U.S. patent application number 10/036761 was filed with the patent office on 2003-06-26 for compression molding process and article made by the process.
This patent application is currently assigned to Seaquist Closures Foreign, Inc.. Invention is credited to Lay, Dieter F., Mueller, Bruce M., Nejad, Ben.
Application Number | 20030116879 10/036761 |
Document ID | / |
Family ID | 21890471 |
Filed Date | 2003-06-26 |
United States Patent
Application |
20030116879 |
Kind Code |
A1 |
Mueller, Bruce M. ; et
al. |
June 26, 2003 |
Compression molding process and article made by the process
Abstract
A molded article is produced by a method of compression molding
employing a specially shaped billet of thermoplastic material which
is positioned at a predetermined location in a predetermined
orientation with respect to the mold cavity surfaces of a mold
part. In a preferred embodiment, the billet has a generally egg
shape and is located adjacent a mold surface defining a small mold
cavity region between two larger cavity regions.
Inventors: |
Mueller, Bruce M.; (Bozeman,
MT) ; Nejad, Ben; (Evansville, IN) ; Lay,
Dieter F.; (Oconomowoc, WI) |
Correspondence
Address: |
ROCKEY, MILNAMOW & KATZ, LTD.
TWO PRUDENTIAL PLAZA, STE. 4700
180 NORTH STETSON AVENUE
CHICAGO
IL
60601
US
|
Assignee: |
Seaquist Closures Foreign,
Inc.
|
Family ID: |
21890471 |
Appl. No.: |
10/036761 |
Filed: |
December 21, 2001 |
Current U.S.
Class: |
264/142 ;
215/235; 264/294 |
Current CPC
Class: |
B29C 2043/5883 20130101;
B29C 43/34 20130101; B29C 43/42 20130101; B65D 47/0809 20130101;
B29L 2031/565 20130101; B29C 43/021 20130101; B29C 45/0081
20130101; B29C 2043/3488 20130101; B29K 2105/251 20130101 |
Class at
Publication: |
264/142 ;
264/294; 215/235 |
International
Class: |
B29C 043/02; B65D
043/00 |
Claims
What is claimed is:
1. A method for making a closure having a body, a lid, and a hinge
connecting said body and lid, said method comprising the steps of:
(A) providing a first mold part having (1) a first surface region
defining a first side of said body, (2) a second surface region
defining a first side of said hinge, and (3) a third surface region
defining a first side of said lid; (B) at a location spaced from
said first mold part, providing a second mold part having (1) a
first surface region defining a second side of said body, (2) a
second surface region defining a second side of said hinge, and (3)
a third surface region defining a second side of said lid; (C)
creating from a melt of thermoplastic material a billet having a
predetermined shape; (D) positioning said billet in a predetermined
orientation with at least a portion of said billet disposed
adjacent said first mold part second surface region; (E) decreasing
the space between said first and second mold parts to compress said
billet so that said thermoplastic material flows between said mold
parts; and (F) after said thermoplastic material has solidified to
form a closure, increasing the space between said mold parts, and
then removing said closure.
2. The method in accordance with claim 1 in which said step (D)
includes placing at least a portion of said billet against said
first mold part second surface region.
3. The method in accordance with claim 2 in which said step (A)
includes orienting said first mold part so that said first mold
part first, second, and third surface regions face generally away
from the direction of the earth's gravitational force; and said
step (D) includes positioning said billet directly on said first
mold part so that at least a portion of said billet is supported by
said first mold part second surface region.
4. The method in accordance with claim 1 in which step (C) includes
creating said billet to have a generally egg shape with a large end
and a small end.
5. The method in accordance with claim 4 in which step (D) includes
positioning said billet with said small end adjacent and sagging
toward said first mold part third surface region, and with said
large end adjacent and sagging toward said first mold part first
surface region.
6. The method accordance with claim 1 in which step (C) includes
extruding said melt through a generally oval shape exit
orifice.
7. A method for making an article of unitary construction having a
first portion, a second portion smaller than said first portion,
and a third portion that is larger than said second portion, said
method comprising the steps of: (A) providing a first mold part
having (1) a first surface region defining a first side of said
first portion, (2) a second surface region defining a first side of
said second portion, and (3) a third surface region defining a
first side of said third portion; (B) at a location spaced from
said first mold part, providing a second mold part having (1) a
first surface region defining a second side of said first portion,
(2) a second surface region defining a second side of said second
portion, and (3) a third surface region defining a second side of
said third portion; (C) creating from a melt of thermoplastic
material a billet having a predetermined shape; (D) positioning
said billet in a predetermined orientation with at least a portion
of said billet disposed adjacent said first mold part second
surface region; (E) decreasing the space between said first and
second mold parts to compress said billet so that said
thermoplastic material flows between said mold parts; and (F) after
said thermoplastic material has solidified to form an article,
increasing the space between said mold parts, and then removing
said article.
8. The method in accordance with claim 7 in which said step (D)
includes placing at least a portion of said billet against said
first mold part second surface region.
9. The method in accordance with claim 8 in which said step (A)
includes orienting said first mold part so that said first mold
part first, second, and third surface regions face generally away
from the direction of the earth's gravitational force; and said
step (D) includes positioning said billet directly on said first
mold part so that at least a portion of said billet is supported by
said first mold part second surface region.
10. The method in accordance with claim 7 in which step (C)
includes creating said billet to have a generally egg shape with a
large end and a small end.
11. The method in accordance with claim 10 in which step (D)
includes positioning said billet with said small end adjacent and
sagging toward said first mold part third surface region, and with
said large end adjacent and sagging toward said first mold part
first surface region.
12. The method accordance with claim 7 in which step (C) includes
extruding said melt through a generally oval shape exit
orifice.
13. A closure having a unitary construction of components which
includes a body, a lid, and a hinge connecting said body and lid,
said closure made by the method of comprising the steps of: (A)
providing a first mold part having (1) a first surface region
defining a first side of said body, (2) a second surface region
defining a first side of said hinge, and (3) a third surface region
defining a first side of said lid; (B) at a location spaced from
said first mold part, providing a second mold part having (1) a
first surface region defining a second side of said body, (2) a
second surface region defining a second side of said hinge, and (3)
a third surface region defining a second side of said lid; (C)
creating from a melt of thermoplastic material a billet having a
predetermined shape; (D) positioning said billet in a predetermined
orientation with at least a portion of said billet disposed
adjacent said first mold part second surface region; (E) decreasing
the space between said first and second mold parts to compress said
billet so that said thermoplastic material flows between said mold
parts; and (F) after said thermoplastic material has solidified to
form a closure, increasing the space between said mold parts, and
then removing said article.
14. An article of unitary construction which includes a first
portion, a second portion smaller than said first portion, and a
third portion that is larger than said second portion, said article
made by the method of comprising the steps of: (A) providing a
first mold part having (1) a first surface region defining a first
side of said first portion, (2) a second surface region defining a
first side of said second portion, and (3) a third surface region
defining a first side of said third portion; (B) at a location
spaced from said first mold part, providing a second mold part
having (1) a first surface region defining a second side of said
first portion, (2) a second surface region defining a second side
of said second portion, and (3) a third surface region defining a
second side of said third portion; (C) creating from a melt of
thermoplastic material a billet having a predetermined shape; (D)
positioning said billet in a predetermined orientation with at
least a portion of said billet disposed adjacent said first mold
part second surface region; (E) decreasing the space between said
first and second mold parts to compress said billet so that said
thermoplastic material flows between said mold parts; and (F) after
said thermoplastic material has solidified to form an article,
increasing the space between said mold parts, and then removing
said article.
15. A billet for compression molding comprising: a mass of
thermoplastic material having a shape with at least one large end
and a smaller region.
16. The billet in accordance with claim 15 in which said mass has a
generally egg shape.
17. The billet in accordance with claim 15 in which said smaller
region in an elongate portion and said one large end has a
generally bone end shape.
18. A billet made by the method comprising the following steps:
extruding a melt of thermoplastic material through an exit orifice
having a generally oval plan shape to form a predetermined mass of
extruded thermoplastic material extending beyond said orifice;
permitting said mass to bulge peripherally; and severing said mass
from said exit orifice to form an egg shape billet.
19. A method for making a billet comprising the steps of: extruding
a melt of thermoplastic material through an exit orifice having a
generally oval plan shape to form a predetermined mass of extruded
thermoplastic material extending beyond said orifice; permitting
said mass to bulge peripherally; and severing said mass from said
exit orifice to form an egg shaped billet.
20. A billet made by the method comprising the following steps:
extruding a melt of thermoplastic material through an exit orifice
having a plan shape with at least one large end and a smaller
region to form a predetermined mass of extruded thermoplastic
material extending beyond said orifice; permitting said mass to
bulge peripherally; and severing said mass from said exit orifice
to form an elongate billet.
21. A method for making a billet comprising the steps of: extruding
a melt of thermoplastic material through an exit orifice having a
plan shape with at least one large end and a smaller region to form
a predetermined mass of extruded thermoplastic material extending
beyond said orifice; permitting said mass to bulge peripherally;
and severing said mass from said exit orifice to form an elongate
billet.
Description
CROSS REFERENCE TO RELATED APPLICATION(S)
[0001] Not applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not applicable.
REFERENCE TO A MICROFICHE APPENDIX
[0003] Not applicable.
TECHNICAL FIELD
[0004] The present invention relates to a compression molded
article and to a compression molding process for making the
article. The process is especially suitable for making a dispensing
closure for a container wherein the closure includes a body, a lid
and a unitary connecting hinge.
BACKGROUND OF THE INVENTION AND TECHNICAL PROBLEMS POSED BY THE
PRIOR ART
[0005] There are two basic types of closures for small, hand-held,
squeezable or rigid containers of products such as lotions,
shampoos, fluent food products (e.g., ketchup, bottled water,
etc.), viscous food products (e.g., peanut butter), powders,
cleaning compositions, and the like.
[0006] One basic type of closure is a simple one-piece cap which
can be screwed on and off or which is held on the container with a
releasable snap-fit bead engagement.
[0007] The other basic type of closure is a "dispensing" closure,
and one form of such a dispensing closure is a hinged dispensing
closure which consists of (1) a body component designed to be
sealingly applied to a container neck or finish, (2) a lid
component, and (3) a hinge attaching the lid to the body so as to
permit the lid to be moved between an open position and a closed
position. The body component has a dispensing orifice or opening
which permits product to be squirted, poured, spooned, or otherwise
expelled, discharged, or dispensed from the container. The lid
component contains a seal member which, when the lid is in the
closed position, seals the body dispensing orifice to prevent
unwanted discharge of product from the container.
[0008] Hinged dispensing closures (as well as many other articles
of irregular or asymmetrical shapes which may have thin members
interconnecting two or more masses) are made of rigid or semi-rigid
thermoplastic resins such as polyethylene, polypropylene, and the
like, and have been present in the commercial market for a number
of years. Packages incorporating such dispensing closures are very
advantageous in providing convenience and aesthetic appeal in the
dispensing of products from containers. However, dispensing
closures have historically suffered from a cost disadvantage
compared to more simple non-dispensing closures owing to the
complexity of molding dispensing closures.
[0009] Hinged dispensing closures are typically or conventionally
injection molded either as a single, unitary structure having a
body, lid, and hinge or as separate body and lid components which
must be subsequently assembled to produce the final, assembled
closure in which the body and lid are hinged together. When a
dispensing closure is injection molded as a multiple piece assembly
(e.g., body piece and lid piece), a separate mold is required for
each of the component pieces. Even if the dispensing closure is
instead injection molded as a single, unitary component, the amount
of surface area or space occupied by the unitary component in the
mold is approximately twice that of a comparable mold for a simple
non-dispensing closure. Thus, the injection molding process for
such a dispensing closure typically requires approximately twice
the investment in injection molds, injection molding presses, and
other molding resource costs compared to the process for injection
molding a simple non-dispensing closure for the same container
finish. It would, therefore, be of significant commercial advantage
to a manufacturer to have an improved method by which the
manufacturer could produce, at a very high output rate and with
little or no waste, hinged dispensing closures for capital
investment costs and operating costs comparable to costs for
producing to non-dispensing closures.
[0010] The method of injection molding has long been used to
produce thermoplastic resin articles, and the method has been made
more efficient over time by the introduction of improved electronic
controls, hydraulic systems, etc. It has also been possible to
increase the productive output of the process by the introduction
of larger mold structures with an increased number of cavities
(i.e., "cavitation"). In addition, molds with multiple molding
surfaces (e.g., "stacked molds") are now in commercial use. Each of
these improvements has helped to increase the productive output of
a single molding machine, but not without size, weight, and
investment cost penalties. The cost, size, and weight of the larger
machines and molds increase disproportionately more with the
increase in size, cavitation, and complexity of the molds and
machines, while the rate of parts produced increases only in
generally direct proportion to the increased number of mold
cavities. In this regard, it can be seen that increases in the size
and weight of larger injection molding machines could approach a
practical limiting case of productive return for the required
financial and resource investment.
[0011] Another method of molding plastic articles, the
"compression" molding method, has existed for many years. In the
earliest practice, compression molding was used to make rigid
thermosetting resin plastic articles from resins such as phenol
formaldehyde, urea formaldehyde, and the like. More recently,
compression molding processes make semi-rigid plastic articles from
thermoplastic resin such as polyethylene, polypropylene, and the
like.
[0012] In the case of making thermosetting resin plastic articles
by the compression molding method, the uncured resin, usually in
granular or powder form, is charged into a heated mold cavity of a
mold cavity segment, and the mold is closed by bringing a mold core
segment against the cavity segment with great force to create high
pressure in the cavity. The resultant combination of heat and
pressure causes the resin material first to melt into a semi-solid
state to completely fill the mold volume between the core segment
and cavity segment, and subsequently to become rigid through
reactive chemical cross linking of the resin. After a sufficient
curing time, the molded article is removed from the mold and
allowed to cool to ambient temperature before further handling or
finishing.
[0013] Plastic articles made by the thermosetting resin compression
molding method are typically very durable and relatively heavy
owing to the physical properties of the resin. Owing to the flow
limitations of the resin during the molding step, such molded
articles are also typically limited in their final geometric
proportions, tending to be of symmetrically shaped cylindrical,
spherical, or rectangular solid configurations. In practice, the
resin cannot successfully be made to flow into a highly irregular
geometrical form.
[0014] In the case of making thermoplastic resin plastic articles
by conventional compression molding, a precisely measured
cylindrical charge of the heated, molten, thermoplastic resin is
created by operation of an extruder, metering pump, and cutting
knife, and the cylindrically shaped charge is dropped into a cooled
cavity of a mold. The mold is then closed by forcing a mold core
segment against the mold cavity segment. Upon closing the mold
segments, the pressurized molten plastic resin quickly fills the
volume between the core and cavity. After a brief cooling period,
the mold is opened, and the finished molded article is removed from
the mold, ready for immediate use. This method and products
produced by it are already well-known in commerce and are described
in various patents such as U.S. Pat. Nos. 4,343,754; 4,664,280;
4,674,643; 4,497,765; 5,650,113; and 5,658,518, and WO 01/34362 A1
(PCT/GB00/04175).
[0015] Compared to a commercial injection molding operation, the
cycle time needed between introduction of the molten plastic into a
commercial compression molding machine and removal of the finished
article is shorter. Heretofore, however, much like their
compression molded thermosetting counterparts, compression molded
thermoplastic articles, while accommodating faster production at
lower overall cost compared to their injection molded counterparts,
have been limited to symmetrically shaped, principally cylindrical,
configurations owing to the flow limitations of the molten
thermoplastic resin as the mold segments are moved into the closed
position to shape the resin into the desired article form. Because
of such geometric and flow constraints, it has not been possible
heretofore to cost effectively use a compression molding process to
produce articles of unusual shapes, such as hinged dispensing
closures, on a commercial scale.
[0016] As currently practiced in conventional commercial
applications, compression molding of a thermoplastic resin article
relies upon physically dropping a cylindrical shaped, measured
charge or pellet of molten resin in a relatively random position in
the mold cavity. In the case of a hinged dispensing closure which
has a body part and a lid part of unequal physical weights and
volumes, and which two parts are joined by a thin film hinge, the
inventors have discovered that it is not acceptable to rely on the
random placement of a symmetrical, cylindrically shaped resin
charge or pellet within the mold cavity. When the mold is closed to
compress such a pellet, it is not possible to reliably and
consistently cause the molten plastic resin to flow into all
regions of the void volume between the mold core and cavity before
solidification takes place.
BRIEF SUMMARY OF THE INVENTION
[0017] An improved system for controlling the shape and placement
of the resin charge within the mold cavity has been invented that
now makes possible the commercial production of irregularly shaped
articles, especially hinged dispensing closures, by a compression
molding process.
[0018] Instead of the traditional method of simply cutting off a
cylindrical pellet or billet of molten plastic extrudate and
dropping it freely into the mold cavity, the extrudate is given a
specific, non-cylindrical volume/shape profile in the form of a
billet or pellet having a particular configuration designed to
introduce the preferred amount of plastic across the various
regions of the mold, such as, for example, the body, hinge, and lid
regions of a dispensing closure. The precisely measured, and
uniquely shaped, extrudate, pellet, or billet is preferably sheared
from the face of the delivery tube, captured by a pick and place
device, and then placed precisely into the desired location of the
mold. Upon closing the mold to pressurize the billet or pellet, the
billet or pellet quickly flows as molten plastic directly to fill
the entire void volume between the preheated mold core segment and
mold cavity segment.
[0019] When using this compression molding method to mold hinged
dispensing closures, it is possible--with the appropriate design of
(1) the extrudate shape, (2) the billet cut off parameters, and (3)
the billet placement across the mold surface--to accurately and
properly distribute the molding resin so as to completely fill all
regions of the molded part at very high speeds, with no wasted
material, and in a substantially stress-free or low stress
condition. This process therefore provides the advantage of
producing such dispensing closures at a significant overall cost
advantage compared to the currently used injection molding
method.
[0020] According to one aspect of the invention, a method is
provided for making a closure having a body, a lid, and a hinge
connecting the body and lid. The method comprises the following
steps:
[0021] (A) providing a first mold part having (1) a first surface
region defining a first side of the body, (2) a second surface
region defining a first side of the hinge, and (3) a third surface
region defining a first side of the lid;
[0022] (B) at a location spaced from the first mold part, providing
a second mold part having (1) a first surface region defining a
second side of the body, (2) a second surface region defining a
second side of the hinge, and (3) a third surface region defining a
second side of the lid;
[0023] (C) creating from a melt of thermoplastic material a billet
(e.g., pellet, mass, etc.) having a predetermined shape;
[0024] (D) positioning the billet in a predetermined orientation
with at least a portion of the billet disposed adjacent the first
mold part second surface region;
[0025] (E) decreasing the space between the first and second mold
parts to compress the billet so that the thermoplastic material
flows between the mold parts; and
[0026] (F) after the thermoplastic material has solidified to form
a closure, increasing the space between the mold parts, and then
removing the closure.
[0027] According to a more general aspect of the invention, a
method is provided for making an article of unitary construction
having a first portion, a second portion smaller than the first
portion, and a third portion that is larger than the second
portion. The method comprises the following steps:
[0028] (A) providing a first mold part having (1) a first surface
region defining a first side of the first portion, (2) a second
surface region defining a first side of the second portion, and (3)
a third surface region defining a first side of the third
portion;
[0029] (B) at a location spaced from the first mold part, providing
a second mold part having (1) a first surface region defining a
second side of the first portion, (2) a second surface region
defining a second side of the second portion, and (3) a third
surface region defining a second side of the third portion;
[0030] (C) creating from a melt of thermoplastic material a billet
having a predetermined shape;
[0031] (D) positioning the billet in a predetermined orientation
with at least a portion of the billet disposed adjacent the first
mold part second surface region;
[0032] (E) decreasing the space between the first and second mold
parts to compress the billet so that the thermoplastic material
flows between the mold parts; and
[0033] (F) after the thermoplastic material has solidified to form
an article, increasing the space between the mold parts, and then
removing the article.
[0034] According to yet another aspect of the invention, a closure
is provided with a unitary construction of components which
includes a body, a lid, and a hinge connecting the body and lid.
The closure is made by the method comprising the following
steps:
[0035] (A) providing a first mold part having (1) a first surface
region defining a first side of the body, (2) a second surface
region defining a first side of the hinge, and (3) a third surface
region defining a first side of the lid;
[0036] (B) at a location spaced from the first mold part, providing
a second mold part having (1) a first surface region defining a
second side of the body, (2) a second surface region defining a
second side of the hinge, and (3) a third surface region defining a
second side of the lid;
[0037] (C) creating from a melt of thermoplastic material a billet
having a predetermined shape;
[0038] (D) positioning the billet in a predetermined orientation
with at least a portion of the billet disposed adjacent the first
mold part second surface region;
[0039] (E) decreasing the space between the first and second mold
parts to compress said billet so that the thermoplastic material
flows between the mold parts; and
[0040] (F) after the thermoplastic material has solidified to form
a closure, increasing the space between the mold parts, and then
removing the article.
[0041] According to a more general aspect of the invention, an
article of unitary construction is provided with a first portion, a
second portion smaller than the first portion, and a third portion
that is larger than the second portion. The second portion extends
between, and connects, the first and third portions. The article is
made by the method comprising the following steps:
[0042] (A) providing a first mold part having (1) a first surface
region defining a first side of the first portion, (2) a second
surface region defining a first side of the second portion, and (3)
a third surface region defining a first side of the third
portion;
[0043] (B) at a location spaced from the first mold part, providing
a second mold part having (1) a first surface region defining a
second side of the first portion, (2) a second surface region
defining a second side of the second portion, and (3) a third
surface region defining a second side of the third portion;
[0044] (C) creating from a melt of thermoplastic material a billet
having a predetermined shape;
[0045] (D) positioning the billet in a predetermined orientation
with at least a portion of the billet disposed adjacent the first
mold part second surface region;
[0046] (E) decreasing the space between the first and second mold
parts to compress the billet so that said thermoplastic material
flows between the mold parts; and
[0047] (F) after the thermoplastic material has solidified to form
an article, increasing the space between the mold parts, and then
removing the article.
[0048] According to yet another aspect of the invention, a billet
(e.g., pellet) is provided for compression molding. The billet is a
mass of thermoplastic material having a shape with at least one
large end and a smaller region. In one form of the billet for a
closure molding application, the billet has a generally egg-like
shape.
[0049] The billet can be characterized as a product made by the
process comprising the following steps:
[0050] (A) extruding a melt of thermoplastic material through an
exit orifice having a plan shape with at least one large end and a
smaller region (e.g., an irregular, non-symmetric shape, such as a
generally oval plan shape) to form a predetermined mass of extruded
thermoplastic material extending beyond the orifice;
[0051] (B) permitting the mass to swell or bulge peripherally;
and
[0052] (C) severing the mass from the exit orifice to form an
elongate billet (e.g., an egg shaped billet).
[0053] According to the invention, a billet can be made by a method
per se comprising the following steps:
[0054] (A) extruding a melt of thermoplastic material through an
exit orifice having a plan shape with at least one large end and a
smaller region (e.g., an irregular, non-symmetric shape, such as a
generally oval plan shape) to form a predetermined mass of extruded
thermoplastic material extending beyond the orifice;
[0055] (B) permitting the mass to swell or bulge peripherally;
and
[0056] (C) severing the mass from the exit orifice to form an
elongate billet (e.g., an egg shaped billet).
[0057] It may be readily seen that thermoplastic dispensing
closures, or other types of products having irregular and/or
asymmetrical shapes, may also be effectively produced by the method
of the present invention.
[0058] Numerous other advantages and features of the present
invention will become readily apparent from the following detailed
description of the invention, from the claims, and from the
accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0059] In the accompanying drawings that form part of the
specification, and in which like numerals are employed to designate
like parts throughout the same,
[0060] FIG. 1 is a perspective view of an embodiment of an article
according to the present invention, which article has the form of a
dispensing closure molded according to one form of the process of
the present invention, and FIG. 1 shows the closure with the lid
open in the as-molded condition prior to closing the lid and
mounting the closure on a container (not illustrated);
[0061] FIG. 2 is a top plan view of the closure;
[0062] FIG. 3 is a cross-sectional view taken generally along the
plane 3-3 in FIG. 2;
[0063] FIG. 4 is a perspective view of a pellet or billet formed
from a melt of thermoplastic material for use in one form of the
process of the present invention to compression mold the closure
illustrated in FIGS. 1-3;
[0064] FIG. 5 is a top plan view of the billet shown in FIG. 4;
[0065] FIG. 6 is a plan view of the exit orifice plate on the
discharge side of a gear pump on an extruder, which exit orifice is
employed in the creation of the billet illustrated in FIGS. 4 and
5;
[0066] FIG. 7 is a simplified, diagrammatic, perspective view of
the billet being formed during discharge of thermoplastic material
from the exit orifice in the gear pump plate;
[0067] FIG. 8 is a simplified, diagrammatic, cross-sectional view
taken generally along the plane 8-8 in FIG. 7;
[0068] FIG. 9 is a simplified, diagrammatic, perspective view
showing a removal device beginning to remove the billet from the
exit orifice of the gear pump;
[0069] FIG. 10 is a simplified, diagrammatic, cross-sectional view
taken generally along the plane 10-10 in FIG. 9;
[0070] FIG. 11 is a simplified, partially diagrammatic, top
perspective view of a first (lower) mold part employed in a mold
assembly for compression molding the closure illustrated in FIGS.
1-3, and FIG. 11 further shows the billet having been oriented and
positioned with respect to the surfaces of the first mold part;
[0071] FIG. 12 is a top plan view of the mold apparatus illustrated
in FIG. 11;
[0072] FIG. 13 is a simplified, diagrammatic, cross-sectional view
of the first (lower) mold part together with a second (upper) mold
part in a mold assembly in a closed condition compressing the
billet so that the thermoplastic material fills the void volume
between the mold parts;
[0073] FIG. 14 is a simplified, diagrammatic, perspective view of
another embodiment of an article which can be compression molded
according to the principles of the present invention, and the
article is a box with a body and lid connected by a thin hinge
extending between the body and the lid;
[0074] FIG. 15 is a simplified, diagrammatic, perspective view of a
first (lower) mold part that can be employed in a mold assembly
with a second (upper) mold part (not illustrated) for compression
molding the article illustrated in FIG. 14, and FIG. 15 further
shows a pellet or billet of thermoplastic material oriented and
positioned with respect to the first mold part;
[0075] FIG. 16 is a plan view of the mold part and billet
illustrated in FIG. 15; and
[0076] FIG. 17 is a cross-sectional view taken generally along the
plane 1717 in FIG. 16.
DETAILED DESCRIPTION
[0077] While this invention is susceptible of embodiment in many
different forms, this specification and the accompanying drawings
disclose only some specific forms as examples of the invention. The
invention is not intended to be limited to the embodiments so
described, however. The scope of the invention is pointed out in
the appended claims.
[0078] For ease of description, most of the figures illustrating
the process and article aspects of the present invention show
articles and components in the typical orientations, and terms such
as upper, lower, horizontal, etc., are used with reference to this
position. It will be understood, however, that the processes of
this invention may be effected in other orientations, and that the
articles of this invention may be manufactured, stored,
transported, used, and sold in orientations other than those
described.
[0079] One embodiment of an article of the present invention, in
the form of a dispensing closure compression molded according to
the process of the present invention, is suitable for use with a
variety of conventional or special containers having various
designs, the details of which, although not illustrated or
described, would be apparent to those having skill in the art and
an understanding of such containers.
[0080] One embodiment of an article of the present invention in the
form of a dispensing closure is illustrated in FIGS. 1-3 and is
designated generally therein by reference number 20 in FIG. 1. The
dispensing closure 20, which is hereinafter sometimes referred to
more simply as the "closure 20," is, in the illustrated embodiment,
provided as a separately manufactured unit or subassembly for
mounting to the top of a container (not shown in FIG. 1).
[0081] The container typically has a conventional mouth or opening
which provides access to the container interior and product
contained therein. The product may be, for example, a beverage such
as water, or other liquid comestible product. The product could
also be any other fluent material, including, but not limited to,
gases, powders, particles, and liquids (including creams, lotions,
slurries, pastes, etc.). Such materials may be sold, for example,
as a food product, a personal care product, an industrial or
household product, or other composition (e.g., for internal or
external use by humans or animals, or for use in activities
involving medicine, manufacturing, commercial or household
maintenance, construction, agriculture, etc.).
[0082] The container may typically have a neck or other suitable
structure defining the container mouth. The neck may have (but need
not have) a circular cross-sectional configuration, and the body of
the container may have another cross-sectional configuration, such
as an oval cross-sectional shape, for example. The container may,
on the other hand, have a substantially uniform shape along its
entire length or height without any neck portion of reduced size or
different cross-section.
[0083] The container may typically be a squeezable container having
a flexible wall or walls which can be grasped by the user and
compressed to increase the internal pressure within the container
so as to squeeze the product out of the container through the
closure 20 when the closure 20 is open. Such a container wall
typically has sufficient, inherent resiliency so that when the
squeezing forces are removed, the container wall returns to its
normal, unstressed shape. Such a structure is preferred in many
applications, but may not be necessary or preferred in other
applications. Indeed, the container may be substantially rigid. A
piston could be provided in such a rigid container to aid in
dispensing a product, especially a relatively viscous product. On
the other hand, the interior of the container need not be
pressurized at all. Instead, the product would be accessed by
reaching through the open closure with a spoon or straw, or the
package could be inverted to let the product discharge through the
open closure solely under the influence of gravity and/or under the
influence of a reduced ambient pressure exterior of the container
(e.g., as by sucking on the open closure 20).
[0084] As can be seen in FIG. 1, the closure 20 includes a body 22,
a lid 24, and a hinge 26 extending between, and connecting, the
body 22 and lid 24. The closure 20 is compression molded, as
described in detail hereinafter, to create a unitary structure,
which, in the as-molded condition, has the lid 24 in a fully opened
orientation as illustrated in FIG. 1.
[0085] The closure body 22 has a generally hollow, generally
cylindrical base or skirt 28, an annular shoulder 30 extending
radially inwardly from the top of the skirt 28, a raised deck 32,
and a reduced diameter spout 34 extending upwardly from the deck 32
to define a dispensing aperture 36.
[0086] As can be seen in FIG. 3, the interior of the skirt 28
defines internal protrusions or snap beads 38. The skirt 28 is
adapted to receive the upper end of a container mouth or neck (not
illustrated). The skirt beads 38 are adapted to matingly engage a
bead or groove on the container mouth or neck.
[0087] Alternatively, the closure skirt 28 could be provided with
some other container connecting means, such as a groove (not
illustrated) or thread (not illustrated) in place of the beads 38
for engaging a mating bead (not illustrated) or thread (not
illustrated), respectively, in the container neck (not
illustrated). In another alternative (not illustrated), the closure
body skirt 28 could have a different configuration so that, after
it is compression molded, the closure could be permanently fixed to
a container by means of induction melting, ultrasonic melting,
gluing, or the like, depending on the materials used for the
container and closure body 22.
[0088] As shown in FIG. 3, the closure body 22 includes an annular
plug seal 39 projecting downwardly from the closure body deck 32.
The plug seal 39 is adapted to enter into the opening of the
container neck and form a seal relative thereto against the
interior surface of the container neck. Other forms of a seal could
be employed instead.
[0089] The closure body 22 may also include an annular wall 40 for
engaging a retainer (not illustrated) to hold a resilient,
slit-type valve (not illustrated) adjacent the dispensing aperture
36. Such valves are disclosed in the U.S. Pat. No. 5,676,289. Such
a valve, and a suitable retainer for holding the valve within the
closure body, form no part of the present invention. Such a valve
need not be employed at all with the closure, and the closure may
merely have a dispensing orifice 36, of any suitable size for the
particular dispensing application, communicating directly with the
container on which the closure 20 is mounted.
[0090] As illustrated in FIG. 1, the front of the closure body
skirt 28 preferably defines an indentation or thumb lift region 42,
accommodating placement of the user's thumb for pushing upwardly to
pry open the lid 24. The lid 24 is held in the closed configuration
(not illustrated) by engagement with a lip 44 (FIG. 3) extending
outwardly from the closure body deck 32. The lid 24 includes a
flange 46 having an inwardly projecting rib 48 (FIG. 3) for
engaging the closure body lip 44 when the lid 24 is closed.
[0091] The lid 24 includes a top wall 50 extending across the
flange 46 and from which projects an annular sealing collar 52 as
shown in FIG. 3. When the lid 24 is closed, the collar 52 sealingly
engages the periphery of the closure body spout 34.
[0092] The closure body lid flange 46 also includes an undercut
front region 56 defining an adjacent, outward projection 58 which
can be engaged by the user's thumb to push the closed lid 24
upwardly away from the closure body 22 to an open position.
[0093] The closure hinge 26, as illustrated in FIG. 3, is typically
a relatively thin portion of material formed as a unitary part of
the closure 20 during the compression molding process. A variety of
hinge designs may typically be employed. One hinge that has
desirable operating characteristics is a bi-stable, snap-action
hinge as illustrated in FIGS. 1-3 and as disclosed in detail in
U.S. Pat. No. 5,642,824. Other kinds of hinge structures may be
employed, such as a floppy hinge or tether hinge.
[0094] Because the hinge 26 is typically relatively thin compared
to the adjacent body 22 and adjacent lid 24, molding of the closure
from thermoplastic materials can be difficult. As described above
in the section entitled "BACKGROUND OF THE INVENTION AND TECHNICAL
PROBLEMS POSED BY THE PRIOR ART," molding difficulties can arise
owing to flow limitations of the thermoplastic material in the mold
cavity. Further, with prior art molding processes, substantial
stresses may undesirably be molded into portions of the closure.
However, according to a process aspect of the present invention,
the above-described closure 20, as well as other closures and
articles, can be effectively molded in an improved manner in a way
that substantially minimizes, if not eliminates, such problems in a
cost effective way.
[0095] The closure 20 can be compression molded from a billet that
is specially shaped and positioned in a particular orientation
within a compression molding apparatus or mold assembly. FIG. 4
shows one form of a specially shaped billet designated generally by
the reference number 60. The billet 60, in the preferred form for
molding the particular closure 20 illustrated in FIGS. 1-3, is a
mass of thermoplastic material having a shape with at least one
large end 62 and a smaller region, such as a small end 64. The
particular billet 60 has an irregular, non-symmetric shape, which
in the preferred form illustrated in FIG. 4, is a generally egg
shape. The billet 60 may be formed from a thermoplastic resin, such
as polyethylene, polypropylene, and the like.
[0096] As shown in FIG. 5, the billet 60, when viewed in elevation
or plan, has a generally elongate profile, and more particularly,
has a generally oval profile, although a central region 66 may have
a somewhat frustoconical shape.
[0097] In a preferred form of one aspect of the process of the
present invention, the billet 60 is produced from a thermoplastic
melt delivered by an extruder to a metering pump that precisely
meters the melt to a die plate, such as die plate 70 shown in FIG.
6. The die plate 70 defines an exit orifice 72 which, in plan view,
has a generally egg shape (i.e., a shape like the lengthwise cross
section of an egg) or generally oval shape, albeit with an
intermediate, substantially straight-sided converging portion 74.
In FIG. 6, the extruder and metering pump beneath the orifice plate
70 are not visible.
[0098] The terms "generally egg shape" and "generally oval shape,"
as applied to the profile of the billet 60 and as applied to the
profile of the orifice 72 and as used in this patent application,
contemplate irregular, nonsymmetrical shapes that can also have
regions with generally straight portions extending between curved
portions.
[0099] FIG. 7 illustrates the melt or molten thermoplastic material
inside the orifice plate 70 being extruded out of the exit orifice
72. The extrudate emerging from the exit orifice 72 is designated
generally by the reference number 78 in FIG. 7. As can be seen in
FIGS. 7 and 8, the mass of extruded material 78 is permitted to
swell or bulge peripherally beyond the opening of the orifice
72.
[0100] As shown in FIGS. 9 and 10, the mass of extruded
thermoplastic material 78 is severed from the remaining portion of
material within the orifice 72 by a pick and place severing device
which includes a lower cutting blade 82 (FIG. 10) that sweeps
across the face of the orifice plate 70.
[0101] The detailed design and operation of the pick and place
severing device 80 may be of any suitable conventional or special
design, the details of which form no part of the present invention.
Indeed, the extruded thermoplastic material 78 extending beyond the
orifice 72 may be severed from the orifice 72 by other
instrumentalities or even manually with a suitable knife or
blade.
[0102] The pick and place severing device 80 is able to lightly
engage end portions of the extruded thermoplastic material and move
the extruded thermoplastic material away from the exit plate 70 to
a predetermined location at a mold part. As the extruded material
78 is moved away from the orifice plate 70, the bottom of the
extruded material is free to bulge peripherally downwardly to form
a generally downwardly exposed oval or egg shaped surface. As the
extruded thermoplastic material 78 is severed and moved away from
the orifice plate 70, it may be characterized as a pellet or billet
having the desired shape, in this case a generally egg shape, shown
in FIG. 4 and designated by the reference number 60 as previously
described above.
[0103] The billet 60 is moved, by the pick and place severing
device 80, or by other means (e.g., even by hand), to a
predetermined location adjacent a mold part, and the billet 60 is
positioned in a predetermined orientation with respect to such a
mold part. FIG. 11 shows a first mold part 90 in a simplified,
diagrammatic view. The first mold part 90 has a first surface
region 91 defining a first side of the closure body 22 (FIG. 1). In
FIG. 11, the first surface region 91 is shown in a greatly
simplified fashion without illustrating all of the various
individual surfaces, protrusions, grooves, indentations, etc., that
are required to define the first side of the closure body 22.
[0104] The first mold part 90 also includes a second surface region
92 defining a first side of the closure hinge 26 (FIG. 1).
[0105] The first mold part 90 also includes a third surface region
93 defining a first side of the closure lid 24 (FIG. 1). The first
mold part third surface region 93 is illustrated in FIG. 11 in
greatly simplified form, and does not necessarily reveal all
surfaces, indentations, grooves, apertures, etc., necessary for
completely defining the first side of the lid.
[0106] The mold assembly includes a second mold part 100 which is
shown in FIG. 13 in a closed condition, but which is not shown in
FIG. 11. The second mold part 100 is initially spaced away from the
first mold part 90 to accommodate positioning of the billet 60. As
shown in FIG. 13, the second mold part 100 has a first surface
region 101 defining a second side of the closure body, a second
surface region 102 defining a second side of the hinge, and a third
surface region 103 defining a second side of the lid.
[0107] With the first mold part 90 and the second mold part 100
initially spaced apart, the billet 60 can be positioned (as shown
in FIG. 11) in a predetermined orientation with at least a portion
of the billet 60 disposed adjacent the first mold part second
surface region 92. In one presently preferred embodiment of the
process, the billet 60 can be actually placed on the second surface
region defining the first side of the hinge 92 so that the larger
end is adjacent, or extends into, the closure body first surface
region 91 of the first mold part, and so that the smaller end of
the billet 60 is adjacent, or extends into or over, the third
surface region 93 that defines the first side of the lid. If the
first mold part 90 is oriented so that the first, second, and third
surface regions of the first mold part 90 face generally upwardly
away from the direction of the earth's gravitational force, then
the billet 60 can sag somewhat on the second surface region 92 as
the two ends of the billet 60 are pulled downwardly under the
influence of gravity.
[0108] After the billet 60 has been placed at the appropriate
location and in the appropriate orientation with respect to the
first mold part 90, the space between first mold part 90 and second
mold part 100 is decreased to compress the billet so that the
thermoplastic material flows between the mold parts as illustrated
in FIG. 13. Either or both of the first and second mold parts could
be moved toward the other. Such movement of the first and second
mold parts should be understood as decreasing the distance between
opposing surfaces of the two mold parts to desired predetermined
spacings, and such movement can be effected by moving only the
first mold part, or only the second mold part, or alternatively,
both mold parts.
[0109] When the mold parts close, to the position illustrated in
FIG. 13, a predetermined spatial configuration or volume exists
between the mold parts 90 and 100 to define the void volume
corresponding to the molded closure 20 (as shown molded in FIG. 1).
The molten plastic of the billet 60 quickly flows directly to fill
such void volume within the mold. Owing to the orientation and
positioning of the billet 60 (as shown in FIG. 11), the molten
thermoplastic material is evenly distributed and flows rapidly to
fill all regions of the closure, with no wasted material, and in a
substantially stress-free condition.
[0110] With respect to FIG. 11, it will be appreciated that the
larger mass closure body region of the closure requires more
thermoplastic material, and thus the billet 60 is oriented with the
larger end of the billet projecting into the closure body region of
the first mold part 90 (and into the corresponding region of the
second mold part 100 when the second mold part 100 is subsequently
closed). Conversely, as can be seen in FIG. 11, the volume of the
closure lid cavity defined by the mold surface region 93 is less.
Less thermoplastic material is required for the lid region. Thus,
the billet 60 is oriented so that its smaller end is adjacent the
first mold part lid region mold surface region 93 (and adjacent the
second mold part lid molding surface when the second mold part 100
is subsequently closed).
[0111] Further, it will be appreciated with reference to FIG. 13
that the hinge region between the closure body and closure lid
portions of the mold cavity is relatively thin or small compared to
the closure body and closure lid portions. The hinge portion is
smaller than the body portion, and the lid portion is larger than
the hinge portion. The hinge portion of the mold cavity, when the
first mold part 90 and second mold 100 are closed, presents a very
small flow region and tends to restrict the flow of a thermoplastic
material. According to the present invention, the billet 60 is
positioned adjacent the hinge area of the mold parts so that the
thermoplastic material needs only a slight amount of lateral flow
to completely fill the relatively thin hinge region of the mold
cavity. This assures that the hinge region will be quickly and
completely filled with the necessary amount of thermoplastic
material.
[0112] Placement of the billet 60 so that opposite end portions of
the billet are each positioned adjacent the body mold cavity
portion and lid mold cavity portion, respectively, accommodates the
flow of the thermoplastic material from the billet end portions
directly throughout the respective body and lid portions of the
cavity without requiring flow of thermoplastic material from the
body cavity region through the thin hinge cavity region to the lid
cavity region, or vice versa.
[0113] After the thermoplastic material has solidified to form the
closure, the space between the mold parts is increased, and the
molded closure is removed.
[0114] An alternate embodiment of an article that can be
compression molded according to the teachings of the present
invention is illustrated in FIGS. 14-17 and is designated therein
generally by the reference number 20A. As can be seen in FIG. 14,
the article 20A is a relatively simple container having a body 22A,
a lid 24A, and a hinge 26A which extends between, and connects, the
body 22A and lid 24A. Compared to the body 22A and lid 24A, the
hinge 26A is relatively thin and contains much less thermoplastic
material.
[0115] As illustrated in FIG. 15, the first mold part 90A includes
a first surface region 91A defining a first side of the container
body, a second surface region 92A defining a first side of the
hinge 26A, and a third surface region 93A defining a first side of
the lid 24A.
[0116] FIG. 15 further illustrates a lower or first mold part 90A
for cooperating with an upper or second mold part (not illustrated)
to form the container 20A in the molded open position illustrated
in FIG. 14. FIG. 15 also shows thermoplastic material, in the form
of a billet 60A, having a predetermined shape and located at a
predetermined position in a predetermined orientation relative to
the first mold part 90A. In the preferred embodiment illustrated,
the billet 60A is placed against, and is initially supported by,
the second surface region 92A of the first mold part 90A.
[0117] The billet 60B is preferably formed in a manner analogous to
the method for forming the billet 60 described above. In
particular, the billet 60A is extruded from a melt of thermoplastic
material from an extruder and is fed by a metering pump through an
orifice defined in a plate. The orifice has a plan shape or
configuration which is the same as the plan view shape of the
billet 60A as viewed in FIG. 16. However, the orifice has somewhat
smaller dimensions than the billet 60A, and the billet 60A is
formed by a swelling or bulging of the thermoplastic material on
the discharge side of the orifice.
[0118] The billet 60A can be cut from the extruded melt at the
discharge plane of the orifice with a suitable knife by hand or by
an appropriate apparatus, such as the apparatus disclosed above
with respect to severing the billet 60 as illustrated in FIGS. 9
and 10. Such an apparatus may include a pick and place feature for
holding and transferring the severed billet 60A to the appropriate
location adjacent a mold part and for orienting the billet 60A in a
predetermined orientation relative to the mold part. The removal
and placement of the billet 60A may be an entirely manual process
or may be automated with appropriate devices. The particular method
and/or devices employed for removing and placing the billet form no
part of the present invention.
[0119] As can be seen in the plan view of FIG. 16, the billet 60A
has one large end 62A and a reduced width extending portion 63A.
The reduced width extending portion 63A has a reduced width portion
65A and a slightly enlarged end portion 67A. The large end 62A has
a generally dog bone end shape.
[0120] The billet 60A is oriented so that the larger, dog bone end
shape 62A extends into the larger body cavity of the mold parts.
The reduced width region 65A is oriented over the narrow and thin
hinge region 92A. At the other end of the billet 60A, the end
portion 67A extends over the smaller volume lid region of the mold
part.
[0121] As shown in FIG. 17, when the first mold part 90A is
oriented horizontally as a lower or bottom mold part and the billet
60A is placed on the first mold part second surface region 92A, the
billet 60A may sag downwardly somewhat so that the billet ends 62A
and 67A sag somewhat into the regions of the mold cavity defined by
the lower mold part 90A.
[0122] After the billet 60A is properly located at a predetermined
position and orientation with respect to the first mold part 90A,
the billet 60A is compressed between the first mold part 90A and a
second mold part (not illustrated). The second mold part has a
first surface region defining a second side of the body, a second
surface region defining a second side of the hinge, and a third
surface region defining a second side of the lid. The billet
compression step may be effected by moving the two mold parts
together to decrease the distance between the two mold parts. The
process could maintain the lower, first mold part stationary, while
moving only the upper, second mold part toward the stationary first
mold part. Alternatively, the process could maintain the upper mold
part stationary while moving the lower, first mold part toward the
stationary upper mold part. Also, each of the lower and upper mold
parts could be simultaneously moved toward each other.
[0123] Owing to the shape of the billet 60A and owing to the
orientation of the billet 60A with respect to the mold parts, the
billet larger end 62A is positioned adjacent the larger body mold
cavity which is defined in part by the first mold surface region
91A. Thus, the article body which requires the most volume of
thermoplastic material can be compression molded mostly from the
adjacent larger mass of thermoplastic material in the billet large
end 62A.
[0124] The thin hinge region 92A does not require as much
thermoplastic material, and thus the billet reduced width portion
65A (FIG. 16) is located adjacent the hinge region defined by the
first mold part surface 92A. Because the smaller billet portion 65A
is located right at the hinge region, the thermoplastic material
does not have to flow very far to fully and completely occupy the
mold cavity region defining the hinge.
[0125] The lid, which requires more thermoplastic material than the
hinge portion but less thermoplastic material than the body, is
completely filled during the compression molding step with
thermoplastic material primarily from the billet end 67A which is
adjacent the lid mold surface region 93A. Very little, or no,
thermoplastic material needs to flow during the compression molding
step through the hinge region from either the lid region to the
body region, or from the body region to the lid region. The molten
plastic from the different portions of the compressed billet 60A
can quickly flow directly to the surrounding regions of the mold
cavity so as to properly distribute the thermoplastic material to
completely fill in all the void volume within the mold regions with
no wasted material and in a substantially stress-free
condition.
[0126] After the thermoplastic material has solidified to form the
article 20A, the space between the mold parts is increased, and the
article is removed.
[0127] The process for molding the article 20A, as well as the
closure 20, as described above, can be effected at relatively high
speeds with a significant overall cost advantage compared to
currently used injection molding methods.
[0128] The process of the present invention is readily adapted for
use in molding articles, including thermoplastic dispensing
closures, that have regular or irregular shapes, and that have
symmetrical or asymmetrical shapes.
[0129] It will be appreciated that the formation of a billet from
an extrusion of thermoplastic material may occur in other
orientations than descried above with respect to billets 60 and
60A. For example, the billet may be formed horizontally, or
downwardly, instead of generally upwardly (with respect to the
force of gravity as illustrated in the accompanying figures
illustrating the formation of the billets 60 and 60A).
[0130] It will also be appreciated that the mold parts need not be
oriented generally horizontally for vertical movement. Instead, the
parting plane of the mold parts could be oriented at an angle, or
even vertically, so long as an appropriate system is employed for
(1) positioning the billet at the predetermined location and
orientation relative to the mold parts, and (2) maintaining that
position until the mold parts are closed.
[0131] The present invention may be employed to provide a variety
of compression molded articles of the general type having a small
or thin region connecting two larger regions, where the flow of
thermoplastic material must be controlled and accommodated so as to
effectively and properly fill all of the void space in the mold
cavity and in a way that results in a substantially stress-free
molded article.
[0132] It will be readily apparent from the foregoing detailed
description of the invention and from the illustrations thereof
that numerous variations and modifications may be effected without
departing from the true spirit and scope of the novel concepts or
principles of this invention.
* * * * *