U.S. patent application number 12/637086 was filed with the patent office on 2010-07-29 for take out and cooling system and method.
This patent application is currently assigned to Graham Packaging PET Technologies, Inc.. Invention is credited to Peter A. Bates, Thomas M. Ingraham, Frank W. Mahr, Nikhil Mani, Thomas E. Nahill, Terry C. Potter.
Application Number | 20100187720 12/637086 |
Document ID | / |
Family ID | 34968709 |
Filed Date | 2010-07-29 |
United States Patent
Application |
20100187720 |
Kind Code |
A1 |
Bates; Peter A. ; et
al. |
July 29, 2010 |
TAKE OUT AND COOLING SYSTEM AND METHOD
Abstract
A take-out and cooling method and apparatus conveys molded
plastic articles from a molding machine to and through a cooling
station and preferably includes a take-out apparatus that has a
main support, a conveyor carried by the main support for movement
in an endless path, a cam adjacent to the support, a plurality of
arms carried by the conveyor for movement with the conveyor along
the endless path and including a follower responsive to the contour
of the cam to vary the position of the arms relative to the
support, and at least one holder carried by each arm. Each holder
is adapted to receive and carry at least one molded article to
facilitate in conveying the molded articles and is flexible and
resilient to permit relative movement of at least a portion of the
holder relative to its associated arm.
Inventors: |
Bates; Peter A.;
(Perrysburg, OH) ; Ingraham; Thomas M.; (Fort
Collis, CO) ; Mahr; Frank W.; (Toledo, OH) ;
Mani; Nikhil; (Billerica, MA) ; Nahill; Thomas
E.; (Amherst, NH) ; Potter; Terry C.;
(Lambertville, MI) |
Correspondence
Address: |
RISSMAN HENDRICKS & OLIVERIO, LLP
100 Cambridge Street, Suite 2101
BOSTON
MA
02114
US
|
Assignee: |
Graham Packaging PET Technologies,
Inc.
York
PA
|
Family ID: |
34968709 |
Appl. No.: |
12/637086 |
Filed: |
December 14, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
10841771 |
May 7, 2004 |
7632089 |
|
|
12637086 |
|
|
|
|
Current U.S.
Class: |
264/237 ;
425/526; 425/537 |
Current CPC
Class: |
B29K 2105/253 20130101;
B29C 2035/1658 20130101; B29C 2043/3288 20130101; Y10S 425/813
20130101; B29C 2043/3472 20130101; B29C 43/34 20130101; B29K
2067/00 20130101; B29C 2043/3689 20130101; B29C 43/50 20130101;
B29C 49/06 20130101; B29C 43/08 20130101; B29C 49/6427 20130101;
B29C 43/52 20130101; B29C 49/4205 20130101; B29C 2043/5061
20130101 |
Class at
Publication: |
264/237 ;
425/526; 425/537 |
International
Class: |
B29C 71/00 20060101
B29C071/00; B29C 49/64 20060101 B29C049/64; B29C 49/70 20060101
B29C049/70 |
Claims
1-34. (canceled)
35. A molded article cooling system, including: a transfer
mechanism that receives a plurality of molded articles and conveys
them along a path from an infeed section to an outfeed section; a
cooling mechanism extending along said path and having an elongate
fluid outlet through which fluid is directed toward said plurality
of molded articles, the fluid outlet being substantially continuous
along at least a portion of said path so that a substantially
continuous stream of fluid is directed toward said molded
articles.
36-61. (canceled)
62. A system for removing molded articles from a molding machine
and cooling the molded articles, the system including: a takeout
apparatus having a plurality of arms adapted to receive molded
articles from the molding machine and to convey molded articles
from the molding machine, the arms being driven in an endless path
to transfer molded articles from the molding machine; an
intermediate conveyor having an infeed section adjacent to at least
a portion of the takeout apparatus to receive molded articles from
the takeout apparatus and convey molded articles away from the
takeout apparatus and an outfeed section from which molded articles
leave the intermediate conveyor; a cooling station through which
the molded articles pass and including at least one fluid outlet
through which a fluid is directed toward the molded articles to
cool them; and a cooling conveyor having an infeed section adjacent
to the outfeed section of the intermediate conveyor to receive
molded articles from the intermediate conveyor and an outfeed
section from which molded articles are removed from the cooling
station.
63-78. (canceled)
79. A method of cooling a molded article, including the steps of:
(a) conveying molded articles along a path; and (b) directing an
elongate stream of coolant onto the molded articles as they are
conveyed along said path, the elongate stream being continuous
along at least a major portion of said path.
80-108. (canceled)
Description
FIELD OF THE INVENTION
[0001] This invention relates generally to molding plastic
articles, and more particularly to an apparatus and a method for
conveying molded articles from a molding machine to and through a
cooling station.
BACKGROUND OF THE INVENTION
[0002] Plastic articles, such as preforms for plastic containers,
can be formed by various methods including injection molding and
compression molding. The molded preforms are subsequently
processed, such as by blow molding, into their desired final shape.
After the initial molding step, the preforms are preferably
promptly removed from the mold tooling in a still somewhat soft and
pliable condition, to increase the efficiency and production rate
of preforms for each mold. It may be desirably to initially cool
the preforms prior to their being formed in a blow molding
apparatus to facilitate handling the preforms, and to control the
cooling of the preforms and thereby control the physical properties
of the preforms prior to being blow molded. Accordingly, challenges
are presented in removing the at least somewhat soft preforms from
the molding machine and transferring them to a cooling machine at a
desired rate and without damaging the preforms. Challenges are also
presented in efficiently and effectively cooling the preforms at a
desired rate and without damaging the preforms as they are moved
through the cooling station.
SUMMARY OF THE INVENTION
[0003] A take-out and cooling method and apparatus, in accordance
with an exemplary but presently preferred first aspect of the
invention, conveys molded plastic articles from a molding machine
to and through a cooling station. The apparatus preferably includes
a take-out apparatus that has a main support, a conveyor carried by
the main support for movement in an endless path, a cam adjacent to
the support, a plurality of arms carried by the conveyor for
movement with the conveyor along the endless path and including a
follower responsive to the contour of the cam to vary the position
of the arms relative to the support, and at least one holder
carried by each arm. Each holder is adapted to receive and carry at
least one molded article to facilitate in conveying the molded
articles and is flexible and resilient to permit relative movement
of at least a portion of the holder relative to its associated
arm.
[0004] In accordance with another exemplary but presently preferred
aspect of the invention, a molded article cooling system includes a
transfer mechanism that receives a plurality of molded articles and
conveys them along a path from an infeed section to an outfeed
section, and a cooling mechanism extending along the path and
having an elongate fluid outlet through which fluid is directed
toward the plurality of molded articles. The fluid outlet is
substantially continuous along at least a portion of the path so
that a substantially continuous stream of fluid is directed toward
said plastic articles. The fluid outlet is preferably defined by at
least two plates that are adjustable to permit the width and/or
direction of the fluid stream discharged from the fluid outlet to
be adjusted as desired. Desirably, the fluid outlet provides a
generally continuous line or knife of coolant flow rather than
intermittent streams of fluid flow such as from a plurality of
spaced nozzles.
[0005] Accordingly to yet another presently preferred embodiment, a
system for removing molded articles from a molding machine and
cooling the molded articles includes a take-out mechanism that
receives molded articles from the molding machine and conveys them
away from the molding machine, an intermediate conveyor that
conveys molded articles away from the take-out apparatus to a
cooling station, and a cooling conveyor that conveys the molded
articles from the intermediate conveyor through the cooling
station. The cooling conveyor preferably includes at least one pair
of spaced apart belts adapted to frictionally engage and carry the
molded plastic articles from an infeed section of the cooling
conveyor to an outfeed section of the cooling conveyor. Preferably,
the cooling conveyor advances molded articles at a slower rate than
does the intermediate conveyor to reduce the spacing between
adjacent molded articles. Also preferably, the intermediate
conveyor preferably includes a permeable belt to communicate with a
vacuum source and adapted to engage an upper end of molded articles
to suspend the molded articles from the permeable belt under the
vacuum force.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] These and other objects, features and advantages of the
present invention will be apparent from the following detailed
description of the preferred embodiments and best mode, appended
claims and accompanying drawings in which:
[0007] FIG. 1 is a side view illustrating a portion of a
compression molding production line including one presently
preferred embodiment of a takeout apparatus;
[0008] FIG. 2 is a side view of the compression molding production
line illustrating the general location of the take-out apparatus
relative to a compression molding machine and an intermediate
conveyor;
[0009] FIG. 3 is a diagrammatic plan view of the compression
molding production line including a take-out and cooling system
with the take-out apparatus, intermediate conveyor and a cooling
station;
[0010] FIG. 4 is a perspective view of the take-out apparatus and
intermediate conveyor with the holders on most of the arms
removed;
[0011] FIG. 5 is an elevational view of the take-out apparatus and
intermediate conveyor with the holders removed from the arms of the
takeout apparatus;
[0012] FIG. 6 is a perspective bottom view of the take-out
apparatus;
[0013] FIG. 7 is an enlarged fragmentary perspective view
illustrating a plurality of arms and holders of the take-out
apparatus according to one presently preferred embodiment;
[0014] FIG. 8 is a side view illustrating holders of a take-out
apparatus and the intermediate conveyor;
[0015] FIG. 9 is a diagrammatic view illustrating the cooling
station and the cooling conveyor within the cooling station;
[0016] FIG. 10 is a diagrammatic view illustrating a cooling
station and cooling conveyor according to one presently preferred
embodiment;
[0017] FIG. 11 is a fragmentary side view of one portion of the
cooling conveyor as shown in FIG. 9;
[0018] FIG. 12 is a side view of a plurality of elongate fluid
outlets aligned to provide a substantially continuous stream of
coolant onto molded articles in the cooling station;
[0019] FIG. 13 is an end view of the portion of the cooling station
shown in FIG. 12 illustrating the aligned elongate fluid
outlet;
[0020] FIG. 14 is a perspective view of the intermediate
conveyor;
[0021] FIG. 15 is a side view of the intermediate conveyor;
[0022] FIG. 16 is a perspective view of a take-out and cooling
apparatus for conveying and cooling molded plastic articles
according to a second presently preferred embodiment;
[0023] FIG. 17 is a side view of the take-out and cooling system of
FIG. 16;
[0024] FIG. 18 is an end view of the system shown in FIGS. 16 and
17;
[0025] FIG. 19 is an enlarged end view illustrating a portion of
the cooling station shown in FIG. 18;
[0026] FIG. 20 is a perspective view of a second presently
preferred embodiment of a cooling station of the system shown in
FIG. 16;
[0027] FIG. 21 is a plan view of the cooling station;
[0028] FIG. 22 is a side view of the cooling station;
[0029] FIG. 23 is an end view of the cooling station;
[0030] FIG. 24 is a perspective view of an alternate embodiment
holder for an arm of the take-out apparatus including a pair of
holders;
[0031] FIG. 25 is a plan view of the holder;
[0032] FIG. 26 is a side view of the holder;
[0033] FIG. 27 is an end view of the holder;
[0034] FIG. 28 is an end view of the second embodiment cooling
station;
[0035] FIG. 29 is a plan view of a corner cam plate that may be
employed with the takeout apparatus;
[0036] FIG. 30 is a fragmentary perspective view of a portion of a
takeout apparatus including cam followers for engagement with the
corner cam plate;
[0037] FIG. 31 is a perspective view of a plenum of the second
embodiment cooling station; and
[0038] FIG. 31A is an enlarged fragmentary view of the encircled
portion 31A in FIG. 31 showing a portion of adjustable plates that
define a fluid outlet in the cooling station.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] Referring in more detail to the drawings, FIGS. 1-3
illustrate a system 10 for conveying and cooling molded plastic
articles 12. In one presently preferred embodiment, the system 10
is used to transfer molded articles 12 in a compression molding
production line 14. The compression molding production line 14
includes, generally, an extruder 16 that provides molten plastic
material from which the plastic articles 12 are molded, a
compression molding machine 18 including a plurality of mold
tooling pairs 20 each having at least one mold cavity in which a
plastic article 12 is formed, and a pellet distributor 22 that
transfers gobs or charges of plastic from the extruder 16 to the
mold tooling 20. The compression molding machine and mold tooling
may be as shown and described in U.S. patent application Ser. Nos.
10/816,498, and 10/822,299, and the pellet distributor as shown in
U.S. patent application Ser. No. 10/822,297, the disclosures of
which are incorporated herein by reference in their entirety. The
conveying and cooling system 10 preferably includes a takeout
apparatus 24 that conveys molded articles 12 away from the molding
machine 18, and a cooling station 26 that receives molded articles
12 downstream of the takeout apparatus 24 and at least partially
cools the molded articles 12 as they pass therethrough.
[0040] In one presently preferred embodiment, the molding machine
18 forms plastic preforms 12 that are subsequently blow molded into
a desired final shape, such as to form plastic containers. The
molding machine 18 may include a plurality of pairs of mold tooling
20 including an upper mold tooling half 28 and a lower mold tooling
half 30 (FIG. 2) each carried by a rotatable turret 95. At least
one of the mold tooling halves 28, 30 is moveable relative to the
other from an open position where the mold tooling halves are
spaced apart to a closed position where the mold tooling halves 28,
30 are brought together to compression mold a plastic article 12.
During the portion of the cycle wherein the mold tooling halves 28,
30 are open or spaced apart, the takeout apparatus 24 receives
already formed molded articles 12 from the mold tooling 20, and the
pellet distributor 22 distributes fresh gobs of plastic into the
mold cavities of the mold tooling 20 for the next forming cycle. To
increase the efficiency of the production line 14, the takeout
apparatus 24 may be disposed in the same general area relative to
the molding machine 18 as the pellet distributor 22. To accomplish
this, arms 32 of the takeout apparatus 24 may be disposed over the
pellet distributor 22 so that in the same general window or space
wherein formed articles 12 are removed by the takeout apparatus 24,
fresh plastic gobs can be distributed into the mold tooling 20 for
a subsequent cycle. This reduces the time that the mold tooling
halves 28, 30 need to be opened or separated from each other, and
thereby increases the time for the compression molding portion of
the molding cycle. Of course, to do this, the takeout apparatus 24
and pellet distributor 22 are designed to avoid interference with
each other and to coexist in a relatively limited window or space.
Accordingly, the following detailed description of the takeout
apparatus 24, cooling station 26, and associated conveyors, is set
forth with regard to the presently preferred system for
manufacturing molded articles 12 and cooling them, and is not
intended to limit the broader aspects of the disclosure and
inventive concepts, as set forth herein and in the appended
claims.
[0041] In more detail, as shown in FIGS. 1-6, the takeout apparatus
24 includes a frame 40, a drive assembly 42, and a plurality of
arms 32 coupled to the drive assembly 42 for movement about the
frame 40 in an endless path. Each arm 32 preferably includes at
least one holder 100 constructed and arranged to receive and convey
a molded plastic article 12 as desired. The frame 40 preferably
includes one or more support rods 46 fixed at one end to a base or
main support 48, and at their other end to a support plate 50. In
one presently preferred embodiment, the support plate 50 is
generally rectangular with rounded corners providing a generally
smooth and continuous periphery about which the arms 32 may be
continuously circulated. As best shown in FIGS. 16-18, the
apparatus 24 may include a main frame 52 having upstanding posts 54
spanned by appropriate beams, with spaced beams 56 interconnected
by cross beams 58. The cross beams 58 may provide rails 60 on which
a support frame 62 is carried with the rods 46 of the takeout
apparatus 24 coupled to the support frame 62 and moveable with the
support frame 62 along the rails 60 to adjust the location of the
takeout apparatus 24 as desired.
[0042] The drive assembly 42 (FIG. 4) preferably includes a motor
64 and a circumferentially continuous transmission member 66 driven
by the motor 64 in an endless path or loop. In one presently
preferred embodiment, the motor 64 is servo-controlled and
preferably communicated with a controller 65 enabling adjustment
and control of the rate at which the transmission member 66 is
driven. The motor 64 is preferably operated so that the arms 32 are
driven as a function of the rotational speed of the turret 95. In
the presently preferred embodiment, the motor 64 is coupled to a
drive sprocket 68 mounted on the support plate 50 by a drive shaft
70 driven for rotation by the motor 64. A plurality of driven
sprockets 72 are also mounted on the support plate 50 by
appropriate shafts 74 about which the driven sprockets 72 rotate,
with each driven sprocket 72 and the drive sprocket 68 preferably
disposed adjacent a rounded corner of the support plate 50. In this
embodiment, the transmission member 66 includes at least one, and
preferably two parallel and substantially inextensible chains 66
having interconnected links and being carried and driven by the
sprockets 68, 72. The chains 66 are formed in an endless loop about
the periphery of the support plate 50 and preferably carry a
plurality of arms 32 that are driven in an endless loop around the
support plate 50. A cam track 76, that is also carried by the
support plate 50, further controls and directs the movement of the
arms 32 as they are circulated about the periphery of the support
plate 50.
[0043] Each arm 32 preferably includes a block 80 slidably carried
on at least one and preferably a pair of slide rods 82 to permit
axial, or vertical (as viewed in FIGS. 4 and 5) slidable movement
or translation toward and away from the support plate 50. Each
block 80 preferably includes at least one cam follower or first
roller 84 responsive to the contour of the cam track 76 and
preferably disposed in the cam track 76 or engaged with an
appropriate cam surface to slidably move the blocks 80 along the
slide rods 82 and relative to the support plate 50. Each slide rod
82 preferably extends through a hollow passage extending through at
least one chain 66 and preferably both chains 66. In this manner,
the slide rods 82 replace the pivot shafts that traditionally
connect adjacent links of the chains 66. Appropriate fasteners 86
can be used to retain the slide rods 82 on the chains 66. In this
manner, the arms 32 are operably associated or connected to the
chains 66 for movement with the chains 66 about the periphery of
the support plate 50. At the opposite end of each slide rod 82,
according to one presently preferred embodiment as shown in FIGS. 4
and 29, a second cam follower 88 or roller may be provided to
engage one or more corner cam plates 90 carried by the support
plate 50 through appropriate supports 92. The corner cam plates 90
preferably have a cam surface 94 constructed and arranged to
prevent radial outward movement of the arms 32 and slide rods 82 as
the arms 32 are moved around a corner of the support plate 50.
[0044] In the presently preferred embodiment, wherein the molding
machine 18 includes a rotary turret 95 (FIG. 3), one or more sides
96 of the support plate 50 may be generally arcuate or curved so
that the arms 32 traverse an arc as they are moved along that side
96. The curvature of the arc traversed by the arms 32 is preferably
generally concave and complimentary to the path of travel of the
mold tooling 20 along the turret 95 so that the arms 32 follow the
motion of the mold tooling 20 to facilitate removing molded
articles 12 from the mold tooling 20. To drive the arms along the
curved path, the cam track 76 preferably has a complimentary
contour so that engagement of the first rollers 84 with the cam
surface moves the chains 66, slide rods 82 and arms 32 along the
desired path. The rate at which the arms are driven by the motor 64
is also preferably controlled as a function of the rate at which
the turret 95 and its mold tooling 20 are moved.
[0045] As best shown in FIGS. 7 and 8, according to one embodiment,
each arm 32 includes at least one and preferably a pair of holders
100 with each holder 100 adapted to receive a separate molded
article 12, so that each arm 32 preferably carries a pair of molded
articles 12 away from the mold tooling 20. Each pair of holders 100
is preferably mounted to a carrier plate 102 that is fixed to a
corresponding arm 32. In this embodiment, each holder 100 includes
a plurality of upstanding fingers 104 fixed at one end to the
carrier plate 102 and having an opposed free end 106. A receptacle
108 is defined between the fingers 104 of each holder 100 with a
molded article 12 adapted to be received in the receptacle 108. The
fingers 104 may include contact members 110 that extend from a
finger into the receptacle 108 defined between the fingers 104. The
contact members 110 are arranged to limit the surface area or
points of contact between the holder 100 and a molded article 12
carried by the holder 100. In one embodiment the contact members
110 may be generally curved, and are preferably at least partially
spherical, and two spaced apart contact members 110 may be provided
on each finger 104. The shape and number of contact members 110 can
be varied as desired for a particular application.
[0046] Each finger 104 is preferably flexible and resilient to
limit the force applied to a molded article 12 if, for example, the
molded article 12 is offset or misaligned slightly from the
receptacle 108. The flexible fingers 104 also prevent damage to the
arms 32 should they encounter interference, and may be constructed
and arranged to break away at a force low enough to prevent damage
to the associated arm 32 in such a situation. In one presently
preferred embodiment, the fingers 104 are composed of coil springs
having a stiffness chosen to adequately support and retain the
molded articles 12 without applying undesirable pressure to the
molded articles 12 through the contact members 110.
[0047] In addition to the fingers 104, each receptacle 108 is
preferably also defined at least in part by a flexible support 114
carried by the carrier plate 102. The flexible supports 114 are
arranged to support a lower surface of the molded articles 12 and
may be formed relatively inexpensively from spring steel. The
flexible supports 114 for both receptacles 108 defined on each arm
32 can be formed from a single spring member attached to the
carrier plate 102 between its ends, with each end being
cantilevered so that it is flexible, resilient and extends into a
corresponding receptacle 108.
[0048] Desirably, the receptacles 108 of each holder 100 are
aligned with a mold core 116 (FIG. 7) of the mold tooling 20 to
receive a molded plastic article 12 off of the mold core 116 and to
convey the molded articles 12 away from the mold tooling 20. In the
embodiment shown, each set of mold tooling 20 includes mold cores
116 in radially aligned pairs. So the holders 100 and receptacles
108 of each arm 32 in this embodiment are constructed to be aligned
with the pairs of mold cores 116 along a predetermined portion of
the path of movement of the mold cores 116 when the mold tooling
halves 28, 30 are separated or open. In one embodiment, each mold
tooling pair 20 defines four mold cavities (in two pairs of
radially aligned cavities) and forms four molded articles 12 in
each cycle. In this embodiment, two arms 32 are needed to remove
the four molded articles 12 from each mold tooling pair 20. The
arms 32 are driven at a rate that is a function of the rotational
speed of the turret 95 to ensure that the holders 100 are properly
aligned with and ready to receive the molded articles 12 as they
are stripped from the mold cores 116. To do this, the
servo-controlled motor 64 that drives the arms 32 can be
communicated with an appropriate controller 65 that is responsive
to the rate of rotation of the turret 95 and/or the rotational
position of the turret 95.
[0049] As best shown in FIGS. 2-5, 8 and 14-17, the system 10
preferably includes an intermediate conveyor 120 disposed between
the takeout apparatus 24 and the cooling station 26. The
intermediate conveyor 120 preferably includes an infeed section 122
wherein molded plastic articles 12 are transferred from the takeout
apparatus 24 to the intermediate conveyor 120, and an outfeed
section 124 wherein molded plastic articles 12 are transferred from
the intermediate conveyor 120 to the cooling station 26. The
intermediate conveyor 120 may be carried by the support plate 50 of
the takeout apparatus 24 by upstanding posts 126 and generally
transverse brackets 128 fixed to the support plate 50. In one
presently preferred embodiment, the intermediate conveyor 120
includes at least one and preferably a pair of parallel belts 130
communicated with a vacuum source to retain the molded plastic
articles 12 on the belts 130 under a vacuum force. To do this, the
belts 130 are permeable, and may be perforated including a series
of holes 132 (FIGS. 8 and 14) through which air is drawn under the
vacuum.
[0050] As best shown in FIG. 8, at the infeed section 122 of the
intermediate conveyor 120 the takeout arms 32 are oriented so as to
engage an upper end of the molded articles 12 with the belts 130 of
the intermediate conveyor 120. Desirably, each of the pair of
molded articles 12 carried by an arm 32 is aligned with a separate
one of the belts 130 and generally simultaneously transferred from
the takeout apparatus 24 to the intermediate conveyor 120. Each
belt 130 is preferably looped around a pair of shafts or pulleys
134 carried by side plates 136 of the intermediate conveyor 120.
One of the pulleys 134 is driven by a motor 138 via a drive pulley
140 driven by the motor 138 and a belt 142. Of course, any number
of pulleys 134 can be utilized. The molded articles 12 are
preferably suspended from the belts 130 and guided along a straight
path from the infeed section 122 to the outfeed section 124.
[0051] As shown in FIGS. 9-13, from the outfeed section 124 of the
intermediate conveyor 120 the molded articles 12 are transferred to
one or more cooling conveyor systems 144 passing through the
cooling station 26 and adapted to convey the molded articles 12
through the cooling station 26. In one embodiment, the cooling
station 26 includes two parallel cooling conveyor systems 144 each
generally aligned with a separate one of the belts 130 of the
intermediate conveyor 120. Each cooling conveyor system 144
includes a lower conveyor 146, and a pair of side conveyors 148.
The lower conveyor 146 includes a belt 150 driven by a pulley 152
carried by a shaft 154 that is driven by a motor 156. The belt 150
is adapted to engage a lower end or bottom surface of a molded
article 12 as the molded article 12 passes through the cooling
station 26.
[0052] Each of the pair of side conveyors 148 preferably includes a
belt 158 wrapped around at least a pair of pulleys 160 with one
pulley 160 at an infeed section 164 of the cooling station 26 and
the other pulley (not shown) at the outfeed section 166 of the
cooling station 26. If desired, multiple pulleys may be provided
between the infeed section 164 and outfeed section 166 providing
additional support for the belt 158. Each side conveyor belt 158 is
adapted to engage a sidewall 168 of the molded articles 12 so that
the molded articles 12 are supported in an upright position as they
are carried through the cooling station 26 by the side conveyors
148 and lower conveyor 146. Each belt 158 may be wrapped partially
about a guide pulley 170 and around a driven pulley 172 fixed to
the shaft 154 and driven by the motor 156 so that each belt 158 of
the side conveyors 148 and the belt 150 of the lower conveyor 146
are driven by the same shaft 154 and motor 156. As best shown in
FIG. 11, each guide pulley 170 and the pulleys 160, 162 between the
infeed section 164 and outfeed section 166 are preferably pivotally
or adjustably mounted to permit the distance between the side
conveyors 148 to be adjusted to accommodate plastic articles 12 of
different sizes.
[0053] As best shown in FIGS. 10 and 12, in one embodiment, the
cooling station 26 preferably includes one or more plenums 174 or
manifolds communicating with a plurality of nozzles having an
outlet directed towards the cooling conveyors, and more
specifically toward the molded articles 12 conveyed by the cooling
conveyors 146, 148. Coolant, which is preferably chilled forced air
as applied to container preforms, is directed onto the molded
articles 12, preferably at various locations on and/or in the
molded articles 12. As shown in this embodiment, coolant is
directed by a series of laterally spaced side nozzles 176 onto the
exterior sidewall 168 of the molded articles 12, and by a series of
central nozzles 178 into an interior cavity 180 of the molded
articles 12. The coolant can also be compressed air or a liquid,
such as water, by way of examples without limitation.
[0054] As best shown in FIGS. 12 and 13, multiple aligned central
nozzles 178 are preferably provided between the infeed section 164
and outfeed section 166 of the cooling station 26. The side nozzles
176 are preferably similarly arranged in series and aligned. The
nozzles 176, 178 preferably include elongate fluid outlets 180 that
preferably provide a relatively wide stream of coolant rather than
a small jet of coolant such as may be delivered from a small
circular nozzle. The nozzles 176,178 are preferably aligned with
minimal spacing between them providing an at least substantially
continuous stream or curtain of coolant onto the molded plastic
articles 12 as they pass through the cooling station 26. To
maximize the cooling efficiency, the streams of coolant directed
toward and into the molded articles 12 are preferably continuous
along the length of the cooling station 26. To accomplish this in
the present embodiment, the nozzles 176,178 can be constructed and
arranged so that the discharge pattern of the nozzles 176,178 join
or overlap at or prior to engagement with the molded articles 12.
Accordingly, coolant is preferably continually provided on and into
the molded articles 12 without interruption as the molded articles
12 are moved through the cooling station 26.
[0055] In FIGS. 16-23, 28 and 31, a second presently preferred
embodiment of a cooling station 200 is shown. Like the first
embodiment cooling station 26, the second embodiment cooling
station 200 preferably includes a pair of cooling conveyors 202
providing parallel paths each adapted to receive molded articles 12
therein and to transfer the molded articles 12 through the cooling
station 200. The cooling station 200 includes a pair of coolant
supply conduits 204 communicated with a supply of coolant, such as
a blower providing forced air, a compressed air source, or a liquid
coolant source. Branch conduits 206 extend from the supply conduits
204 to both a pair of upper main plenums 208 (one for each conveyor
path) and a pair of lower main plenums 210 (also one for each
conveyor path) respectively disposed above and below the cooling
conveyors 202. The cooling station 200 may be supported by
appropriate legs 211 of a frame 244.
[0056] The upper and lower plenums 208, 210 may be similarly
constructed to define an elongate, preferably continuous enclosure
in which coolant is received. Each plenum 208, 210 is defined at
least in part by one or more fluid outlet plates 212 that define an
elongate and preferably at least substantially continuous fluid
outlet 214 through which coolant is discharged from each plenum 208
and toward molded articles 12 being conveyed through the cooling
station 200. In one presently preferred embodiment, each elongate
fluid outlet 214 is defined by a pair of elongate plates 212 fixed
to the associated plenum 208, 210 with a linear slot between the
plates 212 defining the fluid outlet 214. Preferably, the plates
212 include outwardly extending flanges 216 which may be adjustably
carried or connected to an associated plenum 208, 210 to permit the
size and location of the fluid outlet 214, relative to molded
articles 12 conveyed through the cooling station 200, to be
changed. The plates 212 may include slots 215 (FIG. 31A) that
receive fasteners 217 and permit movement of the plates 211
relative to the fasteners 217.
[0057] In one presently preferred embodiment, the plates 212 are
generally L-shaped in section and include flanges 218 extending
into an associated plenum 208, 210 and defining a passage 220
communicating with the fluid outlet 214 through which coolant flows
from the plenum 208, 210 to the fluid outlet 214. In the presently
preferred embodiment, the fluid outlet 214 is continuous and
extends without interruption from a location generally adjacent to
the infeed section 222 of the cooling station 200 to the outfeed
section 224 of the cooling station 200. Accordingly, rather than
discreet or individual coolant nozzles, in this embodiment, a
continuous and preferably generally linear stream, curtain or knife
of coolant is provided onto the molded articles 12 as they are
conveyed through the cooling station 200.
[0058] To convey the molded articles 12 through the cooling station
200, two spaced cooling conveyors 202 are provided. As best shown
in FIG. 28, each cooling conveyor 202 preferably includes a pair of
belts 230 having generally opposed planar faces 232 adapted to
engage diametrically opposed surfaces of the molded articles 12
preferably with a friction fit to carry and convey the molded
articles 12 through the cooling station 200. The opposed faces 232
of the belts 230 preferably extend axially relative to the molded
plastic articles 12 and are generally continuous from the infeed
section 222 to the outfeed section 224 of the cooling station 200.
The belts 230 are preferably trained around a plurality of pulleys
234 and include an outwardly extending projection 236 adapted to be
received in a complementary track or groove 238 formed in each
pulley 234 to facilitate retaining and locating the belts 230
relative to the pulleys 234. In one presently preferred embodiment,
the projection 236 on each belt 230 may be generally V-shaped or
trapezoidal including three generally straight outer edges in
section. At least one pulley 234 associated with each belt 230 of
each cooling conveyor 202 is driven, such as by a motor 235 (FIG.
22), for rotation to advance the belt 230 along the pulleys 234 and
thereby advance the molded articles 12 carried by the belts 230.
The pulleys 234 are preferably mounted on shafts 240 fixed to
plates 242 that are in turn adjustably carried by a frame 244 of
the cooling station 200. Each pulley 234 may be adjustable relative
to the plate 242 on which it is received to facilitate desired
alignment of the pulleys 234 on the plates 242, and the plates 242
can preferably be adjusted relative to the frame 244 to adjust the
position of the pulleys 234 and belts 230 relative to molded
articles 12 in the cooling station 200. Accordingly, the distance
between the belts 230 of a cooling conveyor 202 can be adjusted so
that molded articles 12 of varying sizes can be accommodated by the
cooling station 200.
[0059] In one presently preferred embodiment, the cooling station
200 is employed to cool molded plastic preforms 12 including a
generally cylindrical finish 250 preferably having a plurality of
external threads 252, and a radially outwardly extending flange 254
between the finish 250 and a main body 256 of the preform. In the
preferred embodiment, the belts 230 are arranged to frictionally
engage the threads 252 on the finish 250 of each preform at a
location axially spaced from the flange 254. When carried and
conveyed in this manner, the open upper end 258 of the preforms 12
are exposed to the fluid outlets 214 of an associated upper plenum
208 and the lower portion of the preforms, shown here as a closed
semi-spherical end 260, are exposed to the elongate fluid outlet
214 of an associated lower plenum 210.
[0060] Accordingly, a stream of coolant is directed into the open
upper ends 258 of each preform 12, and against the closed lower end
260 of each preform 12. The stream of coolant directed against the
lower end 260 of the preforms 12 preferably flows upwardly and
around a side wall 168 of the preforms 12 improving the cooling
performance. Because the plates 242 defining the fluid outlets 214
are adjustable relative to the plenums 208, 210 the location of the
fluid outlets 214 relative to an axis 270 of the preforms 12 can be
adjusted. The streams of coolant discharged from the fluid outlets
214 can be arranged to be coincident with a plane including the
axis 270 of each preform 12 along the cooling conveyor 202. The
fluid outlets 214 can also be moved so that the streams are
parallel but spaced from the plane containing the axis 270 of each
preform 12. And the plates 242 can be adjusted so that the
direction of the streams is not parallel to the plane containing
the axes 270 of the preforms. In that arrangement, the stream may
intersect the plane containing the axes 270 of the preforms 12, or
may be entirely separate from that plane, at least from the fluid
outlet 214 to the upper end 258 of the preforms 12.
[0061] The fluid outlet 214 of the upper plenum 208 is preferably
offset from the plane containing the axes 270 of the preforms to
provide a more turbulent flow within the preforms and improved flow
into and out the preforms avoiding a stagnant section or layer of
coolant in the interior of the preforms 12 to improve fluid flow
and more evenly cool the preforms 12. The upper plenum 208 may be
formed in two sections, and each section of the upper plenum 208
may be separately adjusted so that they direct coolant onto or into
the preforms 12 at different locations or in generally different
directions. This may provide more even cooling of the preforms
12.
[0062] Also preferably, the fluid outlet 214 of the lower plenum
210 is directed along or coincident with the plane containing the
axes 270 of the preforms 12 so that the coolant engages the lower
end 260 of the preforms 12 and flows generally evenly around the
exterior of the preforms to improve the cooling properties thereof.
Of course, the width of both the upper and lower fluid outlets 214
can be adjusted as desired, for example by moving the plates 212
further apart from each other.
[0063] In one presently preferred embodiment, the coolant is
chilled forced air. The air may be passed through a heat exchanger
to cool it, and then moved by one or more blowers through the fluid
conduits 204, 206 and into the upper and lower plenums 208, 210.
The temperature of the chilled air can vary widely, and in one
presently preferred embodiment may be between 30.degree. and
80.degree. F., preferably around 40.degree. to 60.degree. F. The
flow rate of coolant provided through the fluid outlets 214 can
also be changed as desired as a function of the flow area of the
fluid outlet 214, as well as the flow rate of fluid delivered to
the plenums 208, 210. Other coolants may be used, including by way
of example without limitation, compressed air and/or liquid
coolants, such as water. Additionally, the cooling conveyors 202
may convey the preforms 12 through a coolant bath such as by
passing the preforms 12 through a pool or bath of water or other
coolant.
[0064] Preferably, the cooling conveyors 202 are driven at a rate
that is slower than the rate at which the intermediate conveyor 120
is driven to reduce the pitch or spacing between adjacent preforms
12 and thereby increasing the time that the preforms 12 spend in
the cooling station 26, 200. This increases the efficiency of the
cooling station 26, 200 by increasing the potential cooling
available per length of cooling station 26, 200 and also reduces
the required floor space for the apparatus.
[0065] An alternate embodiment holder assembly 300 for the take-out
apparatus 24 is shown in FIGS. 24-27. This embodiment preferably
includes a carrier plate 302, and a pair of flexible supports 304,
that may be formed on a single strip of bent spring steel, as set
forth with regard to the previous embodiment holders 100. The
holders 300 themselves, like the previous embodiment, preferably
include a plurality of upstanding fingers 306 and also preferably
include at least one contact member 308 carried by the fingers 306
and defining in part a receptacle 310 between the fingers 306.
[0066] In the embodiment shown, each holder 300 includes four
upstanding, flexible and resilient fingers 306 and a pair of
axially spaced contact members 308. Each contact member 308 is
preferably annular, and is fixed to the fingers 306 so that
openings 312 of associated contact members 308 are coaxially
aligned. To facilitate alignment of a molded article 12 with a
receptacle 310, the openings 312 through the contact members 308
preferably have an entrance portion 314 that is beveled or tapered.
The flexible and resilient fingers 306 can be formed from
appropriate springs, as set forth with regard to previous
embodiment. The springs or other finger arrangement are preferably
received through circumferentially spaced bores 315 in the contact
members 308. The contact members 308 can be retained on the fingers
306 by set screws 316 disposed in radial 318 bores in the contact
members 308 and extending into engagement with the fingers 306.
Desirably, the annular contact members 308 are generally thin in
the axial direction to limit the surface area or contact area of
the contact members 308 with the molded plastic articles 12. Any
number and arrangement of contact members 308, or no contact
members, may be provided for each holder 300, as desired.
[0067] In use, the molding machine 18 produces a plurality of
molded articles 12, such as molded plastic preforms 12 that are
subsequently processed or formed into plastic containers. The mold
tooling 20 may include a female mold cavity and a male mold core
116 removably disposed in the mold cavity to form a preform 12.
When the mold tooling halves 28, 30 are separated after a
compression molding cycle, the preforms 12 are preferably carried
by the mold cores 116 so that they are removed from the mold
cavities when the mold tooling halves 28, 30 are separated.
[0068] During this time, an arm 32 of the take-out apparatus 24 is
disposed beneath a pair of aligned mold cores 116 so that when the
preforms 12 are released from the mold cores 116 the preforms 12
are disposed in the receptacles 108, 310 of the holders 100, 300 on
the arm 32. The arm 32 continues to be driven about the periphery
of the support plate 50 to carry the molded preforms 12 away from
the molding machine and toward the intermediate conveyor 120. In
the area of the infeed section 122 of the intermediate conveyor
120, the arms 32 are arranged so that the upper end of each preform
12 is generally aligned with an associated belt 130 of the
intermediate conveyor 120. Desirably, the upper end of each preform
12 is brought into engagement with its associated belt 130 as the
take-out arms 32 are driven relative to the intermediate conveyor
120. To prevent excessive force from being applied to the preforms
12 as they are brought into engagement with the belts 130, the
flexible supports 114, 304 in the receptacle 108 are designed to
flex to limit or prevent damage to the preforms under this load.
The preforms are then held on the vacuum belt 130 under vacuum
force, and the take-out arms 32 can be lowered away from the
intermediate conveyor 120 as controlled by engagement of the cam
followers 84 with the cam track 76 of the take-out apparatus
24.
[0069] The preforms 12 continue along the intermediate conveyor 120
until they reach the outfeed section 124 whereupon they are
transferred to the cooling conveyors 146, 148, 202 of the cooling
station 26, 200. Preforms 12 are carried by the belts 150, 158, 230
of the cooling conveyors 146, 148, 202 through the cooling station
26, 200 wherein one or more streams of coolant are directed at and
into the preforms 12 to cool them. Hence, the preforms 12 are moved
to and through the cooling station in-line with a plurality of
preforms 12 being simultaneously cooled as they are moved through
the cooling station. The preforms 12 are at least substantially
continuously cooled as they are moved in-line through the cooling
station, and are preferably continuously cooled by a continuous
stream of fluid directed at the preforms as they are moved along at
least a portion of the cooling path or cooling station. As noted
herein, a plurality of lines of preforms may be formed for
increased production rate and efficiency. While the terms "in-line"
and "lines" have been used to describe the consecutive travel of
the preforms 12, it is to be understood that the preforms do not
have to travel linearly. Curved lines or other configurations can
be employed.
[0070] While certain preferred embodiments and constructions and
arrangements of particular components of the takeout and cooling
system and method have been shown and described herein, one of
ordinary skill in this art will readily understand that
modifications and substitutions can be made without departing from
the spirit and scope of the invention as defined by the appended
claims. Further, relative adjectives like "upper," "lower,"
"central," and the like are used to describe features of system,
apparatus and method with respect to the position and orientation
of such features as shown in the accompanying drawings of the
presently preferred embodiments.
* * * * *