case  10  at this stage, drainage of the blowing fluid is almost instantaneous. Similarly, large volumes of air can be quickly circulated inside the case  10 , quickly cooling and solidifying the walls of the case. In these ways, the time required for the blow molding cycle is greatly reduced. 
   In some embodiments, when the punch  56  is in the unactivated position, the punch  56  protrudes out beyond the mold surface  72  into the cavity  70 , as shown in  FIG. 4A . As a result, when the wall of the blow molded case  10  is blown against the cavity surface  80  (which includes part of the punch  56 ), the wall of the case  10  is formed around the punch  56 . In this way, a recessed portion is formed in the wall of the case. Accordingly, when the punch is moved to the activated position (thereby punching the tool-shaped hole  20  in the wall of the case  10  as shown in  FIG. 4B ) the sidewall  40  remains along the perimeter of the tool-shaped hole  20 . This permits a tighter, press-fit insertion of the tool into the cavity  26 . 
   In some embodiments, the second mold portion  54  includes a boss  84  that extends into the cavity  70 . Accordingly, when the wall of the blow molded case is blown against the cavity surface  80 , a boss, such as boss  46 , is created. In certain of these embodiments, the boss  84  corresponds to the outline of an aperture of the tool to be housed in the case  10 , such as a handle. 
   In certain advantageous embodiments, the first mold portion  54  includes a boss  86  so that the wall of the blow molded case  10  is formed therearound in a manner similar to boss  84 , thereby producing an aperture in the wall of the case  10 , such as aperture  42 . In some of these embodiments, the boss  86  is specifically configured to produce an aperture adapted to receive an accessory of the tool, such as a power cord, drill bits, etc. 
   In some embodiments, at least one additional punch is provided in addition to the first and second punches  56 ,  58 . Like punches  56 ,  58 , these additional punches, when in an unactivated position, form part of the cavity surface  80  and, when in an activated position, extend out beyond the mold surface  72  to create an aperture in the wall of the blow molded case. Depending on the particular tool to be housed in the case  10  and the particular function desired, the aperture can be a through hole or a blind hole, and can be specifically configured to produce an aperture adapted to receive an accessory of the tool. 
   In certain advantageous embodiments, the mold surface  72  includes a recess  88  adjacent the punch  56  so that, when the wall of the blow molded case is blown against the mold surface  72 , flange  44  is formed, thereby providing greater rigidity to the inner wall  32  of the case  10 . 
   It should be understood that the foregoing is illustrative and not limiting, and that obvious modifications may be made by those skilled in the art without departing from the spirit of the invention. Accordingly, reference should be made primarily to the accompanying claims, rather than the foregoing specification, to determine the scope of the invention.