Patent Publication Number: US-8113820-B2

Title: Method and apparatus for molding and assembling plural-part plastic assemblies

Description:
RELATED APPLICATIONS 
     The present application is a divisional of and claims priority to U.S. patent application Ser. No. 11/453,179, filed Jun. 13, 2006 now U.S. Pat. No. 7,951,322. 
    
    
     FIELD 
     The field relates generally to manufacture of composite articles and, more specifically, to manufacture of assemblies of injection-molded parts. 
     BACKGROUND 
     Manufacturers of injection-molded parts have an ongoing need to make a wide range of parts in a highly efficient and cost-effective manner. Increasingly, there is a need to provide composite part assemblies made up of plural component parts. These composite part assemblies frequently require movement by one or more of the component parts. Representative composite part assemblies which include movable parts are closures of the type used for packaging of food and personal care products. 
     Manufacture of composite part assemblies may require separate forming and assembly steps in which the component parts are first formed in the mold and then assembled to make the finished product. Separate forming and assembly steps can decrease throughput and increase the cost of the finished product. 
     One approach toward improving the efficiency of manufacturing composite parts is referred to by some as in-mold assembly. In-mold assembly refers to the forming of one or more parts followed by assembly of the parts before ejection from the mold. Various approaches to in-mold assembly have been proposed. Examples include: U.S. Patent Publication Nos. 2006/0033238 (Gram), 2004/0033287 (Gram) and 2004/0119200 (Gram) and U.S. Pat. Nos. 4,744,741 (Glover et al.) and 4,330,257 (Rees et al.). These approaches have certain disadvantages and limitations associated with them. 
     For example, the process described in Publication No. 2006/0033238 relates to production of hinged-together plastic objects. After part formation, a closing mechanism works in combination with a rotating tool to partially close one portion of the hinged part while a portion of the hinged part remains in the tool. This process lacks the capability of assembling a finished part consisting of separate plural parts. 
     The process described in Publication No. 2004/0033287 relates to forming and assembly of at least two part objects. Separate parts are formed in separate rotating tools. After forming, the part edge surfaces are heated and the rotating tools are moved together so that the heated edge surfaces touch and are thermally bonded together. This process has limitations in that thermal joining of parts may not be satisfactory for certain other types of manufacturing processes. 
     U.S. Pat. No. 4,744,741 describes a process for simultaneous forming and assembly of plural-part molded objects. This process requires thermal bonding of the parts immediately following forming and may be subject to unduly long cycle times because coordinated movement of separate tools is required to assemble the parts. 
     U.S. Pat. No. 4,330,257 describes a process for efficient forming of molded parts using a rotating tool but does not provide for assembly of the parts. 
     It would represent a significant improvement in the art to provide a method and apparatus for molding and assembling of plural-part plastic assemblies which would facilitate the manufacture of plural-part assemblies, which would facilitate manufacture of assemblies including one or more moving parts, which would increase throughput and decrease production cycle times and which would be efficient and cost-effective to implement. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention may be understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals identify like elements throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. 
         FIG. 1  is a schematic diagram showing an exemplary composite part final assembly made according to the present improvement. 
         FIG. 2  is a schematic diagram showing an exploded view of the exemplary parts comprising the final assembly of  FIG. 1 . 
         FIG. 3  is a schematic diagram showing a side elevation view of an injection-molding and assembly apparatus embodying the present improvement. The apparatus is shown with each turret in a forming operating position in which parts are formed. 
         FIG. 4  is a schematic diagram showing a top view of the injection-molding and assembly apparatus taken along section  4 - 4  of  FIG. 3 . 
         FIG. 5  is an enlarged schematic diagram of a mold cavity and formed part taken along detail section  5  of  FIG. 4 . 
         FIG. 6  is an enlarged schematic diagram of a mold cavity and formed parts taken along detail section  6  of  FIG. 4 . 
         FIG. 7  is a schematic diagram showing a top view of the injection-molding and assembly apparatus taken along section  4 - 4  of  FIG. 3  but with the turrets rotated 90° from the position of  FIGS. 3-4 . The apparatus is shown with each turret in a cooling operating position in which the formed parts are cooled. 
         FIG. 8  is an enlarged schematic diagram taken along detail section  8  of  FIG. 7 . 
         FIG. 9  is a schematic diagram showing a top view of the injection-molding and assembly apparatus taken along section  4 - 4  of  FIG. 3  but with turrets rotated 180° from the position of  FIGS. 3-4 . The apparatus is shown with one turret in a further cooling operating position, and the other turret is in an assembly operating position in which the formed parts are assembled together. 
         FIG. 10  is an enlarged schematic diagram taken along detail section  10  of  FIG. 9 . 
         FIG. 11  is a schematic diagram showing a top view of the injection-molding and assembly apparatus taken along section  4 - 4  of  FIG. 3  but with turrets rotated 270° from the position of  FIGS. 3-4 . The apparatus is shown with each turret in a pre-final assembly operating position. 
         FIG. 12  is an enlarged schematic diagram taken along detail section  12  of  FIG. 11 . 
         FIG. 13  is a schematic diagram showing a top view of the injection-molding and assembly apparatus taken along section  4 - 4  of  FIG. 3  but with each turret in a final assembly operating position in which one turret is moved toward the other turret for assembly of parts into a final assembly. 
         FIG. 14  is an enlarged schematic diagram taken along detail section  14  of  FIG. 13 . 
         FIG. 15  is a schematic diagram showing a side elevation view of the injection-molding and assembly apparatus of  FIG. 3  but with each turret in an ejection operating position in which one turret is moved away from the other turret and the final assembly is fully ejected. Certain surfaces are not shown to facilitate understanding. 
     
    
    
     DETAILED DESCRIPTION 
       FIGS. 3-15  are schematic diagrams showing an embodiment of an injection-molding and assembly apparatus  10 . Injection-molding and assembly apparatus  10  is provided to make separate parts and to efficiently and rapidly assemble the parts into composite part assemblies. 
       FIGS. 1 and 2  show exemplary parts  11 ,  13 ,  15 ,  19 , a composite part assembly  17  and a final assembly  21  capable of being made with the injection-molding and assembly apparatus  10 . In the example, parts  11 ,  13 ,  15  are first formed in a mold. The apparatus  10  then assembles parts  11 - 15  into a composite part assembly  17  while parts  11 - 15  remain associated with a mold portion in which they are formed. Male parts  11   a,    15   a  are seated in respective female parts  13   a,    13   b  forming assembly  17  in this example. Injection-molding and assembly apparatus  10  embodiments may include machine structure permitting assembly  17 , as a sub-assembly, and a complementary part  19  or parts to be assembled together into a final assembly  21 . 
     Apparatus  10  enables parts  11 ,  13 ,  15 ,  19  to be joined together mechanically, permitting automatic manufacture of complex assemblies  17 ,  21 , including assemblies with complex moving parts thereby providing the manufacturer with a heretofore unavailable level of manufacturing capabilities. And, apparatus  10  eliminates separate assembly steps occurring after ejection of the parts completely from the mold thereby reducing both manufacturing costs and production cycle time. 
     The injection-molding and assembly apparatus  10  embodiment shown schematically in  FIGS. 3-15  is preferably adapted for use in conjunction with any vertical or horizontal platen injection-molding machine. The exemplary injection-molding and assembly apparatus  10  comprises base  23 , turrets  25 ,  27  and related components and actuators as described herein. As will be discussed in more detail below, the number of turrets utilized is not critical as any number of turrets may be utilized depending on the manufacturer&#39;s requirements. 
     Base  23  is mounted with respect to the injection-molding machine (not shown) between mold plates  29 ,  31 . Mold plates  29 ,  31  are displaced relative to the other to increase and, alternatively, decrease the distance between mold plates  29 ,  31  by a displacement actuator  35 . Relatively displaced means or refers to any arrangement in which the distance between parts may be increased or decreased. Therefore, both of mold plates  29 ,  31  may be movable or one mold plate (e.g., mold plate  29 ) may be stationary while the other mold plate (e.g., mold plate  31 ) is movable toward and away from the other. 
     In the preferred embodiment of  FIGS. 3-15 , mold plate  29  is stationary and mold plate  31  is movable toward and away from mold plate  29  along a path in the directions of dual-headed arrow  33  ( FIG. 4 ). In the embodiment, displacement actuator  35  is the reciprocating hydraulic ram (identified by reference number  35 ) of the injection-molding machine. Ram  35  displaces mold plate  31 . The term actuator as used herein means or refers to a mechanism that puts another part into automatic action. While ram  35  is a preferred actuator, any suitable actuator may be provided to displace mold plate  31 . Exemplary actuators include a rack-and-pinion mechanism, a mechanical screw and a hydraulic actuator. Mold plate  31  translates toward and, alternatively, away from mold plate  29 , base  23  and turrets  25 ,  27  of apparatus  10  in the directions of dual-headed arrow  33  during each production cycle as described below. 
     In the embodiment, base  23  is movably mounted on rods  37 ,  39  extending outwardly from mold plate  29  and between mold plates  29 ,  31 . Rods  37 ,  39  are received in sleeves  41 ,  43  provided in base  23 . Bearings (not shown) within sleeves  41 ,  43  facilitate displacement of base  23  along rods  37 ,  39 . As an alternative to rods  37 ,  39 , base  23  may be supported by the tie bars or guides of the injection molding machine. 
     Base  23  is displaced relative to mold plates  29 ,  31  to increase and, alternatively, decrease the distance between base  23  and mold plates  29 ,  31  to free turrets  25 ,  27  for rotation between operating positions. Ram-driven movement of mold plate  31  moves base  23  along the path represented by dual-headed arrow  33 . More specifically, movement of mold plate  31  toward mold plate  29  causes mold plate  31  to contact base  23  and to push base  23  toward and into contact with mold plate  29 . Base  23  and turrets  25 ,  27  are clamped between mold plates  29 ,  31  by extension of ram  35  ( FIGS. 4 ,  7 ,  9 ,  11 ) closing mold cavities  83 ,  85 . 
     Mold plate  31  and base  23  may be connected together through a linkage  45 . Linkage  45  may comprise a chain, mechanical latch or other mechanical linkage. Ram-driven movement of mold plate  31  away from mold plate  29  causes mold plate  31  to pull base  23  away from mold plate  29  through linkage  45 . Linkage  45  is sized to permit spacing between base  23  and mold plate  29  and between base  23  and mold plate  31  when mold plate  31  is retracted by ram  35  to the position of  FIG. 13  in which mold cavities  83 ,  85  are opened. As noted, such spacing frees turrets  25 ,  27  for rotation between operating positions. In the example, ram  35  controls relative displacement of turrets  25 ,  27  and mold plates  29 ,  31 . 
     In other embodiments, an actuator or drive mechanism, other than the ram actuator  35 , may be provided to displace base  23  (and turrets  25 ,  27  mounted thereon) along the path represented by dual-headed arrow  33  and to control displacement of base  23  relative to mold plates  29 ,  31 . By way of example only, a rack-and-pinion mechanism, mechanical screw or hydraulic actuator could be used to displace base  23  between the positions shown in  FIGS. 4 and 13 . 
     In the example, mold plate  29  is shown supporting or carrying a pair of mold portions  47 ,  49 . Mold portions  47 ,  49  may be referred herein as first mold portions. Any number of mold portions  47 ,  49  may be utilized as required by the manufacturer. Mold portions  47 ,  49  may be elements which are secured to mold plate  29  by, for example, threaded fasteners (not shown). Alternatively, mold portions  47 ,  49  may be formed directly in mold plate  29 . Mold portions  47 ,  49  may be of any suitable design and may comprise cores, cavities and combinations thereof. 
     Each turret  25 ,  27  is preferably provided with one or more face  51 ,  59 . In the example, each turret  25 ,  27  has four faces  51 ,  53 ,  55 ,  57  and  59 ,  61 ,  63 ,  65 . Each face  51 - 57  and  59 - 65  is provided to support or carry a mold portion  67 ,  69 ,  71 ,  73 ,  75 ,  77 ,  79 ,  81 . In the two turret  25 ,  27  example shown, mold portions  67 - 73  have an identical structure and mold portions  75 - 81  each have an identical structure. Mold portions  67 - 81  may be referred herein as second, or complementary, mold portions. Mold portions  67 - 73  are the complement of mold portion  47  and mold portions  75 - 81  are the complement of mold portion  49 . Mold portions  67 - 81  may be of any suitable design complementary to respective molds  47 ,  49  and may comprise cores, cavities and combinations thereof. Any number of mold portions  67 - 81  may be utilized depending on the overall mold configuration desired. 
     Mold portions  47 ,  49  and  67 - 81  may be adapted to receive and support parts and things useful in plastic part manufacture. For example, insert pieces (e.g., bushings, bearings, couplings, etc.) of metal and other materials may be supported by mold portions to become integral elements of the formed plastic parts once plastic material is injected into a mold cavity (e.g., cavity  83 ). By way of further example, films and substrates may be loaded in a mold portion  47 ,  49 ,  67 - 81  to become an integral element of the molded part. 
     Ram-driven  35  displacement of mold plate  31 , base  23  and turrets  25 ,  27  toward mold plate  29  closes aligned mold portion  47  together with one of mold portions  67 - 73  and mold portion  49  together with one of mold portions  75 - 81  to provide separate mold cavities  83 ,  85  for forming parts when plastic material is injected therein. Such mold closure occurs with turrets  25 ,  27  in the forming operating position indicated as position A on  FIG. 4 . One or both of cavities  83 ,  85  comprises a multiplicity of cavities provided for forming plural separate and discrete parts as described herein. The cavities for forming the plural parts  11 - 15  can be provided by the same mold or plural molds. In the example, mold portions  67   a,    67   b  define surfaces of mold cavities  83   a,    83   b.  Molten plastic is admitted into mold plate  29  and into mold cavities  83 ,  85  by way of one or more barrels associated with the injection-molding machine (not shown) and through a runner system and gate (not shown) in mold plate  29  in the direction of arrows  89 ,  91  as described below. Of course, plastic material may be injected in other directions, including through mold plate  31  or, for example, by means of a “bolt on” plastic injection unit bolted to mold plate  29 . 
     Preferably, mold portions  67 - 81  are secured to a respective turret  25 ,  27  by threaded fasteners. It is preferred that mold plate  29  and turrets  25 ,  27  be adapted to respectively support mold portions  47 ,  49  and  67 - 81  by means of fasteners because such arrangement provides the manufacturer with the flexibility to use many different mold portions with mold plate  29  and turrets  25 ,  27  for molding a variety of different plastic parts. 
     In the example, two turrets  25 ,  27  are shown and each turret is provided with four faces  51 - 57  and  59 - 65  providing the preferred turrets  25 ,  27  with a cube-like appearance. However, any number of turrets may be utilized depending on the needs of the manufacturer. Thus, one, two or more turrets may be utilized according to the principles described herein. Moreover, turrets  25 ,  27  may be provided with any suitable geometry and are not limited to the cube-like geometry with four faces or sides as shown. For example, turrets  25 ,  27  could each be provided with a triangular or octagonal geometry with a mold portion (e.g., mold portion  67 ) supported along each face or side thereof. Alternatively, and while not preferred for reasons of efficiency, each turret could be provided with a single face or side for supporting a mold portion (e.g. mold portion  67 ). It is not required that a “face” be provided. Any mounting location for a mold portion (e.g., one or more mold portions  67 - 81 ) will suffice. Alternatively, mold portions  67 - 81  may be formed directly in one or both turrets  25 ,  27 . 
     In the example, turrets  25 ,  27  are rotatably mounted on base  23 . Turret  25  is mounted on base  23  on a fixed position axis  93  by means of a shaft  95  journaled in base  23 . An indexing apparatus  97  causes turret  25  to rotate or shift in an indexed manner between four operating positions. Indexing apparatus  97  preferably includes an actuator  99  linked to shaft  95 . Actuator  99  is preferably a motor such as a stepper motor or servo motor. 
     Turret  27  is rotatably mounted on carriage  101 . Carriage  101  travels along guide  103  of base  23  toward and, alternatively, away from turret  25  along a path in the directions of dual-headed arrow  105 . Guide  103  can be rails, rods, walls, tracks or any suitable structure permitting movement of turret  27  along base  23  and carriage  101  can be any structure capable of supporting turret  27  along the guide. In the embodiment, the path of carriage  101  travel represented by dual-headed arrow  105  is transverse to the path of base  23  and mold plate  31  travel as represented by dual-headed arrow  33 . Movement of turret  27  toward turret  25  enables separate parts  17 ,  19  carried on respective turrets  25 ,  27  to be joined together into final assembly  21  as described below. 
     Turret  27  carried on carriage  101  rotates on axis  107  spaced apart from axis  93  by means of shaft  109  journaled in carriage  101 . Indexing apparatus  111  causes turret  27  to rotate or shift in an indexed manner between operating positions. Indexing apparatus  111  preferably includes a second actuator  113  linked to shaft  109 . Actuator  113  is preferably a servo motor or a stepper motor such as described above in connection with actuator  99 . Indexing apparatus  97 ,  111  could also comprise a linkage system synchronized to rotate turrets  25 ,  27  in response to ram-driven  35  movement of mold plate  31  rather than through motors  99 ,  113 . 
     A further actuator, or turret-displacement actuator,  115  produces movement of carriage  101  along guide  103 , alternatively, in the directions of dual-headed arrow  105 . Actuator  115  is preferably a dual-action linear actuator linked to carriage  101  by means of actuator rod  117 . Other types of mechanical apparatus may be utilized, for example a movement device operated by relative displacement of mold plates  29 ,  31 . 
     In alternative embodiments, turret  25  and turret  27  could each be mounted for movement on a carriage  101  or another type of movement-enabling device. Such carriage or movement-enabling device may be driven, for example, by an actuator such as actuator  115 . Such an arrangement would permit relative turret  25 ,  27  displacement so that each turret moves toward the other for assembly of final assembly  21 . It is not required that turrets  25 ,  27  move relatively together to make a final assembly  21  or other part as it may be satisfactory in certain applications for each turret  25 ,  27  to produce parts (e.g., part assemblies  17 ) independent of the other. 
     Water may be introduced into turrets  25 ,  27  through a rotary union  119 ,  121  for the purpose of cooling turrets  25 ,  27  thereby minimizing the time required for each production cycle. 
     Persons of skill in the art will appreciate that actuators other than actuators  99 ,  113 ,  115  can be used to power movement of turrets  25 ,  27  and carriage  101 . Many actuator types, such as rack-and-pinion mechanisms or air or hydraulic-powered actuators can be used. 
     Referring next  FIGS. 9-10 , assembly apparatus  123  (two shown along each face  51 - 57 ) are provided to assemble plural parts  11 - 15  into a composite part assembly  17  at an assembly operating position identified by position C on  FIG. 9 . In the embodiment, an assembly apparatus  123  is associated with each face  51 - 57  of turret  25 . An assembly apparatus  123  could also be associated with the faces  59 - 65  of turret  27  depending on the manufacturer&#39;s requirements. Providing assembly apparatus  123  associated with each face  51 - 57  of turret  25  permits the manufacturer to improve throughput and reduce cost because a composite part assembly  17  can be manufactured from parts  11 - 15  formed along each face  51 - 57  of turret  25  without separate assembly steps following part ejection. 
       FIGS. 9-10  show assembly apparatus  123  along face  51  of turret  25 . Each assembly apparatus  123  associated with faces  53 - 57  has the same structure and operation as assembly apparatus  123  associated with turret  25  face  51  in this example. Assembly apparatus  123  includes a pair of contact-element supports  125 ,  127  mounted on turret  25  proximate each face  51 - 57  and mold portion  67 - 73 . Proximate means or refers to a position sufficiently close to the position of the formed parts (e.g., parts  11 - 15 ) to assemble the formed parts into an assembly (e.g., assembly  17 ). Each contact-element support  125 ,  127  supports at least one contact element  129 ,  131  mounted thereon. The contact elements  129 ,  131  urge a formed plural part  11  or  15  together into assembled contact with part  13  to form assembly  17 . The contact-element supports  125 ,  127  of assembly apparatus  123  are carried on turret  25  such that contact-elements supports  125 ,  127  and contact elements  129 ,  131  travel with turret  25  as turret  25  rotates between the operating positions. 
     Each contact element  129 ,  131  has a body  133 , a first end  135  and a second end  137  although other configurations may be utilized. Body  133  is mounted for reciprocating axial movement in opening  139  provided in contact-elements supports  125 ,  127 . Opening  139  is oriented so that contact elements  129 ,  131  move inwardly toward mold portion  67  in the direction of arrows  141 ,  143  in  FIGS. 4 ,  7   9 ,  10 ,  11 ,  13 . A spring  145  biases each contact element  129 ,  131  away from mold portion  67 . In the example, first end  135  of contact elements  129 ,  131  forms a wall or surface of mold portion  67   a,    67   b.  Contact element first end  135  may be mechanical device which urges a part and need not form a portion of mold  67 . And, in this example, mold portions  67   a,    67   b  are joined with respective contact-element supports  125 ,  127 . First end  135  contacts at least one of the formed plural parts (e.g. part  11  or  15 ) to urge such part or parts into assembled contact with another of the formed parts (e.g., part  13 ) in the assembly operating position C. Second end  137  is driven by an assembly actuator, or contact-element actuator,  147 ,  149  inwardly toward mold portion  67 . 
       FIGS. 6 ,  8 ,  10 ,  12  and  14  show an enlarged view of an exemplary release apparatus  151  along face  51  of turret  25 . A release apparatus  151  is associated with each face  51 - 57  and mold portion  67 - 73  as illustrated in  FIGS. 4 ,  7 ,  9 ,  11  and  13 . Each release apparatus  151  associated with faces  53 - 57  has the same structure and operation as release apparatus  151  associated with turret  25  face  51 . Each release apparatus  151  is provided to partially release one or more of parts  11 - 15  from second or complementary mold portion  67 ,  69 ,  71  or  73  so that the parts are in alignment for assembly by contact element  129  or  131 . 
     In the example, it is necessary to displace mold portions  67   a,    67   b  defining cavity portions  83   a,    83   b  outward from mold portion  67  after part forming so that male portions  11   a,    15   a  of formed parts  11 ,  15  are in axial alignment with female portions  13   a,    13   b  of part  13  ( FIGS. 2 ,  8 ,  12 ). 
     As can be appreciated, in other embodiments, it may be necessary to displace part  13  outwardly or inwardly in order to align that part with parts  11 ,  15 . Thus, in certain embodiments it may be desired to move mold portion  67  inwardly and away from part  13  while holding part  13  in place while in other embodiments it may be desired to move part  13  outwardly from mold portion  67 . 
     Release apparatus  151 , as illustrated, comprises base  153  behind mold portion  67  joined to contact-element supports  125 ,  127  and springs  155 ,  157  which bias base  153  toward mold portion  67 . Contact-element supports  125 ,  127  are positioned in openings  159 ,  161  of turret  25  permitting contact elements  129 ,  131  to travel outwardly and inwardly from face  51  as base  153  moves. Mold portions  67   a,    67   b  travel with the respective contact-element support  125 ,  127  with contact element first ends  135  in alignment with mold portions  67   a,    67   b  for part assembly. In the example, mold portions  67   a,    67   b  and contact-element supports  125 ,  127  serve as part holders for parts  11  or  15  holding such parts in alignment for assembly. 
     Referring to  FIG. 6 , in the forming operating position A, mold portion  47  shoulder  163  contacts surfaces  165 ,  167  of contact-element supports  125 ,  127  and urges base  153  to retract away from mold portion  67  and face  51  so that contact-element supports  125 ,  127  and mold portions  67   a,    67   b  are in position to receive the plastic material with mold cavities  83 ,  83   a,    83   b  closed. Opening of mold portions  47 ,  67  releases the force applied to surfaces  165 ,  167  allowing springs  155 , 157  to bias base  153  toward mold portion  67  and contact-element supports  125 ,  127  and mold portions  67   a,    67   b  outwardly from mold portion  67  to displace formed parts  11 ,  15  outward a sufficient distance so as to be in alignment with part  13  just prior to part assembly. 
     If it is desired to displace a part formed along an interior region of mold portion  67  (e.g., part  13 ) then release apparatus  151  may be provided with a part holder (not shown) extending from base  153  and having a surface which forms a part of mold portion  67 . Plastic is formed against such surface in the forming position. The surface of the part holder may both partially release the part (e.g., part  13 ) from the mold portion  67  and hold such part proximate mold portion  67  for assembly when base  153  is biased toward mold portion  67  following mold opening. 
     Referring to  FIGS. 9-10 , assembly actuators  147 ,  149  drive contact elements  129 ,  131  inwardly in this example when turret  25  is in the assembly operating position C. Each assembly actuator  147 ,  149  is mounted in a cavity  169  provided in mold plate  31 . Each assembly actuator  147 ,  149  has a rod which drives a contact element second end  137  driving a contact element first end  135  to urge a part (e.g., part  11  or  15 ) out of a mold portion  67   a,    67   b  and into contact with an aligned part such as part  13  enabling, for example, male portion  11   a  to be seated in corresponding female portion  13   a.  Assembly actuators  147 ,  149  are preferably dual or single action linear actuators. 
     Other assembly actuators may be used in place of actuators  147 ,  149 . By way of example, mold plates  29 ,  31  can serve as an assembly actuator. Ram-driven  35  relative displacement of mold plates  29 ,  31  toward one another can cause mold plates  29 ,  31  to contact and drive contact elements  129 ,  131  inward to assemble the formed plural parts (e.g., parts  11 - 15 ) when turret  25  is rotated 90° away from the forming position and in a position such as the operating position indicated by the letter B in  FIG. 7 . By way of further example, a pin (not shown) carried on mold plate  29  or  31  can be urged into contact with a contact element  129 ,  131  second end  137  also by ram-driven  35  relative displacement of mold plates  29 ,  31  with the turret rotated in the position indicated by the letter B in  FIG. 7 . As yet another example, extensible pins (not shown) guided by mold plates  29  or  31  or inserts within mold plates  29 ,  31  pushed forward by systems such as an ejector system within the mold plates or by other mechanical means (e.g, an actuator or mechanical linkage) can drive one or both contact elements  129 ,  131  to assemble the parts. 
     Assembly apparatus  123  may be provided in configurations other than those described herein. For example, one contact-element support (or three or more supports) could be utilized rather than two supports  125 ,  127 . Contact elements  129 ,  131  could be mounted on supports  125 ,  127  for movement other than axial movement. Plural contact elements (e.g., elements  129 ,  131 ) may be supported on each contact-element support  125 ,  127 . 
     Referring to  FIGS. 8 ,  10 ,  12  and  14 , ejection apparatus  171  may be provided for each face  51 - 57  and mold portion  67 - 73  of turret  25  to eject final assembly  21  from one of mold portions  67 - 73  following movement of turret  27  from the final assembly operating position indicated by position E in  FIG. 13 . Ejection apparatus may comprise a linear actuator  173  which urges ejector base  175  outward causing ejector pins  177 ,  179  to urge final assembly  21  fully out of mold portion  67 . Final assembly  21  may be received onto a belt or other apparatus (not shown) for further processing. 
     Operation of actuators  35 ,  99 ,  113 ,  115 ,  147 ,  149 ,  173  is synchronized by any suitable controller (not shown) or combination of controllers known to persons of skill in the art. Representative controllers are Programmable Logic Controllers (PLCs). 
     Operation 
     Operation of the illustrated exemplary embodiment of an injection-molding and assembly apparatus  10  including two turrets  25 ,  27  will next be described. In  FIGS. 3-15 , apparatus  10  is shown with tooling provided for manufacture of an exemplary composite part final assembly  21  ( FIGS. 1-2 ). It is to be understood that a broad range of parts can be made using injection-molding and assembly apparatus  10  and that the parts illustrated are merely representative. 
     Injection-molding and assembly apparatus  10  is configurable to provide the manufacturer with the capability to manufacture this broad part range. For example, injection molding and part assembly may occur in connection with each of turrets  25 ,  27  or a single turret  25 . More than two turrets may be utilized. Production of a final assembly  21  by coordinated use of turrets  25 ,  27  is optional and represents an advantageous capability available to the manufacturer. 
     The following operational description of apparatus  10  relates to an example in which a part assembly  17  is formed and assembled along face  51  of turret  25  and a complementary part  19  is formed along face  59  of turret  27 . It is to be understood that the following description is applicable to the processes occurring along each other like face of turret  25 ,  27 . 
     Turning then to  FIGS. 3 and 4 , a production cycle begins with apparatus  10  shown in a forming operating position indicated by position A in which plastic parts  11 - 15  and  19  are formed by injection molding along faces  51 ,  59  of turrets  25 ,  27 . As shown in  FIG. 4 , turrets  25 ,  27  are clamped between mold plates  29 ,  31  by ram-driven  35  movement of mold plate  31  toward mold plate  29 . 
     First mold portion  47  supported on mold plate  29  is closed together against second mold portion  67  on face  51  to form mold cavity  83  and first mold portion  49  on mold plate  29  is closed together against second mold portion  75  on face  59  to form mold cavity  85 . Mold portions  67   a,    67   b  further form cavity portions  83   a,    83   b.  Complementary mold portions  47 ,  67  and  49 ,  75  are clamped tightly together between mold plates  29 ,  31  in this mold-closed forming operating position shown in  FIG. 4 . 
     Plastic material is injected into mold plate  29  from barrels (not shown) in the directions indicated by the arrows  89 ,  91 . The plastic material travels through a runner system and gate (not shown) and is injected into mold portions  47 ,  49  and into cavities  83 ,  85  to fill such cavities. Mold cavity  83  includes plural cavities defining plural parts  11 - 15  which will be assembled into a sub-assembly  17 . 
     After the plastic material in mold cavities  83 ,  85  has cooled sufficiently to retain form, the mold cavities  83 ,  85  are opened by moving mold portions  67 ,  75  away from mold portions  47 ,  49  to the mold-opened position such as shown in  FIG. 13 . This displacement is accomplished by ram-driven movement of mold plate  31  away from base  23  and turrets  25 ,  27  along the path defined by arrows  33 . Mold plate  31  moves base  23  and turrets  25 ,  27  away from mold plate  29  through linkage  45  to the mold-open position shown in  FIG. 13 . The formed parts  11 - 15 ,  19  remain associated with mold portions  67 ,  75  on turrets  25 ,  27 . 
     As shown in  FIG. 8 , opening of mold cavities  83 ,  85  causes release apparatus  151  to displace contact-element supports  125 ,  127  and mold portions  67   a,    67   b  outwardly to partially release formed plural parts  11  and  15  from mold portion  67  placing parts  11 , in alignment for assembly with part  13  by contact elements  129 ,  131 . It is not necessary to release complementary part  19  from mold portion  75  in this embodiment. In the example, parts  11 ,  15  are displaced sufficiently from mold portion  67  so that male parts  11   a,    15   a  are axially aligned with corresponding female parts  13   a,    13   b.    
     Referring to  FIGS. 7-8  and  13 , with mold plates  29 ,  31  spaced from base  23  ( FIG. 13 ), turrets  25 ,  27  are rotated by indexing apparatus  97 ,  111  to a cooling operating position indicated by position B. Turrets  25 ,  27  are rotated 90° in an indexed manner in the directions of arrows  181 ,  183  to arrive at the positions shown in  FIG. 7 . Ambient air and water circulating in turrets  25 ,  27  cool the formed parts  11 - 15 ,  19  carried on mold portions  67 ,  75 . 
     While in the cooling operating position, ram-driven  35  movement of mold plate  31  toward mold plate  29  again clamps turrets  25 ,  27  between mold plates  29 ,  31  so that mold portions  47 ,  69  and  49 ,  77  are aligned and closed together to again provide cavities  83 ,  85  at a forming operating position along turret faces  53 ,  61  occurring simultaneously with the cooling operating position occurring along turret faces  51 ,  59 . Ram-driven movement of mold plate  31  away from base  23  and mold plate  29  again opens mold cavities  83 ,  85  and displaces base  23  from mold plates  29 ,  31  as in  FIG. 13  so that turrets  25 ,  27  may be rotated to the next position. 
     Referring now to  FIGS. 9-10 , turrets  25 ,  27  are next rotated a further 90° (i.e., 180° from the initial forming operating position) in an indexed manner by indexing apparatus  97 ,  111  in the directions of arrows  181 ,  183 . After this further indexed rotation, turret face  51  and parts  11 - 15  are in an assembly operating position C and turret face  59  is in a further cooling operating position B. With face  51  in the assembly position and face  59  in the further cooling position, ram-driven movement of mold plate  31  again clamps turrets  25 ,  27  between mold plates  29 ,  31  urging mold portions  47 ,  71  and  49 ,  79  to close together again providing mold cavities  83 ,  85  at the forming operating position along turret faces  55 ,  63 . 
     With faces  51 ,  59  in the assembly position of  FIGS. 9-10 , actuators  147 ,  149  drive contact elements  129 ,  131  held on supports  125 ,  127  inwardly in the directions of arrows  141 ,  143  causing first ends  135  of contact elements  129 ,  131  to respectively urge parts  11  or  15  together with part  13  to form sub-assembly  17 . Male parts  11   a  and  15   a  are held in place within respective female portions  13   a,    13   b.  Parts  11  and  15  could be sized to rotate on part  13  if desired. Springs  145  bias contact elements  129 ,  131  back to a retracted position after assembly. Ram-driven movement of mold plate  31  away from base  23  and mold plate  29  as in  FIG. 13  again opens mold cavities  83 ,  85  and displaces base  23  from mold plates  29 ,  31  so that turrets  25 ,  27  may be rotated to the next position. 
     Referring to  FIGS. 11-12 , indexing apparatus  97 ,  111  rotate turrets  25 ,  27  a further 90° (i.e., 270° from the initial forming operating position) in an indexed manner in the directions of arrows  181 ,  183  to a pre-final assembly operating position indicated by position D. Turret faces  51 ,  59  are now in a facing position with sub-assembly  17  facing complementary part  19  in alignment and ready for mechanical assembly to form final assembly  21 . When mold plates  29 ,  31  are spaced apart from base  23  ( FIG. 13 ) and turrets  25 ,  27  are in position D, carriage  101  supporting turret  27  can be displaced toward turret  25 . 
     Referring to  FIGS. 13-14 , actuator  115  drives carriage  101  along guide  103  toward turret  27  to the final assembly operating position indicated by position E. In this final assembly position, male part  19   a  is inserted into corresponding female part  13   c  of sub-assembly  17  by the relative displacement of turrets  25 ,  27 . Part  19   a  is held in place by mechanically joining complementary part  19  and sub-assembly  17  into final assembly  21 . Actuator  115  then drives carriage  101  away from turret  25  back to the position shown in  FIGS. 4 ,  7 ,  9  and  11 . Part  19  remains associated with the final assembly  21  in mold portion  67 . 
     As shown in  FIG. 15 , the final assembly  21  is ejected from mold portion  67  by ejection apparatus  171  completing the production cycle. 
     Next, indexing apparatus  97 ,  111  rotate turrets  25 ,  27  a further 90° (i.e., 360° from the initial forming operating position) in an indexed manner in the directions of arrows  181 ,  183  so that faces  51 ,  59  are returned to the forming operating position A in which mold portions  47 ,  67  and  49 ,  75  are again in alignment. Ram-driven  35  movement of mold plate  31  toward base  23  and mold plate  29  returns apparatus  10  to the position shown in  FIG. 4  so that plastic material can again be received in mold cavities  83 ,  85  and a new production cycle commenced. 
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     While the principles of this invention have been described in connection with specific embodiments, it should be understood clearly that these descriptions are made only by way of example and are not intended to limit the scope of the invention.