Injection molding apparatus, method, and system

A mold system for producing a molded article by injection molding, the molded article having an article first portion and an article second portion, the mold system comprising:

• a) a first mold apparatus mountable to a first platen of an injection molding machine;
• b) a second mold apparatus mountable to a second platen of the injection molding machine, the first and second mold apparatuses translatable relative to each other between a mold closed position in which the first and second mold apparatuses enclose at least one cavity for receiving injection molding material to form the molded article, and a mold open position in which the first and second mold apparatuses are spaced apart for ejecting the molded article, the second mold apparatus comprising:
• i) a base plate for attachment to the second platen;
• ii) a core plate carried by and translatable relative to the base plate;
• iii) a core first portion rotatably supported by the base plate, the core first portion comprising a thread mold for forming internal threads of the article first portion;
• iv) a core second portion mounted to the core plate for forming the article second portion;
• v) a drive mechanism comprising a mechanical actuator coupled to the core plate, and a first servomotor for operating the actuator to translate the core plate relative to the base plate between a plate advanced position and a plate retracted position;
• and
• vi) a manipulation mechanism coupled to the core plate, the manipulation mechanism comprising an engagement member and a second servomotor for moving the engagement member along a path to move the article second portion relative to the article first portion;
• and
• c) a controller configured to (i) operate the first servomotor to translate the core plate between the plate advanced position and the plate retracted position, and (ii) operate the second servomotor to move the engagement member along the path;
• wherein the controller is configured to operate the first servomotor to rotate the core first portion in synchronization with the translation of the core plate to correspond to a lead of the thread mold;
• and
• wherein the drive mechanism further comprises a clutch coupling the first servomotor and the actuator, and the controller is configured to operate the clutch in an adjustment mode to decouple the first servomotor and the actuator and operate the first servomotor when the clutch is in the adjustment mode to rotate the core first portion while the core plate remains axially fixed relative to the base plate.

A mold apparatus for producing a molded article by injection molding, the mold apparatus comprising:

• a) a base plate for mounting to a platen of an injection molding machine;
• b) a core plate movably coupled to the base plate;
• c) a mechanical actuator coupled to the core plate for translating the core plate relative to the base plate between a plate advanced position and a plate retracted position;
• d) a core first portion rotatably coupled to the base plate, the core first portion comprising a thread mold for forming internal threads of the molded article;
• e) a first motor operable to rotate the core first portion relative to the core plate and energize the actuator to translate the core plate in synchronization with rotation of the core first portion to correspond to a lead of the thread mold;
• and
• f) a clutch coupling the first motor and the actuator, the clutch configured to operate in an adjustment mode to decouple the first motor and the actuator so that the core first portion is rotatable by the first motor while the core plate remains axially fixed relative to the base plate.

A mold for an injection molding machine, comprising:

• a) a first mold apparatus mountable to a first platen of the injection molding machine;
• b) a second mold apparatus mountable to a second platen of the injection molding machine, the first and second mold apparatuses translatable relative to each other between a mold closed position in which the first and second mold apparatuses enclose at least one cavity for receiving injection molding material to form a molded article, and a mold open position in which the first and second mold apparatuses are spaced apart for ejecting the molded article, the second mold apparatus comprising:
• i) a base plate for mounting to the second platen of the injection molding machine;
• ii) a core plate movably coupled to the base plate and axially translatable relative to the base plate between a plate advanced position and a plate retracted position, the core plate including a first abutment surface and a second abutment surface spaced axially apart from and directed toward the first abutment surface;
• iii) a lead screw rotatably supported by, and axially fixed relative to, the base plate;
• and
• iv) a lead nut coupled to the lead screw and rotationally fixed relative to the core plate, the lead nut translatable relative to the core plate in response to rotation of the lead screw between a nut-advanced position and a nut-retracted position, wherein
• when in the nut-advanced position, the lead nut:
• bears against the first abutment surface for moving the core plate to the plate advanced position, and
• is spaced apart from the second abutment surface;
• and
• when in the nut-retracted position, the lead nut:
• bears against the second abutment surface for moving the core plate to the plate retracted position, and
• is spaced apart from the first abutment surface.

A mold for an injection molding machine, comprising:

• a) a first mold apparatus mountable to a first platen of the injection molding machine;
• b) a second mold apparatus mountable to a second platen of the injection molding machine, the first and second mold apparatuses translatable relative to each other between a mold closed position in which the first and second mold apparatuses enclose at least one cavity for receiving injection molding material to form a molded article, and a mold open position in which the first and second mold apparatuses are spaced apart for ejecting the molded article, the second mold apparatus comprising:
• i) a base plate for mounting to the second platen of the injection molding machine;
• ii) a core plate movably coupled to the base plate;
• iii) a mechanical actuator coupled to the core plate for translating the core plate relative to the base plate between a plate advanced position and a plate retracted position;
• iv) a core first portion rotatably coupled to the base plate, the core first portion comprising a thread mold for forming internal threads of the molded article;
• v) a first motor operable to rotate the core first portion relative to the core plate and energize the actuator to translate the core plate;
• and
• vi) a clutch coupling the first motor and the actuator to permit the first motor to drive rotation of the core first portion and energize the actuator simultaneously, the clutch configured to operate in an adjustment mode to decouple the first motor and the actuator so that the core first portion is rotatable by the first motor while the core plate remains axially fixed relative to the base plate.