Abstract:
A pick and place tool including a part penetration element adapted to induce a generation of a compressive force by the part against the part penetration element, securing the part to the part penetration element. The pick and place tool secures a part at first location employing an induced compressive force by the part against a part penetration element of the pick and place tool. In one embodiment, a pick and place tool for picking a part while maintaining a selected part orientation includes a tool body and a part penetration element attached to the tool body, the part penetration element adapted to induce a compressive force by the part against the part penetration element, securing the part to the part penetration element in a selected part orientation.

Description:
BACKGROUND OF THE INVENTION 
   1. Technical Field 
   The present invention relates generally to plastic injection molding and more particularly to a positioning jig and pick and place tooling for an injection molding device and process. 
   2. Background 
   In the field of plastic molding, it is well known that a plastic component may be molded to a non-plastic element. For instance, in one application, a plastic connector is molded to a fabric strap to provide a means for attaching the strap to yet another component or part, or for connecting two molded connecting buckle ends to one another, for instance, to be used as a belt. 
   According to the prior art, positioning a part with respect to a mold, may be achieved by positioning a portion of the part to which a plastic element is to be molded, in a detent or recessed portion of a first mold section or mold insert. According to the prior art, once a part that is to be attached to the molded component is positioned on the mold insert, the mold insert must be handled rather delicately, until the insert is mated with the a second mold section pinching or compressing the part between the mold insert and the second mold section. In practice, the mold section to upon which the part that is to be attached to the molded component is positioned typically remains in a horizontal position until the molding process is complete. 
   The described process or methodology provides distinct limitations particularly when considering the use of vertical injection molding devices and processes or various tooling for automated settings. Maintaining the location of the part with respect to the mold insert in production settings has proven challenging. Because of the orientation of the mold, parts are prone to shifting and displacement during the course of the process. Additionally, placing parts to which a component is to be molded is similarly challenging, particularly in a production setting. 
   Advantage may be found therefore in providing a plastic injection molding system that includes a device for positively locating a part to which a plastic element is to be molded with respect to the mold. Additional advantage may be found in providing a plastic injection molding system that includes a positioning jig for accurately locating and positioning a part to which a plastic element is to be molded, in a selected orientation for subsequent placement in a mold section. Additional advantage may be found in providing a pick and place tool adapted to pick the part to which a plastic element is to be molded from the positioning jig and accurately transport the part to a mold section, accurately placing the part with respect to the mold section in the selected orientation. Additional advantage may be found in providing a pick and place tool adapted to pick the part to which a plastic element is to be molded from the positioning jig and transport the part to the mold, accurately placing the part in a selected orientation for a subsequent molding process. Additional advantage may be found in providing a mold section having a face oriented in a substantially vertical plane that is adapted to receive a part to which a plastic element is to be molded, accurately maintaining a selected orientation for a subsequent molding process until the injection molding process has been completed. 
   An objective of the present invention therefore is to provide a plastic injection molding system that includes a device that positions a part to which a plastic element is to be molded in a selected position with respect to the mold. An additional objective of the present invention is providing a plastic injection molding system that includes a positioning jig for accurately positioning a part to which a plastic element is to be molded, for subsequent placement in a mold section. An additional objective of the present invention is providing a pick and place tool adapted to pick the part to which a plastic element is to be molded from the positioning jig and transport the part to the mold, accurately positioning the part in the mold maintaining the selected position of the part. An additional objective of the present invention is providing a mold section adapted to receive a part to which a plastic element is to be molded, accurately maintaining the selected position of the part until the injection molding process has been completed. 
   These and other objectives of the present invention are provided by the various embodiments of the invention disclosed herein and by other embodiments that will or may fall within the claimed scope of the present invention as set forth in the appended claims. 
   SUMMARY OF THE INVENTION 
   The present invention is directed to a pick and place tool including a part penetration element adapted to induce a compressive force by the part against the part penetration element, securing the part to the part penetration element. The pick and place tool secures a part at first location employing an induced compressive force by the part against a part penetration element of the pick and place tool. 
   The present invention is also directed to an injection molding system that includes an injection molding device including a pick and place tool having a first part penetration element adapted to induce a compressive force by the part against the first part penetration element, securing the part to the part penetration element. The injection molding system may also include a positioning jig for positioning a part to which a plastic component is to be molded in a selected position. Employing the compressive force induced in the part against the first part penetration element, the pick and place tool picks the part from a positioning jig and transports the part to a mold section of the injection molding device and releases the part to the mold section. Transport of the pick and place tool part with the attached part is accomplished by a pick and place tool transport means attached to the pick and place tool. The pick and place tool transport means may be accomplished either manually or by well known automated means. In the preferred embodiment of the invention, the mold section includes a second part penetration element adapted to induce a compressive force by the part against the second part penetration element. The pick and place tool also includes a part release system adapted to release the part from the first part penetration element of the pick and place tool to the second part penetration element of the mold section. 
   The present invention is also directed to a method for picking a part with a pick and place tool including a first part penetration element adapted to induce a generation of a compressive force by the part against the part penetration element, securing the part to the part penetration element. The method includes securing a part by the first part penetration element at first location employing an induced compressive force by the part against a part penetration element of the pick and place tool and transporting the part to a second location. The method may also include transferring the part from the pick and place tool to a second part penetration element at the second location. 
   Additional advantages and novel features of the invention will be set forth in part in the description that follows, and in part will become apparent to those skilled in the art upon examination of the following, or may be learned by practice of the invention. Additionally, the advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims. 

   
     BRIEF DESCRIPTION OF DRAWINGS 
       FIG. 1  is a schematic representation of a plastic injection molding system according to the present invention; 
       FIG. 2  is a representative top view of a positioning jig according to the present invention; 
       FIG. 3  is a representative top view of a positioning jig, having a part positioned on an upper face according to the present invention; 
       FIG. 4  is a representative top view of a pick and place tool according to the present invention; 
       FIG. 5  is a representative bottom view of a pick and place tool according to the present invention; 
       FIG. 6  is a representative detail bottom view of a pick and place tool according to the present invention; 
       FIG. 7  is a representative side view of a pick and place tool according to the present invention; 
       FIG. 8  is a representative side view of a pick and place tool according to the present invention; 
       FIG. 9  is a representative top view of a pick and place tool positioned above a positioning jig according to the present invention; 
       FIG. 10  is a representative side cutaway view of a pick and place tool positioned on an upper face of positioning jig according to the present invention; 
       FIG. 11  is a representative detail side cutaway view of a pick and place tool positioned on an upper face of positioning jig according to the present invention; 
       FIG. 12  is a representative bottom view of a pick and place tool according to the present invention; 
       FIG. 13  is a representative front view of a mold section adapted to receive a part from the pick and place tool according to the present invention; 
       FIG. 14  is a representative top view of a pick and place tool positioned against a mold section according to the present invention; 
       FIG. 15  is a representative side cutaway view of a pick and place tool positioned against a mold section according to the present invention; 
       FIG. 16  is a representative side cutaway view of a pick and place tool positioned against a mold section according to the present invention; and 
       FIG. 17  is a representative front view of a mold section according to the present invention. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   Referring to  FIG. 1  injection molding system  10  includes injection molding device  15 , positioning jig  30  and pick and place tool  50 . Injection molding device  15  includes stationary first mold section  20  positioned in opposing relationship to moveable second mold section  11 . Moveable second mold section  11  is extendable and retractable along line L against stationary first mold section  20  by operation of ram  14 . Pressurized fluid system  12  provides necessary fluid power for operation of ram  14 . As shown  FIG. 1 , stationary first mold section  20  is fluidly connected to plastic injection system  16  by conduit  19 . Plastic injection system  16  is adapted to inject plastic P into stationary first mold section  20  and moveable second mold section  11 , when the respective sections are in contact. Control system  17  provides necessary control for operation of injection molding device  15 . 
   As shown  FIG. 1 , positioning jig  30  includes jig platen  31  which is fluidly connected to vacuum system  40  through vacuum tube  45 . Vacuum system  40  provides a negative pressure at an upper surface of jig platen  31 . Pick and place tool  50  is fluidly connected to compressor  70  through air line  75 , which provides compressed air for operation of actuator  52 . As shown in  FIG. 1 , operator OP provides transport means for movement of pick and place tool  50  between positioning jig  30  and stationary first mold section  20 . 
   Referring to  FIGS. 2 and 3 , positioning jig  30  is shown in greater detail. Positioning jig  30  includes jig platen  31  having platen surface  37 . A plurality of positioning detents  33 A,  33 B,  33 C and  33 D are formed on platen surface  37 . Alignment studs  32 A and  32 B provide a means for aligning a pick and place tool with positioning jig  30  as discussed herein below. As shown in  FIG. 2 , a plurality of vacuum passages, typified in  FIG. 2  by vacuum passage  34 , are fluidly connected to vacuum tube  45  and provide negative air pressure at positioning detents  33 A,  33 B,  33 C and  33 D for aiding in the initial placement of a part, (not shown), in the positioning detents  33 A,  33 B,  33 C and  33 D.  FIG. 2  also shows a plurality of jig pin receiving apertures forming a plurality of jig pin receiving aperture arrays, indicated by the by the dashed triangles,  35 A,  35 B,  35 C and  35 D, each jig pin receiving aperture array including, in this case, three distinct jig pin receiving apertures, each typified by jig pin receiving aperture  36 . In other embodiments, the jig pin receiving aperture arrays may include any arrangement of two or more jig pin receiving apertures. 
   Referring to  FIG. 3 , positioning jig  30  is shown with two parts positioned for picking, in the case strap S 1  and strap S 2 . More particularly, ends E 1  and E 2  are shown positioned in positioning detents  33 A and  33 B respectively and ends E 3  and E 4  are positioned in positioning detents  33 C and  33 D respectively. Vacuum tube  45  is shown connected to jig platen  31 . 
   Referring to  FIGS. 4 ,  5  and  7 - 10 ,  12  and  14 - 16 , various features of pick and place tool  50  are shown in greater detail. As shown, pick and place tool  50  includes tool body  68  having first tool body element  51 , shown in  FIGS. 4 ,  7 - 12  and  14 - 16 , to which pneumatic actuator  52  is mounted.  FIGS. 5-8 ,  10 - 12  and  15 - 16  show second body element  58  of tool body  68 .  FIGS. 4 ,  9  and  14 , show pneumatic valve  53  connected to pneumatic actuator  52 . Pneumatic valve  53  includes actuator operator  54 , which upon operation permits a flow of pressurized air through bypass  56  into pneumatic actuator  52 .  FIGS. 4 ,  5 ,  7 - 10 , and  14 - 16  show air line  75  connected to pneumatic valve  53 .  FIGS. 4 ,  5 ,  9 ,  12  and  14  show alignment apertures  55 A and  55 B, which facilitate alignment of pick and place tool  50  with both positioning jig  30  as shown in  FIG. 9 , and with stationary first mold section  20 , as shown in  FIG. 14 , and as discussed herein below. 
   Referring to  FIG. 5 , pick and place tool  50  is shown in a bottom view. From this perspective, lower plate  58  is shown including a plurality of penetration elements located on bottom face  57 . Each penetration element includes a pick and place tool pin array indicated by the dashed triangles,  60 A,  60 B,  60 C and  60 D, each pick and place tool pin array including, in this case, three pins, typified by pin  59 . Each pin of pick and place tool pin arrays  60 A,  60 B,  60 C and  60 D extends through lower plate  58  in one of a plurality of pin sheath apertures. The plurality of pin sheath apertures form pin sheath aperture arrays indicated by the dashed triangles  61 A,  61 B,  61 C and  610 D, each pin sheath aperture typified in  FIG. 5  by pin sheath aperture  71 . Lower plate  58  also includes a plurality of mold pin receiving aperture arrays, shown by the by the dashed triangles,  65 A,  65 B,  65 C and  65 D, each mold pin receiving aperture array including, in this case, by three distinct mold pin receiving apertures, each typified by mold pin receiving aperture  66 .  FIG. 5  also shows alignment apertures  55 A and  55 B, which facilitate alignment of pick and place tool  50  with both positioning jig  30  as shown in  FIG. 9 , and with stationary first mold section  20 , as shown in  FIG. 14 , and as discussed herein below. 
     FIG. 6  is a bottom view detail showing that part of bottom face  57  of lower plate  58  that includes pick and place tool pin array  60 D including three pins, each pin typified in  FIG. 6  by pin  59 . As shown in  FIG. 6 , each pin of pick and place tool pin array  60 D extends through a pin sheath aperture, the plurality of pin sheath apertures forming pin sheath aperture array  610 D.  FIG. 6  also shows mold pin receiving aperture array  65 D including, in this case, three distinct mold pin receiving apertures, each of the mold pin receiving apertures typified in  FIG. 6  by mold pin receiving aperture  66 .  FIG. 6  also shows alignment aperture  55 B located on bottom face  57  of lower plate  58 . 
   Referring to  FIGS. 7 and 8 , pick and place tool  50  is shown in a side view. As shown, pick and place tool  50  includes tool body  68  including first tool body element  51  lying substantially in a first plane P 1  and second tool body element  58  lying substantially in a second plane P 2 . The pins of pick and place tool pin arrays  60 B and  60 D, typified in  FIGS. 7 and 8  by pin  59 , are shown extending through lower plate  58 . Referring to  FIG. 7 , first tool body element  51  and second tool body element  58  are in contact and as shown and pick and place tool pin arrays  60 B and  60 D are exposed. As shown in  FIG. 8 , operation of part release system  69  is demonstrated. When pneumatic actuator  52  is energized, displaceable rod  62  extends displacing second tool body element  58  with respect to first tool body element  51 , to third plane P 3 . 
   Referring to  FIGS. 9 and 10 , pick and place tool  50  is shown positioned on top of jig platen  31  of positioning jig  30 . As shown in  FIG. 9 , pick and place tool  50  is aligned with respect to positioning jig  30  by insertion of alignment studs  32 A and  32 B through alignment apertures  55 A and  55 B. The end portions of straps S 1  and S 2 , (not shown in  FIG. 9 ), are positioned between pick and place tool  50  and positioning jig  30 .  FIG. 9  shows vacuum tube  45  pneumatically connected to jig platen  31 . Referring to  FIG. 10 , pick and place tool  50  is shown including tool body  68  having first tool body element  51  and second tool body element  58 . End E 2  of strap Si and end E 4  of strap S 2  are shown disposed between second tool body element  58  and jig platen  31 . 
     FIG. 11  shows a detail side cutaway view of end E 4  of strap S 2  positioned in positioning detent  33 D between bottom face  57  of second tool body element  58  of pick and place tool  50  and against upper face  37  of jig platen  31  of positioning jig  30 . As pick and place tool  50  is pressed against jig platen  31 , each pin of the pick and place tool pin arrays  60 A,  60 B,  60 C and  60 D, (shown in  FIG. 5 ), and typified in  FIG. 11  by pin  59 , pierces through end E 4  of strap S 2 , entering jig pin receiving aperture  36 , one of the jig pin receiving apertures forming the plurality of jig pin receiving aperture arrays,  35 A,  35 B,  35 C and  35 D, (shown in  FIG. 2 ). As each pin pierces through the strap, a compressive force is induced in the strap about each pin. With specific reference to  FIG. 11 , by way of illustration, as pin  59  is forced through end E 4  of strap S 2 , projecting into jig pin receiving aperture  36 , first compressive force C 1  is induced in strap S 2  against pin  59 .  FIG. 11  also shows pin  59  attached to first tool body element  51  and extending through pin sheath aperture  71 , typical of the plurality of pin sheath apertures forming the pin sheath aperture arrays  61 A,  61 B,  61 C and  61 OD, (shown in  FIG. 5 ). Also shown in  FIG. 11  is mold pin receiving aperture  66 . 
     FIG. 12  shows strap S 1  and S 2  positioned against bottom face  57  of second tool body element  58  of pick and place tool  50 . As shown, end E 1  of strap S 1  is held in position by pick and place tool pin array  60 A and end E 2  of strap S 1  is held in position by pick and place tool pin array  60 B. Similarly, end E 3  of strap S 2  is held in position by pick and place tool pin array  60 C and end E 4  of strap S 2  is held in position by pick and place tool pin array  60 D. Compressive force C 1  is induced in straps S 1  and S 2  against the pins of pick and place tool pin arrays  60 A,  60 B,  60 C and  60 D, each pin typified by pin  59 , at the location at which the pins penetrate the straps. Also shown in  FIG. 12  are alignment apertures  55 A and  55 B. 
     FIGS. 13 and 17  show stationary first mold section  20  for molding a plastic element at each end of a pair of straps S 1  and S 2  as shown in  FIG. 17 .  FIGS. 13 ,  14  and  17  show stationary first mold section  20  including first mold plate  21  having face  29 .  FIGS. 13 and 17  show face  29  including a plurality of part positioning detents  22 A,  22 B,  22 C and  22 D, which provide locations at which parts are to be positioned. 
   Contiguous to each of the part positioning detents  22 A,  22 B,  22 C and  22 D are mold cavities  24 A,  24 B,  24 C and  24 D respectively. First mold plate  21  includes a plurality of mold section penetration elements located on face  29 . Each mold section penetration element includes a mold section pin array indicated by the by the dashed triangles,  25 A,  25 B,  25 C and  25 D, each mold section pin array including, in this case, three pins, typified in  FIGS. 13 and 17  by pin  28 . Referring to  FIG. 13 , first mold plate  21  also includes a plurality of pick-up pin receiving aperture arrays, shown by the by the dashed triangles,  27 A,  27 B,  27 C and  27 D, each mold pin receiving aperture array including in this case by three distinct pick-up pin receiving apertures, each typified in  FIG. 13  by pick-up pin receiving aperture  26 .  FIGS. 13 and 17  show alignment studs  23 A and  23 B, which provide a means for aligning pick and place tool  50 , as shown in  FIGS. 14-16 , with stationary first mold section  20  as discussed herein below. 
   Referring to  FIGS. 14 and 15 , pick and place tool  50  is shown positioned in an interfacing relation against face  29  of first mold plate  21 . As shown in  FIG. 14 , pick and place tool  50  is aligned with respect to first mold plate  21  of stationary first mold section  20  by insertion of alignment studs  23 A and  23 B through alignment apertures  55 A and  55 B. Straps S 1  and S 2  are positioned partially between pick and place tool  50  and first mold plate  21 .  FIGS. 15 and 16  show, end E 2  of strap S 1  and end E 4  of strap S 2  disposed between second tool body element  58  and first mold plate  21  with ends E 2  and E 4  extending into mold cavities  24 B and  24 D respectively. 
   As pick and place tool  50  is pressed against first mold plate  21 , each pin of the pick and place tool pin arrays  60 A,  60 B,  60 C and  60 D, (shown in  FIG. 5 ), typified in  FIG. 15  by pin  59 , pierces through the strap section entering one of the pick-up pin receiving apertures,  27 A,  27 B,  27 C and  27 D, (shown in  FIG. 13 ), each pick-up pin receiving aperture typified in  FIG. 15  by pick-up pin receiving aperture  26 , shown in  FIG. 15 . At the same time, as pick and place tool  50  is pressed against first mold plate  21 , each pin of the mold section pin arrays  25 A,  25 B,  25 C and  25 D, (shown in  FIG. 13 ), typified in  FIG. 15  by pin  28 , pierces through the strap section entering one of the mold pin receiving apertures of the mold pin receiving aperture arrays  65 A,  65 B,  65 C and  65 D, (shown in  FIG. 5 ), each mold pin receiving aperture typified in  FIG. 15  by mold pin receiving aperture  66 . With specific reference to  FIG. 15 , and by way of illustration, as pin  59  pierces end E 4  of strap S 2  it projects into pick-up pin receiving aperture  26 . Similarly, as pin  28 , pierces end E 4  of strap S 2  it projects into mold pin receiving aperture  66 .  FIG. 15  also shows pin  59  attached to first tool body element  51  and extending through pin sheath aperture  71 . Also shown in  FIG. 11  is mold pin receiving aperture  66 . 
   Referring to  FIG. 16 , once strap S 1  and S 2  are positioned as shown in  FIG. 15 , actuator  52  of pick and place tool  50  is energized extending displaceable rod  62  thereby displacing second tool body element  58  of tool body  68  with respect to first tool body element  51 . As second tool body element  58  is displaced, each pin sheath aperture of the pin sheath aperture arrays  61 A,  61 B,  61 C and  610 D, (shown in  FIG. 5 ), typified in  FIG. 15  by pin sheath aperture  71  extends over the pin of the pick and place tool pin arrays  60 A,  60 B,  60 C and  60 D, (shown in  FIG. 5 ), typified in  FIG. 15  by pin  59 , associated with a particular pin sheath aperture, releasing straps S 1  and S 2  from the pick and place tool pin arrays  60 A,  60 B,  60 C and  60 D, (shown in  FIG. 5 ).  FIG. 16  shows alignment studs  23 A and  23 B, which are exposed when second tool body element  58  is displaced with respect to first tool body element  51 . With specific reference to  FIG. 16 , and by way of illustration, as second tool body element  58  is displaced with respect to first tool body element  51  of tool body  68  by displaceable rod  62 , pin sheath aperture  71  extends with respect to pin  59 , releasing end E 4  of strap S 2  from pick and place tool  50 . When pick and place tool  50  is moved away from first mold plate  21 , and referring to  FIG. 17 , ends E 1 -E 4  of straps S 1  and S 2  remain supported by mold section pin arrays  25 A,  25 B,  25 C and  25 D, (shown in  FIG. 13 ), each pin being typified in  FIG. 17  by pin  28  which is shown projecting into mold pin receiving aperture  66 . 
   Referring again to  FIG. 1 , once pick and place tool  50  is moved away from stationary first mold section  20 , operation and extension of moveable second mold section  11  is initiated by operation of pressurized fluid system  12  and ram  14 . Once moveable second mold section  11  and stationary first mold section  20  are in contact, plastic injection system  16  is energized and, referring to  FIGS. 1 and 15 , molten plastic, (not shown), is injected through conduit  19  to the mold cavities  24 A,  24 B,  24 C and  24 D, seen in  FIG. 13 . Following injection, and referring again to  FIG. 1 , ram  14  retracts and moveable second mold section  11  is separated from stationary first mold section  20 . 
   It is to be understood that the invention is not limited to the embodiment shown and described above. It will be appreciated for instance that the transport means for movement of pick and place tool  50  between positioning jig  30  and stationary first mold section  20  may include other means known to those skilled in the art including robotics or other mechanized means. Similarly, where  FIG. 1  depicts a single positioning jig  30  it will be appreciated that two or more positioning jigs may be positioned about a turntable that allows parts to be placed of a positioning jig at a first station while pick and place tool  50  is picking from another positioning jig located a second station accessible for instance by a robot. Additionally, while the specification and figures discuss a preferred embodiment wherein a part is transferred onto a stationary first mold section  20  by pick and place tool  50 , it is conceivable that embodiments may exist wherein a part is transferred onto a movable mold section by pick and place tool  50 . Various other embodiments of the invention may be made and practiced without departing from the scope of the invention, as defined in the following claims.