Patent Publication Number: US-2016236397-A1

Title: Deep grip mechanism within blow mold hanger and related methods and bottles

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a divisional of U.S. patent application Ser. No. 14/703,602, filed on May 4, 2015, which is a divisional of U.S. application Ser. No. 13/841,745, filed on Mar. 15, 2013, which issued as U.S. Pat. No. 9,022,776 on May 5, 2015, the contents of each of which are incorporated by reference in their entirety, and to each of which priority is claimed. 
    
    
     BACKGROUND 
     The present invention relates generally to blow molding containers, and more particularly to using moveable inserts to mold a deep-grip bottle, for example. 
     A prior art arrangement  102  for blow molding containers is shown in  FIG. 1 . A rotatable blow molding module  110  may have sixteen blow molding stations  12 , for example. This may be a known Sidel-type SB0-16 GUPM module. The arrangement may include heating module  104 , transfer module  106 , and transfer module  108 . The horizontal dimensions of a given blow molding module  12  define a space envelope  99 . 
     In another prior art arrangement shown in  FIG. 12 , a rotatable blow molding module may have ten blow molding stations  12 . This may be a known Sidel-type SB0-10 GUPM module. 
     In the prior art arrangements, each blow molding station  12  may include a mold  16  supported by a mold hanger  14 , as depicted in  FIG. 2 . The mold may include cavity  345  for forming bottle  24  with grip  39 . The blow molding station  12  may open in two halves  13 . The mold may have a bottom  47  that needs to move downward to release bottle  24  at exit station  101  depicted in  FIG. 12 . 
     SUMMARY 
     As embodied herein, the present disclosure is directed to methods of retrofitting an original rotatable blow molding module having multiple existing blow molding stations affixed to the rotatable blow molding module, each existing blow molding station having an existing mold hanger for supporting and encasing a mold for a bottle, each existing mold hanger defining an existing outer envelope, the method comprising: providing in each blow molding station an improved mold hanger, the improved mold hanger substantially contained within the respective existing outer envelope and configured to support and encase a mold for blow molding a bottle from plastic; and providing in each improved mold hanger a pair of low-profile drive mechanisms configured to opposably drive a respective pair of moveable inserts at least one half inch into a cavity of the mold while the plastic is molten. 
     As embodied herein, the present disclosure is directed to methods of manufacturing a blow molded bottle with a deep pinch grip comprising: providing a mold hanger defining an outer envelope; providing in the mold hanger a mold with a cavity configured to receive molten plastic; providing within the outer envelope a first moveable insert; providing within the outer envelope a second moveable insert; providing within the mold hanger a first drive mechanism configured to drive the first moveable insert in a first direction into the cavity; providing within the mold hanger a second drive mechanism configured to drive the second moveable insert in a second direction into the cavity, the second direction being generally opposed to the first direction; blowing molten plastic into contact with the mold; and after blowing the molten plastic into contact with the mold, operating the first and second drive mechanisms to drive the first and second moveable inserts into the cavity while the plastic is still pliable and form a blow-molded bottle with a deep pinch grip, and to blow-molded bottles manufactured according to such methods. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a diagram of a prior art arrangement for blow molding containers. 
         FIG. 2  is a perspective view of part of a prior art blow molding station. 
         FIG. 3  is a front view of part of an inventive blow molding station at an early stage of operation. 
         FIG. 4  is a front view of the part of an inventive blow molding station from  FIG. 3 , shown at a later stage. 
         FIG. 5  is a cross-sectional view of an inventive mold with moveable inserts at a first stage. 
         FIG. 6  is a cross-sectional view of the mold of  FIG. 5  shown at a second stage. 
         FIG. 7  is a cross-sectional view of the mold of  FIG. 5  shown at a third stage. 
         FIG. 8  is a cross-sectional view of the mold of  FIG. 5  shown at a fourth stage. 
         FIG. 9  is a cross-sectional view of the mold of  FIG. 5  shown at a fifth stage. 
         FIG. 10  is a perspective view of an inventive mold hanger. 
         FIG. 11  is a top down view of an inventive mold hanger, piston, and mold. 
         FIG. 12  is a diagram of a prior art module with blow molding stations for blow molding containers. 
         FIG. 13  is a composite front view of an inventive blow molding station shown at two different times. 
         FIG. 14  is a top down plan of the composite view shown in  FIG. 13 . 
     
    
    
     DETAILED DESCRIPTION 
     Under a cooperative research and development agreement, it has been suggested to the present inventors to provide moveable inserts or slides in a mold to provide a grip deeper than the grip  39  provided by the conventional arrangement shown in  FIG. 2 . The moveable inserts would move into the mold toward the end of the blowing process, but while the plastic was still malleable. The inventors have recognized that providing for moveable inserts in a low profile manner will permit the moveable inserts to be used in a conventional rotatable blow molding module where space is limited. This preserves a favorable production rate and efficiency of existing arrangements, such as the ten station rotatable blow molding module depicted in  FIG. 12  and the sixteen station rotatable blow molding module  110  depicted in  FIG. 1 . Providing and actuating moveable inserts in the low profile manner as described herein obviates the need to use fewer stations on a given rotatable blow molding module or the need to increase the size of the rotatable blow molding module which would otherwise be necessary if lateral space envelope  99  of each blow molding station were significantly enlarged. 
     In a conventional ten station rotatable blow molding module as depicted in  FIG. 12 , finished bottle  24  is ejected at an ejection station  101  having a certain clearance  130  between an open mold hanger  314  in one existing blow molding station  12  and an open mold hanger  414  in an identical adjacent existing blow molding station  12 . The outer envelope  99  of each mold hanger  314  and  414  of each existing blow molding station  12  cannot be increased by more than the clearance distance  130 . In other words, the increase in lateral direction  103  and the increase in lateral direction  105  cannot together total more than clearance distance  130 . Otherwise, mold hangers  314  and  414  would collide when they are opened at the ejection station. Preferably, the total increase of outer envelope  99  is significantly less than clearance distance  130 . This allows for clearance distance  130  to be at least as large as a desired safety margin allowing for machining tolerances, positioning tolerances, hoses possibly getting positioned between adjacent hangers, and other safety considerations. 
     For a typical Sidel-type ten station rotatable blow molding module, e.g. Sidel SB0-10 GUPM, clearance  130  may be 66 millimeters. In that case, the desired safety margin may be 25 millimeters, permitting the total increase of outer envelope to be equal to, or preferably less than, 41 millimeters. All of the various inventive mechanisms described herein can easily be installed in each blow molding station while adding no more than 26 millimeters to the outer envelope  99 . With further refinements, such as for example using stronger (and therefore thinner) metal in the mold hanger, the inventive drive mechanisms described herein may be added to an existing blow molding station  12  without causing the improved blow molding station to extend laterally beyond outer envelope  99 . 
     Use of moveable inserts at various stages of a blow molding process is depicted in  FIGS. 5 through 9 . 
       FIG. 5  is a cross-section of a mold at a first stage. Here, preform  124  is shown centered on axis  194  of cavity  345  in mold  116 . Moveable inserts  118  and  120  are shown in their outward or fully retracted position. Moveable insert  118  is slideably engaged in moveable insert pocket  122 . 
       FIG. 6  is a cross-sectional view of the mold of  FIG. 5  shown at a second stage. By this time, preform  124  has been blown somewhat outward to intermediate form  224 . 
       FIG. 7  is a cross-sectional view of the mold of  FIG. 5  shown at a third stage. By this time, intermediate form  224  has expanded to pre-shape  324  in partial contact with cavity  345 . 
       FIG. 8  is a cross-sectional view of the mold of  FIG. 5  shown at a fourth stage. By this time, pre-shape  324  has expanded to initial shape  424  in substantially full contact with cavity  345 . Such contact may cause initial shape  424  to start cooling and hardening slightly. 
       FIG. 9  is a cross-sectional view of the mold of  FIG. 5  shown at a fifth stage. Shortly after the stage shown in  FIG. 8 , moveable inserts  118  and  120  will advance into cavity  345  before initial shape  424  significantly hardens. Moveable inserts  118  and  120  are shown in  FIG. 9  having moved to their inward or fully engaged position. The movement of moveable inserts  118  form their outward position to their inward position while the plastic is still molten moves the shallow grip in initial shape  424  into a deep pinch grip  539  to form deep pinch grip bottle  524 . 
     Deep pinch grip  539  has a width  525  smaller than a width that would be possible in these circumstances without moveable inserts. It is difficult and costly to attempt to blow mold such a deep pinch grip bottle without using slides. Deep pinch grip  539  provides larger ledges  526  and  526  to rest on fingers and a thumb of a user. For example, ledges  526  and  528  may each have a depth indicated at dimension  527 . Dimension  527  may be at least 29 milimeters, providing a secure ledge for pinch grip  539 . Use of the moveable inserts can increase the depth of the ledges from 16 millimeters to 29 millimeters and decrease the width  525  of the grip from 3 and ⅛ inch to 2 and ⅛ inch in a 1.75 liter bottle, for example. This is especially beneficial in a large heavy bottle, such as a 1.75 liter liquor bottle. Deep pinch grip  539  provides stability in an energy- and plastic-efficient design. 
     The inventors have devised several ways of adding moveable inserts to a blow molding station in a manner having a profile low enough to permit use of an otherwise standard blow molding module. In one embodiment, the moveable inserts are moved by a low-profile piston preferably contained in a mold hanger. In another embodiment, the moveable inserts are moved by a low-profile cam preferably contained in a mold. A low-profile piston and a low-profile cam are both means for driving moveable inserts. 
       FIG. 3  is a front view of part of an inventive blow molding station  112  with mold hanger  114  and mold  116 , at an early stage of operation. Initial shape  424  is still molten and moveable inserts  118  and  120  are just about to start travelling inward from the outward position shown in  FIG. 3 . Piston  166  is provided in piston sleeve  159 . In this figure, piston top  165  of piston  166  is adjacent piston sleeve head end  164 . Piston  166  is ready to start pushing moveable insert  118  inward through insert pocket  122 , by piston  166  advancing in piston sleeve  159  into annular space  123 . 
       FIG. 4  is a front view of the part of an inventive blow molding station from  FIG. 3 , shown at a later stage. Initial shape  424  has been pushed inward by inserts  118  and  120 , to form bottle  524 . The movement of piston  166  has filled annular space  123  and vacated annular space  119 . That motion has pushed inserts  118  through insert pocket  122 . 
     At the stage shown in  FIG. 4 , piston top  165  has advanced beyond optional latches  181  and  183 . Latches  181  and  183  may be moved from outside piston sleeve  159  to protrude into annular space  119  by fluid pressure or spring force, for example. By thus protruding, latches  181  and  183  resist movement of piston  166  in the outward direction. Such engagement of latches  181  and  183  can ensure moveable insert  118  stays in place in its inward position even if air pressure blowing outward from center line  193  applies outward pressure to moveable insert  118 . Latches  181  and  183  may remain engaged until bottle  524  has hardened sufficiently to move piston  166  back to its outward position where piston top  165  is adjacent piston sleeve head end  164 . At that time, latches  181  and  183  may be disengaged by application or release of spring or fluid pressure, for example. 
       FIG. 10  is a perspective view of an inventive mold hanger. Piston sleeve  159  meets piston sleeve head end  164  in mold hanger  114 . Piston sleeve head end  164  has first source of fluid pressure  162  centered therein. Mold hanger  114  has hinge  150  to be rotatably secured to the back of blow molding station  112  and clasp  152  to close the front of blow molding station  112  during blow molding. Mold hanger  114  may be characterized by vertical direction  189  and horizontal direction  187 . 
       FIG. 11  is a top down view of an inventive mold hanger, piston, and mold. Piston  166  rides in piston sleeve  122 , secured by annular seal  182 . Piston  166  drives moveable insert  118  in insert picket  122 , guided by guides  190  cooperating with bushings (not shown). Duct  170  may have a female pipe thread and brings fluid pressure through high pressure fluid inlet hole  168  to first source of fluid pressure  162 . Duct  170  preferably travels down within hanger  114  to obtain fluid pressure from the bottom of blow molding station  112 . Alternately, duct  170  may connect to a feed hose supplying fluid pressure. Fluid pressure form first source of fluid pressure  162  presses against piston top  165  to urge piston  166  inwardly in piston sleeve  159  which in turn pushes moveable insert  118  inwardly in moveable insert pocket  122 . The fluid in moveable insert pocket  122  may be exhausted to feed hole  178  via passage  177  in mold hanger  114 . Feed hole  178  is preferably a low pressure air return line which originates at the bottom of mold hanger  114 . 
     Once piston  166  and moveable insert  118  are in their inward position, they form deep pinch grip  539  as previously described. When deep pinch grip bottle  524  is sufficiently hardneded, moveable insert  118  can be moved in back to its outward position, forcing piston top  165  out to its outward position adjacent piston sleeve head end  164 . This backward movement can be accomplished by applying fluid pressure against the bottom  184  of piston  166 , such as by introducing fluid pressure from second source of fluid pressure  174  supplied by duct  187  through passage  177 . 
     In  FIG. 11 , optional latches  181  and  183  are shown in their disengaged position. 
       FIG. 12  is a diagram of a prior art module with blow molding stations for blow molding containers. 
       FIG. 13  is a composite front view of an inventive blow molding station shown at two different times. Mold  216  is secured by mold hanger  214  and contains moveable insert  118 . Moveable insert  118  is completely contained within mold  216 . As shown in the right half of  FIG. 13 , moveable insert  120  is in its outward position. Fluid actuation cylinder  19  is prepared to push cylinder  161  up through path  171  to force cam follower  15  from position  5  to position  1  along path  4 . Because the groove  3  cam follower  15  rides in is angled outwardly and upwardly, the force of cam follower  15  being forced from position  5  to position  1  pushes moveable insert  120  inwardly under the force of the inclined plane along dogleg path  2 . 
     The inward position is shown at a later time in the left half of  FIG. 13 . There, the cam follower is in the up position  6 , holding moveable insert  118  in its inward position to form a deep grip pinch in bottle  624 . When bottle  624  is sufficiently cooled and hardened in mold cavity  126 , moveable insert  118  can be moved to the outward position by fluid actuation cylinder  919  operating in reverse. That is, fluid actuation cylinder  919  pulls the cam follower from position  6  to position  9  along dogleg path  7  in groove  8 . Because groove  8  is angled downwardly and inwardly, pulling the cam follower down from position  6  to position  9  applies an inclined plane force pulling moveable insert  118  outward away from bottle  624  and out of cavity  126 . 
     Thus, drive mechanism  312  comprises a cam follower or roller in groove  8  and cylinder shaft  313 , all contained in mold  216 . 
       FIG. 14  is a top down plan of the composite view shown in  FIG. 13 . In the bottom half, moveable element  218  is in the inward position. In the top half, moveable element is shown being retracted from the inward position shown in the bottom half, at a later time than that depicted in the bottom half. Cylinder linkage  12  is shown linking cylinder  161  with cam follower  15  via shaft  13  holding cam follower  15  and cam follower  715 . 
     In one exemplary embodiment, the invention comprises a mold hanger  114  for supporting a bottle mold  116  in a blow molding station  112 , the mold hanger  114  having a vertical direction  189  and a horizontal direction  187 , the mold hanger  114  comprising a piston sleeve  159  fully contained within the mold hanger  114  and orthogonal to both the vertical direction  189  and the horizontal direction  187 ; a piston sleeve head end  164  capping the piston sleeve  159 ; a piston  166  slideably engaged with and fully contained within the piston sleeve  159 , the piston  166  having a piston top  165  conforming to the size and shape of the piston sleeve head end  164  and a piston bottom  184 ; a moveable insert  118  integral with the piston bottom  184  and configured to be pushed by the piston bottom  184  in an inward direction away from the piston sleeve head end  164  into a mold  116  supported by the mold hanger  114 ; and a first source of fluid pressure  162  configured to apply pressure to the piston top  165  to push the piston  166  slideably away from the piston sleeve head end  164  and toward the mold  116 ; wherein the piston top  165  has an area larger than a cross sectional area of the moveable insert  118 . 
     The mold hanger  114  may have a second source of fluid pressure  174  configured to apply pressure to the piston bottom  184  to push the piston  186  slideably toward the piston sleeve head end  164 . 
     The first source of fluid pressure  162  preferably provides pressurized air from a pressurized air source that is also used to blow mold a bottle  24  in the bottle mold. Alternatively, the first source of fluid pressure  162  may provide hydraulic pressure. 
     Preferably, fluid pressure from the first source of fluid pressure  162  is sufficient to hold piston  166  and moveable insert  118  in the inward position shown in  FIGS. 3 and 9  against outward pressure from pressurized air used to mold the bottle. However, latches  181  and  183  may be provided to hold piston  166  and moveable insert  118  in that inward position. Latches  181  and  183  may contain springs and/or may be actuated by fluid pressure available in mold hanger  114 . 
     A central axis  192  of piston  166  may be parallel to and laterally displaced from a central axis  194  of moveable insert  118 . This lateral offset may provide room for second source of fluid pressure  174  to communicate with fluid passage  178  in mold hanger  114 . The lateral offset may permit piston  166  to be centered along the horizontal direction  187  of mold hanger  114  while moveable insert  118  is off center to provide deep grip  539  offset from the center of the bottle which may be at axis  192 . 
     Moveable insert  118  of mold hanger  114  may be configured to be pushed at least about one half inch into mold  116  supported by mold hanger  114 . With such inserts in both halves of mold  116 , deep grip  539  may be at least one inch deeper than without the insert. This may permit ledges  526  and  528  each to have a depth  527  of at least 29 millimeters instead of only about 16 millimeters without the moveable insert. 
     Piston sleeve  159  may be no more than one inch long in its axial direction along its axis  194 . This length accommodates both the travel distance of piston  166  and the thickness of piston  166  itself. For example, if piston  166  is one half inch thick, piston  166  may travel one half inch within a one inch piston sleeve  159 . If piston  166  were one quarter inch thick, piston  166  could travel three quarters of an inch within a one inch piston sleeve  159 . 
     With the low profile of a once inch piston sleeve  159 , mold hanger  114  may be no more than about two inches thick in the portion  675  surrounding piston sleeve  159 . Mold hanger  114  may be no more than about one inch thick in the portion  677  beyond the piston sleeve head end  164 . The thickness of mold hanger  114  could be reduced further by use of stronger metal, such as titanium. The thickness of a standard existing Sidel mold hanger is shown in  FIG. 11  by phantom line  172 . As can be seen, the added thickness at portion  675  and  677  is minimal. 
     In a second exemplary embodiment, there is provided a method of retrofitting an original rotatable blow molding module  110  having multiple existing blow molding stations  112  affixed to the rotatable blow molding module  110 , each existing blow molding station  112  having an existing mold hanger  14  for supporting and encasing mold  16  for a bottle  24 , each existing mold hanger  14  defining an existing outer envelope  99 , the method comprising: providing in each blow molding station  112  an improved mold hanger, the improved mold hanger substantially contained within the respective existing outer envelope  99  and configured to support and encase a mold for blow molding a bottle  524  from plastic; and providing in each improved mold hanger a pair of low-profile drive mechanisms configured opposably to drive a respective pair of moveable inserts  118  and  120  at least one half inch into a cavity of the mold  116  while the plastic is molten. 
     The method may further comprise providing a fluid pressure source in fluid communication with the drive mechanisms. The fluid pressure source may provide pneumatic or hydraulic pressure and may include pressure duct  170 , for example. The method may include redirecting fluid pressure pre-existing on each existing blow molding station  112 . In that case, pressure duct  170  may receive pressure from the same source of pressure used to blow mold containers in the mold, for example. 
     Alternately the fluid pressure source used in the method may comprise or be in fluid communication with a low profile, high pressure, canister  19 . The method may include securing low profile, high pressure, canister  19  in each blow molding station below the respective mold in fluid communication with the respective drive mechanisms. 
     In the method, providing an improved mold hanger may comprises replacing the existing mold hanger  14 . Or it may comprise reusing the existing mold hanger in altered form. 
     The method may include providing a drive mechanism comprising a slotted cam or a piston, for example. In the case of a piston, the piston may have a cross-sectional area larger than a cross-sectional area of the moveable insert. In this manner, the cross-sectional surface area of the piston that is impacted by fluid pressure pushing the piston in toward the mold is greater than the cross-sectional area of moveable insert subject to outward pressure from the air pressure used to blow mold a bottle in the mold. This helps ensure that the force of the drive mechanism pushing the moveable insert into the mold is strong enough to overcome friction and outward pressure even if the fluid pressure used to blow mold the bottle is the same as or less than the fluid pressure used to drive the drive mechanism inward. 
     In the method, the drive mechanism may be configured to drive the moveable insert within an insert pocket in the mold. 
     The method may be used where the original rotatable blow molding module before the retrofitting has no more than about 66 millimeters clearance between respective existing blow molding stations in operation. The rotatable blow molding module may be a ten-station Sidel-type GUPM wheel, for example. Before the retrofitting, the original rotatable blow molding module may have no moveable mold inserts. 
     In the method the moveable insert may be configured to move at least about one half inch into an interior cavity inside the mold. 
     A third exemplary embodiment provides a method of manufacturing a blow molded bottle  524  with a deep pinch grip  539  comprising: providing a mold hanger defining an outer envelope; providing in the mold hanger a mold with a cavity  345  configured to receive molten plastic; providing within the outer envelope a first moveable insert  118 ; providing within the outer envelope a second moveable insert  120 ; providing within the mold hanger a first drive mechanism configured to drive the first moveable insert  118  in a first direction into the cavity  345 ; providing within the mold hanger a second drive mechanism configured to drive the second moveable insert  120  in a second direction into the cavity  345 , the second direction being generally opposed to the first direction; blowing molten plastic into contact with the mold; and after blowing the molten plastic into contact with the mold, operating the first and second drive mechanisms to drive the first and second moveable inserts into the cavity  345  while the plastic is still pliable and form a blow-molded bottle  534  with a deep pinch grip  539 . 
     The method may include operating the first and second drive mechanisms to drive the first moveable insert  118  at least about one half inch into the cavity  345  and to drive the second moveable insert  120  at least about one half inch into the cavity  345 . 
     In this method, deep pinch grip  539  may have a first ledge  526  at least about 29 millimeters deep formed by the first moveable insert  118  and a second ledge at least about 29 millimeters deep formed by the second moveable insert  120 , as depicted in  FIG. 9 . Deep pinch grip  539  may have a width  525  equal to or less than about 2 and ⅛ inches, for example. 
     The exemplary method of manufacturing a blow molded bottle  524  with a deep pinch grip  539  may further comprise operating the first and second drive mechanisms in reverse to move the first and second moveable inserts away from the blow-molded bottle. 
     A fourth exemplary embodiment is a blow molded bottle  524  with a deep pinch grip  539  manufactured according to a method described above in the third exemplary embodiment. Such a bottle may be, for example, a 1.75 litre bottle with a deep pinch grip  539  no more than about 2 and ⅛ inch wide (shown as dimension  525  in  FIG. 9 ) and having a ledge  526  at least about 29 millimeters deep on a first side of the grip and a ledge  528  at least about 29 millimeters deep on a second side of the grip (shown as dimension  527  in  FIG. 9 ). 
     In a fifth exemplary embodiment, the invention provides a mold with a cavity for forming a deep grip container, the mold comprising: a first mold pocket configured to receive a first moveable insert; a second mold pocket configured to receive a second moveable insert; a first drive mechanism fully contained within the mold and configured to drive the first moveable insert in a first direction through the first mold pocket into the cavity; and a second drive mechanism fully contained within the mold and configured to drive the second moveable insert in a second direction through the second mold pocket into the cavity, the second direction being generally opposed to the first direction. 
     The first drive mechanism may include a slotted cam. The mold may further comprise a cylinder shaft positioned in a cylinder shaft hole in the mold, the cylinder shaft in mechanical cooperation with the first drive mechanism. Such a mold may also have a linkage between the cylinder shaft and the first drive mechanism. It may further have an angled roller slot in the mold, angled upward and outward in relation to the cavity and a roller mounted to the linkage and adapted to roll in the roller slot. The angled roller slot may be a dog leg configuration with a straight portion of the slot located above an angled portion. The cylinder shaft can be configured to be operated by a fluid pressure cylinder mounted to a bottom surface of the mold. The fluid pressure cylinder may operate under hydraulic or pneumatic pressure. 
     In the mold of the fifth exemplary embodiment, the first drive mechanism may be configured to drive the first moveable insert in the first direction at least one half inch into the cavity and the second drive mechanism may be configured to drive the second moveable insert in the second direction at least one half inch into the cavity. 
     In a sixth exemplary embodiment, there is provided a method of retrofitting an existing blow molding station  12  having an existing mold hanger  14  for supporting and encasing a mold  16  for a bottle  24 , the existing mold hanger defining an existing outer envelope  99 . The method may comprise providing in the blow molding station an improved mold hanger, the improved mold hanger substantially contained within the existing outer envelope  99  defined by the existing mold hanger  14  and configured to support and encase a mold  116  for blow molding a bottle  524  from plastic; and providing in the improved mold hanger a pair of low-profile drive mechanisms configured to opposably drive a respective pair of moveable inserts  118  and  120  at least one half inch into a cavity  345  of the mold  116  while the plastic is molten. 
     This method may further include providing a fluid pressure source in fluid communication with the drive mechanisms. The fluid pressure source may be configured to provide hydraulic pressure or pneumatic pressure and, on one hand, may include fluid pressure pre-existing on and redirected from the existing blow molding station. 
     On the other hand, the fluid pressure source may be provided by a low profile, high pressure, canister. The canister may be secured below the mold in fluid communication with the drive mechanisms. 
     In the sixth exemplary embodiment, providing an improved mold hanger may include replacing the existing mold hanger, reusing the existing mold hanger in altered form, or reusing the existing mold hanger. Providing in the improved mold hanger a pair of low-profile drive mechanisms may include providing the drive mechanisms in a mold supported by the existing mold hanger. 
     In the method of retrofitting an existing blow molding station, the improved mold hanger laterally extends beyond the existing outer envelope by a cumulative total of less than the clearance distance  130 , e.g. 66 millimeters. To include a safety margin, the improved mold hanger laterally extends beyond the existing outer envelope by a cumulative total of less than 41 millimeters. In the disclosed method, the improved mold hanger can easily be arranged to extends laterally beyond the existing outer envelope by a cumulative total of less than 26 millimeters. By making certain adjustments, the improved mold hanger will not extend laterally beyond the existing outer envelope  99  at all. 
     The drive mechanism in this method may be configured to drive the moveable insert within an insert pocket in the mold. The moveable insert may be configured to slide within the insert pocket at least about one half inch into an interior cavity inside the mold. 
     In this method the existing blow molding station  12  may be part of a ten-station Sidel-type GUPM wheel indicated in  FIG. 12  or a sixteen-station Sidel-type GUPM wheel indicated in  FIG. 1 , for example. 
     In this exemplary method, the drive mechanism may comprise a slotted cam or a piston, for example. In the case of a piston, the top surface  165  of the piston may have a cross-sectional area larger than a cross-sectional area of the moveable insert. 
     In a seventh exemplary embodiment, there is provided a method of manufacturing a blow molded bottle with a deep pinch grip comprising: providing a mold hanger having an outer envelope; providing in the mold hanger a mold with a cavity configured to receive molten plastic; providing within the outer envelope a first pocket configured to receive a first moveable insert; providing within the outer envelope a second pocket configured to receive a second moveable insert; providing within the outer envelope a first drive mechanism configured to drive the first moveable insert in a first direction through the first pocket into the cavity; providing within the outer envelope a second drive mechanism configured to drive the second moveable insert in a second direction through the second mold pocket into the cavity, the second direction being generally opposed to the first direction; blowing molten plastic into contact with the mold; and after blowing the molten plastic into contact with the mold, operating the first and second drive mechanisms to drive the first and second moveable inserts into the cavity while the plastic is still pliable and form a blow-molded bottle with a deep pinch grip. 
     This exemplary method may further include operating the first and second drive mechanisms in reverse to move the first and second moveable inserts away from the blow-molded bottle. 
     An eighth exemplary embodiment is a blow molded bottle with a deep pinch grip manufactured according to the method of the seventh exemplary embodiment. This bottle may be a 1.75 litre bottle with a deep pinch grip no more than about 2 and ⅛ inch wide and having a ledge at least about 29 millimeters deep on a first side of the grip and a ledge at least about 29 millimeters deep on a second side of the grip. Any of the bottles mentioned herein may desirably be a 1.75 litre liquor bottle.