Patent Abstract:
A parts collection system for injection molding machines is disclosed. The system provides for easy and quick changing of devices adapted for receiving molded parts discharged from the molding machine. Generally, the parts collection system of the present invention includes a pair of support tracks for mounting to the frame of the molding machine having a pair of mold member operably connected thereto. Adjustably mounted to the support tracks are a pair of retaining beams for suspending devices adapted to receive parts dropped from the mold members.

Full Description:
RELATED APPLICATIONS 
     This application claims the benefit of U.S. Ser. No. 60/130,689, filed on Apr. 23, 1999, which is incorporated herein by reference. 
    
    
     TECHNICAL FIELD 
     The present invention generally relates to systems for collecting parts from injection molding machines, and in particular to a system that provides for easy and quick changing of devices for receiving molded parts and/or runners. 
     BACKGROUND ART 
     A typical machine for injection molding of plastic parts is shown in FIG.  1 . The machine  10  includes a suitable frame  12  which carries a fixed platen  14  and a movable platen  16 . The movable platen  16  is carried by a plurality of support rods  18  for movement toward and away from the fixed platen  14  by a suitable hydraulic mechanism. Conventional mold members  20  and  22  are mounted in the customary manner to the platens  14  and  16 , respectively, for moving towards and away from one another with the platens. The mold members  20  and  22  include complimentary mold cavities (not shown) into which liquid plastic is injected from a conventional ram-type injection mechanism  24 . 
     Generally located below the platens  12 , 14  and defined within the frame  12  of the molding machine  10  is an open horizontal passage  26  for receiving a freestanding conveyor or the like (not shown). Also, the passage  26  is in communication with an opening  28  positioned generally below the platens  12 , 14  for allowing molded plastic parts to fall from the mold members  20 , 22  and into the passage  26  when the mold members  20 , 22  are separated from each other. 
     The type of freestanding receiving device positioned underneath the molding machine platens  14 , 16  and within the passage  26  typically varies as the mold members  20 , 22  are changed. The swapping of freestanding receiving devices is a time consuming procedure since these devices are separate from the molding machine  10  and thus must be adapted to stand at the desired position and attitude within the passage  26 . 
     SUMMARY OF THE INVENTION 
     Generally, the parts collection system of the present invention includes a pair of support tracks for mounting to the frame of an injection molding machine having a pair of platens adapted to receive mold members. Adjustably mounted to the support tracks are a pair of retaining beams for suspending a device adapted to receive parts dropped from the mold members. 
    
    
     Other advantages and features of the present invention will be apparent from the following description of specific embodiments illustrated in the accompanying drawings. 
     BRIEF DESCRIPTION OF DRAWINGS 
     FIG. 1 is a perspective view of a typical molding machine; 
     FIG. 2 is an exploded view of a parts collection system in accordance with the present invention for mounting to the molding machine of FIG. 1; 
     FIG. 3 is a perspective view of another embodiment of a parts collection system in accordance with the present invention having a frame for operably mounting, for example, a conveyor to the molding machine of FIGURE 1; 
     FIG. 4 is a top view of the parts collection system of FIG. 3; 
     FIG. 5 is a side view of the parts collection system of FIG. 3; 
     FIG. 6 is a front end view of the parts collection system of FIG. 3; 
     FIG. 7 is a perspective side view of a screw type separator that can be substituted for the conveyor of FIG. 3; 
     FIG. 8 is a perspective side view of a combination conveyor and separator that can be substituted for the conveyor of FIG. 3; 
     FIG. 9 is a perspective end view of a conveyor having actuators for automated lateral movement of one end of the conveyor; 
     FIG. 10 is a perspective view of another parts collection system in accordance with the present invention mounted to a conventional molding machine; 
     FIG. 11 is a perspective view of the parts collection system of FIG. 10 removed from the molding machine; 
     FIG. 12 is a side view of the parts collection system of FIG. 11; 
     FIG. 13 is an end view of the parts collection system of FIG. 11; 
     FIG. 14 is a top view of the parts collection system of FIG. 11; and 
     FIG. 15 is a perspective view of a plurality of different receiving devices for use with the parts collection system disclosed herein. 
    
    
     DETAILED DESCRIPTION 
     While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention. The present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspects of the invention to the embodiments illustrated. 
     Referring now to the drawings, and particularly to FIG. 2, a parts collection system  30  in accordance with the present invention is depicted for mounting to the frame  12  of the molding machine  10  depicted in FIG.  1 . The system  30  includes a pair of slotted support tracks  32  for mounting to the molding machine frame  12 . Preferably, the support tracks  32  are in spaced parallel relationship to each other and are mounted about the opening  28  below the platens  14 , 16  of the molding machine  10 . 
     Adjustably mounted to the support tracks  32  are a pair of slotted  33  retaining beams  34  for receiving respective flanges  36  projecting from a receiving device such as a bin  38 , a conveyor or the like. The retaining beams  34  are preferably maintained in spaced parallel relationship with respect to each other, and can be slidingly positioned and locked into place along the lateral axis  40  of the injection molding machine opening  28 . 
     As will be appreciated by those having skill in the art, a plurality of different mounting systems can be provided for mounting support tracks  32  to the injection molding machine. Such mounting systems include, but are not limited to, the use of L-shaped plates fastened to the underside of the press frame, U-shaped plates fastened to the side of the press frame, extrusions of aluminum or steel fastened with brackets to the press frame, adjustably clamp brackets, pivoted clamps and brackets, set screws, side clamps, top clamps, and the like. 
     As indicated above, and illustrated in FIG. 15, a plurality of different receiving devices can be provided with outwardly projecting flanges for engaging the slots  36  of the retaining beams  34  operably mounted to the frame  12  and about the opening  28  in the molding machine  10 . Accordingly, the inventive parts collection system provides for quickly substituting one type of receiving device for another by slidingly removing the unwanted device and slidingly installing another. 
     Referring to FIGS. 3-6, another embodiment of a parts collection system in accordance with the present invention is depicted. The system  130  includes a frame  142  for attachment to the molding machine  10  depicted in FIG.  1 . The frame  142  preferably consists of a plurality of T-slotted aluminum extensions including a front pair  144  of vertical support tracks  132 , a back pair  146  of vertical support tracks  132 , two pairs of crossbars  150 , 152 , a pair of upper horizontal support beams  154 , and a pair of lower retaining beams  134 . 
     Attached to the marginal ends of the vertical support tracks  132  are joining plates  156  adapted for bolting the support tracks to the frame  12  of the molding machine  10 . Preferably, the vertical support tracks  132  are mounted within the passage  26  of the molding machine  10 . 
     Coupled to each pair  144 , 146  of vertical support tracks  132  is a pair of crossbars comprising an upper crossbar  150  and a lower crossbar  152 . The upper crossbars  150  are attached, and perpendicularly extend from, the upper ends of the vertical support tracks  132 . The lower crossbars  152  are adjustably mounted to the vertical support tracks  132  by locking members  158  having a lever  160  for manually releasing and fixing each locking member to a user selected location along the length of the vertical support tracks. 
     The upper horizontal support beams  154  are attached to the upper crossbars  150 . The support beams  154  are preferably positioned in spaced parallel relationship to each other and provide for mounting a guide skirt assembly  162  thereto. The guide skirt assembly  162  includes a pair of plastic or like material side panels  164  wherein one longitudinal marginal end of each panel is attached to a brace  166  mounted to one of the support beams  154 . Preferably, the brace  166  projects into the opening  28  located below the platens  14 , 16  of the molding machine  10  depicted in FIG.  1 . 
     The lower retaining beams  134  of the parts collection frame  142  are attached to the lower crossbars  152  and extend within the passage  26  of the molding machine  10  depicted in FIG.  1 . Preferably, the retaining beams  134  are in spaced parallel relationship to each other and include an upper longitudinal slot  133 . Received within the longitudinal slots  133  of the retaining beams  134  are a plurality of roller wheels  168  extending from a receiving device comprising a bi-directional parts conveyor  138 . 
     The conveyor  138  includes an elongated frame defined by a pair of spaced parallel side rails  172  formed of extruded aluminum. The side rails  172  are similar to each other and include an outer face with a longitudinal slot extending the rail&#39;s length for mounting of the roller wheels  168  by conventional means. 
     The conveyor  138  includes an endless conveyor belt  171  trained over a pair of pulleys (not shown) at each end of the conveyor. Operably connected to one of the pulleys is a drive assembly  173 , such as an electric motor, for bi-directional rotation of the conveyor belt  171 . 
     Attached to the side rails  172  of the conveyor  138  are a pair of ridge elongated rectangular guide members  174  defining a pocket holder for receiving an end portion of the guide skirt  162 . The guide members  172  have planar inner surfaces that diverge from each other as they extend from the conveyor  138 . In an embodiment, the rate at which the guide members  172  diverge from each other is user adjustable. 
     The conveyor  138  can be quickly and easily removed from the parts collection system frame  142  by rolling the conveyer along the slotted retaining beams  134  and off one end of the beams. Likewise, the conveyor  138  is installed onto the parts collection system frame  142  by engaging the wheels  168  of the conveyor into the slots  133  of the retaining beams  134  and rolling the conveyor to a desired location. Also, the height of the conveyor  138  from the floor surface, and the attitude of the conveyor, can be adjusted by releasing and then fixing the position of the lower crossbars  152  via locking members  158 . 
     FIG. 7 depicts another receiving device, in particular a screw type separator, for replacing the conveyor of FIG.  3 . The separator  238  includes a conventional hopper  276  with a threaded shaft  278  rotatably mounted thereto. A pair of side rails  272  (only one side rail shown) are attached and extend from the hopper  276 . Mounted onto the side rails  272  are a plurality of roller wheels  268  adapted to ride on the slotted retaining beams of the parts collection system for ease in installing and removing the separator  238  from the parts collection system frame. 
     FIG. 8 illustrates a combination conveyor and belt type separator for replacing the conveyor of FIG. 3. A pair of side rails  372  (only one rail shown) are attached and extend for the combination conveyor and belt type separator  338 . Operably connected to the side rails  372  are a plurality of roller wheels  368  to facilitate the installation and removal of the combination conveyor and belt type separator  338  from the parts collection system frame. 
     FIG. 9 shows a conveyor  438  having actuators  480  for automated lateral movement of one end of the conveyor as shown by arrows  482 . The actuators  480  can consist of air pistons, hydraulics, or like devices. The actuators  480  and the conveyor  438  are operably mounted to a pair of side rails  472  (only one rails shown) having a plurality of roller wheels  468  for engagement and support of the conveyor  438  by the slotted retaining beams of the parts collection system frame. 
     The conveyor  438  can also include a guide skirt  162  attached proximate to one end of the conveyor as disclosed in U.S. Pat. No. 4,295,815, filed Oct. 20, 1981, and incorporated herein by reference. The guide skirt  162  can be formed of a limp, flexible fabric having fasteners  484  for hanging from the molds of the molding machine wherein the guide skirt prevents the molded parts from bouncing away as they fall to the belt  471  of the conveyor. 
     In an embodiment, one or more actuators can also be attached to the conveyor  438  and the frame of the parts collection system for longitudinally moving the conveyor along the retaining beams to predetermined positions at preselected times. This embodiment can be used, for example, to move the ends of the conveyor  438  at preselected times for depositing molded parts into different receptacles. Moreover, actuators can be provided for moving the conveyor vertically up and/or down. 
     Other receiving device that can be mounted to the parts collection system frame include, but are not limited to, vertical transfer platforms, front and rear sorters, front discharge deflections chutes, chutes to blow parts, chutes to vacuum parts, two stage screw type separators, and sorters such as disclosed in U.S. Pat. No. 4,387,064, filed Jun. 7, 1983, and incorporated herein by reference. 
     In an embodiment, the parts collection system is distributed as a kit that can be assembled and installed onto a molding machine by a user. The kit preferably includes at least one shipping box containing all collection system frame members, all parts for attaching the frame members together, and instructions for assembling and installing the frame onto a molding machine. The kit preferably is contained within a box suitable for shipping and delivery to a location where the molding machine is used. 
     Turning to FIGS. 10-14, another embodiment of a parts collection system  530  in accordance with the present invention is depicted having two vibrating conveyors  586 , 587  mounted in parallel spaced relationship to each other. This embodiment can be used, for example, to separate molded parts from larger plastic runners produced and discharged from mold cavities as a result of the molding process. 
     The system  530  includes a frame  542  for attachment to the conventional molding machine  510  depicted in FIG.  10 . Preferably, the frame  542  is contained within the passage  526  extending into the molding machine  510 . The frame  542  consists of a plurality of metal tubes that are square in cross section and have a plurality of equally spaced open apertures on two opposite side surfaces. The metal tubes include a front pair  544  of vertical support tracks  532 , a back pair  546  of vertical support tracks  532 , two sets of crossbars  550 , 551 , 552 , and a pair of upper horizontal support beams  554 . 
     Mounted to each pair  544 , 546  of vertical support tracks is a set of crossbars comprising an upper crossbar  550 , an intermediate crossbar  551 , and a lower crossbar  552 . The upper crossbars  550  are coupled, and perpendicularly extend from, the upper ends of the vertical support tracks  532 . Also, the intermediate crossbars  551  and the lower crossbars  552  are mounted, via bolted joining plates  558 , to the vertical support tracks  532  below the upper crossbars  550 . 
     The upper horizontal support beams  554  are attached to the upper crossbars  550  between the front pair  544  and the back pair  546  of vertical support tracks  532 . The upper support beams  554  provide for mounting a guide skirt assembly  562  thereto. The guide skirt assembly  562  includes a pair of plastic or metal side panels  564  with one longitudinal marginal end of each panel attached to a brace  566  extending from a support beam  554 . 
     Mounted to the intermediate crossbars  551  and the lower crossbars  552  are vibrating conveyors  586  and  587 , respectively. The vibrating conveyors  586 , 587  are conventional in construction and each conveyor includes an elongated trough  588  having a planar bottom  590  and a drive mechanism (not shown) for reciprocal vibratory motion of the trough along its longitudinal axis. 
     The conveyors  586 , 587  are preferably mounted in spaced parallel relationship to each other with the upper conveyor  586  positioned directly over the lower conveyor  587 . The upper conveyor  586  has a plurality of parallel spaced transverse openings  592  in the bottom  590  of its trough  588 . The openings  592  are dimensioned for allowing molded parts to drop through the openings and into the trough of the lower conveyor  587 . 
     Preferably, the trough length of the upper conveyor  586  is longer than the trough length of the lower conveyor  587 . Accordingly, a marginal discharge end  594  of the upper conveyor  586  overhangs a like discharge end  596  of the lower conveyor  587 . 
     In operation, molded parts and larger runners drop from mold members of the molding machine  510  and are received in the trough  588  of the upper conveyor  586 . The parts and runners are moved by the conveyor  586  across openings  592  wherein the parts, but not the runners, drop through the openings and into the lower conveyor  587 . The runners are then discharged from the end  594  of the upper conveyor  586  where the runners drop into a receptacle or the like (not shown) for receiving only runners. Likewise, molded parts received by the lower conveyor  587  are moved by the conveyor and are discharged from end  596  where the parts drop into a receptacle or the like (not shown) for only receiving molded parts. 
     As will be appreciated by those having skill in the art, a plurality of other devices can also be attached to the parts collection system for receiving parts. For example, a short stroke (Vertical Transfer Platform) can be mounted directly under the mold and contain a load cell to checkweigh the shot before leaving the molding tress. 
     While the specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention and the scope of protection is only limited by the scope of the accompanying claims.

Technology Classification (CPC): 1