Blow-molding large, relatively thick-walled, thermoplastic resin products

A blow-mold assembly for use in a blow-molding machine which processes a heated thermoplastic resin parison to form a blow-molded thermoplastic resin product having integrally attached gutter flash surrounding the product, and to progressively separate the surrounding gutter flash from the product while the product is retained in the blow-mold assembly, and comprising:

• a cap blow-mold sub-assembly having a product cavity that is defined in-part by a cavity mold parting-line perimeter and that is surrounded by a cap blow-mold sub-assembly gutter flash clamping surface extending outwardly from said product cavity mold parting-line perimeter;
• a base blow-mold sub-assembly having a support structure, and having a product cavity that is carried by said support structure and that is defined in-part by a cavity mold parting-line perimeter corresponding to said cap blow-mold sub-assembly product cavity mold parting-line perimeter;
• multiple base blow-mold sub-assembly elongate gutter plate segments that are each pivotable and movable relative to said base blow-mold sub-assembly support structure, that together surround said base blow-mold sub-assembly product cavity mold parting-line perimeter when end-butted, that each have two, spaced-apart pivot connections each one of which is positioned in a different one of the elongate gutter plate segment end regions, and that each have a gutter flash clamping surface opposing and spaced-apart from said cap blow-mold sub-assembly gutter flash clamping surface;
• and
• multiple bi-directional actuators that are each supported by said base blow-mold sub-assembly support structure, that are each connected to a respective one of said elongate gutter plate segment pivot connections, and that are each actuated to cause pivoting of its respective one of said base elongate gutter plate segments in directions that are parallel to the plane of said base blow-mold sub-assembly product cavity mold parting-line perimeter to separate the integrally attached gutter flash surrounding the product from the product progressively along said base blow-mold assembly product cavity mold parting-line perimeter, said multiple elongate gutter plate segment pivot connections each having a longitudinal pivot axis oriented normal to the plane of said base blow-mold sub-assembly mold parting-line perimeter, and said multiple elongate gutter plate segment pivot connections each permitting its incorporating gutter plate segment to be rotated relative to said base blow-mold sub-assembly product cavity mold parting-line perimeter and to be translated linearly in directions that are parallel to said gutter plate segment pivot connection longitudinal axis.

A blow-mold assembly for use in a blow-molding machine which processes a heated thermoplastic resin parison to form a blow-molded thermoplastic resin product having integrally attached gutter flash surrounding the product, and to progressively separate the surrounding gutter flash from the product while the product is retained in the blow-mold sub-assembly, and comprising:

• a cap blow-mold sub-assembly having a product cavity that is defined in-part by a mold parting-line perimeter, and that is surrounded by a cap blow-mold sub-assembly gutter flash clamping surface extending outwardly from said product cavity mold parting-line perimeter;
• a base blow-mold sub-assembly having a support structure, and having a product cavity that is carried by said support structure and that is defined in-part by a mold parting-line perimeter corresponding to said cap blow-mold sub-assembly product cavity mold parting-line perimeter;
• multiple base blow-mold sub-assembly elongate gutter plate segments that are each pivotable and movable relative to said base blow-mold sub-assembly support structure, that together surround said base blow-mold sub-assembly product cavity mold parting-line perimeter when end-abutted, that each have two, spaced-apart pivot connections each of which is positioned in a different one of the elongate gutter plate segment end regions, that each have a gutter flash clamping surface opposing and spaced-apart from said cap blow-mold sub-assembly gutter flash clamping surface;
• a controlled bi-directional gutter plate segment drive that is actuated to cause pivoting of each said elongate gutter plate segments in directions away from said base blow-mold sub-assembly product cavity mold parting-line perimeter to separate the product surrounding gutter flash from the product progressively along said base blow-mold sub-assembly product cavity mold parting line perimeter, said multiple elongate gutter plate segment pivot connections each having a longitudinal pivot axis oriented normal to the plane of said base blow-mold sub-assembly mold parting-line perimeter, said two pivot connections in each elongate gutter plate segment each permitting its incorporating elongate gutter plate segment to be translated linearly in directions that are parallel to said gutter plate segment pivot connection longitudinal axis, one of said two pivot connections in each elongate gutter plate segment being translatable linearly and the other of said two pivot connections in each elongate gutter plate segment being non-translatable linearly in directions that are parallel to the plane of said base blow-mold sub-assembly product cavity mold parting line perimeter, and said controlled bi-directional gutter plate segment drive being operably connected only to those of said multiple elongate gutter plate segment two pivot connections which are translatable linearly in directions that are parallel to the plane of said base blow-mold sub-assembly product cavity mold parting-line perimeter.

A blow-mold assembly for use in a blow-molding machine which processes a heated thermoplastic resin parison to form a blow-molded thermoplastic resin product having integrally attached gutter flash surrounding the product, and to progressively separate the surrounding gutter flash from the product while the product is retained in the blow-mold assembly, and comprising:

• a cap blow-mold sub-assembly having support structure, and having a product cavity that is carried by said cap blow-mold sub-assembly support structure and that is defined in-part by a mold parting-line perimeter;
• multiple cap blow-mold sub-assembly elongate gutter plate segments that are each pivotally connected and movable relative to said cap blow-mold sub-assembly support structure, that together surround said cap blow-mold sub-assembly product cavity mold parting-line perimeter when end-abutted, that each have a gutter flash clamping surface extending outwardly and away from said cap blow-mold sub-assembly product cavity mold parting-line perimeter;
• and that each have multiple convex or concave cleat elements;
• a base blow-mold sub-assembly having support structure, and having a product cavity that is carried by said base blow-mold sub-assembly support structure and that is defined in-part by a cavity mold parting-line perimeter corresponding to said cap blow-mold sub-assembly product cavity mold parting-line perimeter;
• multiple base blow-mold sub-assembly elongate gutter plate segments that are each pivotally connected and movable relative to said base blow-mold sub-assembly support structure, that together completely surround said base blow-mold sub-assembly product cavity mold parting-line perimeter when end-butted, that each have two, spaced-apart pivot connections each one of which is positioned in a different one of the elongate gutter plate segment end regions, that each have a gutter flash clamping surface opposing and spaced-apart from a respective one of said cap blow-mold sub-assembly elongate gutter plate segment gutter flash clamping surfaces,
• a bi-directional gutter plate segment drive carried by said base blow-mold assembly support structure and co-operably connected to said multiple base blow-mold sub-assembly elongate gutter plate segments;
• and
• guide pin elements provided in one of said cap blow-mold assembly multiple elongate gutter plate segments and said base blow-mold sub-assembly multiple elongate gutter plate segments;
• and
• guide pin receptacle elements provided in the other of said cap blow-mold assembly multiple elongate gutter plate segments and said base blow-mold sub-assembly multiple elongate gutter plate segments and co-operating with said guide pin elements, said co-operating guide pin and guide pin receptacle elements causing said cap blow-mold sub-assembly multiple elongate gutter plate segments and said base blow-mold sub-assembly multiple elongate gutter plate segments to be pivoted simultaneously when said bi-directional gutter plate segment drive is actuated to pivot said base blow-mold sub-assembly multiple abutting gutter plate segments and thereby progressively separate integrally attached gutter flash from the product.

A blow-mold assembly for use in a blow-molding machine which processes a heated thermoplastic resin parison to form a blow-molded thermoplastic resin product having integrally attached gutter flash surrounding the product, and to progressively separate the surrounding gutter flash from the product while the product is retained in the blow-mold assembly, comprising:

• a cap blow-mold sub-assembly having a product cavity that is defined in-part by a cavity mold parting-line perimeter, and that is surrounded by a cap blow-mold sub-assembly gutter flash clamping surface extending outwardly from said cap blow-mold sub-assembly product cavity mold parting-line perimeter;
• a base blow-mold sub-assembly having a support structure, and having a product cavity defined in-part by a cavity mold parting-line perimeter corresponding to said cap blow-mold sub-assembly product cavity mold parting-line perimeter;
• multiple elongate gutter plate segments that are each pivotally connected to and supported by said base blow-mold sub-assembly support structure, that together surround said base blow-mold sub-assembly product cavity mold parting-line perimeter when abutted, that each have a pivot connection near each gutter plate segment end region, that each have a gutter flash clamping surface extending outwardly from said base blow-mold sub-assembly product cavity mold parting-line perimeter;
• and
• crash pad element formed integrally with said multiple elongate gutter plate segments, projecting from said elongate gutter plate segment gutter flash clamping surfaces toward said cap blow-mold sub-assembly gutter flash clamping surface, and spaced-apart from each other at opposed sides of said base blow-mold sub-assembly by a distance which exceeds the width of said mold cavity;
• said multiple crash pad elements each contacting said cap blow-mold sub-assembly gutter flash clamping surface to establish the desired separation between said cap and base blow-mold sub-assembly product cavity mold parting line perimeters when said base and cap blow-mold sub-assemblies are operationally closed, thereby determining the thickness of gutter flash surrounding said base and cap blow-mold sub-assembly product cavity mold parting-line perimeters and further determining the wall thickness and the interior surface configuration characteristic of the product at the product mold parting-line perimeter.

A blow-mold assembly for use in a blow-molding machine which processes a heated thermoplastic resin parison to form a blow-molded thermoplastic resin product having integrally attached gutter flash surrounding the product, and to progressively separate the surrounding gutter flash from the product while the product is retained in the blow-mold assembly, comprising:

• a cap blow-mold sub-assembly having a product cavity that is defined in-part by a cavity mold parting-line perimeter and that is surrounded by a cap blow-mold sub-assembly gutter flash clamping surface extending outwardly from said product cavity mold parting-line perimeter;
• a base blow-mold sub-assembly having a support structure, and having a product cavity that is carried by said support structure and that is defined in-part by a cavity mold parting-line perimeter corresponding to said cap blow-mold sub-assembly product cavity mold parting-line perimeter;
• two elongate gutter plate segments that are each pivotally connected to and movable relative to said base blow-mold sub-assembly support structure, that together surround said base blow-mold sub-assembly product cavity mold parting-line perimeter when end-butted, that each have two pivot connections, each of said two pivot connections being located in a different one of the elongate gutter plate segment end regions, that each have a gutter flash clamping surface opposing and spaced-apart from said cap blow-mold sub-assembly gutter flash clamping surface;
• a bi-directional gutter plate segment drive that is carried by said base blow-mold sub-assembly support structure, that is co-operably connected to said base blow-mold sub-assembly gutter plate segments, and that is actuated to cause pivoting of each said base blow-mold sub-assembly elongate gutter plate segment relative to said base blow-mold sub-assembly product cavity mold parting-line perimeter in directions away from said base blow-mold sub-assembly product cavity mold cavity parting-line perimeter to separate integrally attached gutter flash from the product progressively along said base blow-mold sub-assembly product cavity mold cavity parting-line perimeter, said elongate gutter plate segment pivot connections each having a longitudinal pivot axis oriented normal to the plane of said base blow-mold sub-assembly product cavity mold cavity parting-line perimeter, and each said elongate gutter plate segment pivot connection permitting its co-operating elongate gutter plate segment to be translated linearly in directions parallel the plane of said base blow-mold sub-assembly product cavity mold parting-line perimeter when separating integrally attached gutter flash from the product progressively along said base blow-mold sub-assembly product cavity mold cavity parting-line perimeter.

In a method of separating integrally-attached gutter flash from a hollow molded product having a product surrounding mold parting line perimeter and a product interior mold parting-line perimeter interior, the steps of:

• forming, from a heated thermoplastic resin parison, a blow-molded product having an exterior, integrally-attached gutter flash extending away from the product surrounding mold parting line;
• forming, from said heated thermoplastic resin parison, a blow-molded gutter flash core extending to the product interior mold parting-line perimeter and having an integral elongate bellows void;
• progressively separating said blow-molded product exterior, integrally-attached gutter flash from said blow-molded product, and
• collapsing said blow-molded gutter flash core integral elongate bellows void to thereby separate said gutter flash core from said blow-molded product.

In a blow-mold assembly which processes a heated thermoplastic resin parison to form a hollow blow-molded thermoplastic resin product having an interior through-opening mold parting-line perimeter and having an integrally-attached gutter flash core that extends to the product interior through-opening mold parting-line perimeter, and which separates the integrally-attached gutter flash core from the hollow blow-molded product while that product is retained in the blow-mold assembly, in combination:

• a cap blow-mold sub-assembly having an interior gutter flash core clamping surface that extends to the product interior through-opening mold parting-line perimeter and having an elongate bellows void cavity recessed in said interior gutter flash core clamping surface;
• a base blow-mold sub-assembly having a support structure, having a bellows block carried by said support structure, and having an elongate bellows void cavity recessed in said bellows block in registration with said cap blow-mold sub-assembly elongate bellows void cavity;
• two base blow-mold sub-assembly gutter plate segments that are each pivoted relative to said base blow-mold sub-assembly support structure and the product interior through-opening mold parting-line perimeter, that extend to the product interior through-opening mold parting-line perimeter and are separated from each other by an elongate bellows gap registering with said cap and base blow-mold sub-assembly elongate bellows void cavities, that each have two pivot connections each one of which is located adjacent a different end of the elongate bellows gap separating said gutter plate segments, that each have a gutter flash core clamping surface opposing and spaced-apart from said cap blow-mold sub-assembly interior gutter flash core clamping surface;
• a bi-directional gutter plate segment drive that is carried by said base blow-mold sub-assembly support structure, that is co-operably connected to said base blow-mold sub-assembly gutter plate segments, and that is actuated to cause pivoting of each said base blow-mold sub-assembly gutter plate segment relative to said base blow-mold sub-assembly support structure and the product interior through-opening mold parting-line perimeter to separate the integrally attached gutter flash core from the product progressively along the product interior through-opening mold parting-line perimeter, said gutter plate segment pivot connections each having a longitudinal pivot axis oriented normal to the plane of the product interior through-opening mold parting-line perimeter, and each said gutter plate segment pivot connection permitting its co-operating gutter plate segment to be rotated in directions parallel to the plane of the product interior through-opening mold parting-line perimeter when separating the integrally-attached gutter flash core from the product along the product interior through-opening mold parting-line perimeter.

A blow-mold assembly for use in a blow-molding machine which processes a heated thermoplastic resin parison to form a blow-molded thermoplastic resin product having integrally-attached gutter flash surrounding the product and an integrally-attached interior gutter flash core, and to progressively separate the surrounding gutter flash and interior gutter flash core from the product while the product is retained in the blow-mold assembly, comprising:

• a cap blow-mold sub-assembly having a product cavity that is defined in-part by a product cavity mold parting-line perimeter and that is surrounded by a cap blow-mold sub-assembly exterior gutter flash clamping surface extending outwardly from said product cavity mold parting-line perimeter, and having an interior gutter flash core clamping surface that is defined by a product interior through-opening mold parting-line perimeter and that has an elongate bellows void cavity recessed in said interior gutter flash core clamping surface;
• a base blow-mold sub-assembly having a support structure, having a product cavity that is carried by said support structure and that is defined in-part by a product cavity mold parting-line perimeter corresponding to said cap blow-mold sub-assembly product cavity mold parting-line perimeter, having a bellows block carried by said support structure, and having an elongate bellows void cavity recessed in said bellows block in registration with said cap blow-mold sub-assembly elongate bellows void cavity;
• two elongate exterior gutter plate segments that are each pivotally connected to and movable relative to said base blow-mold sub-assembly support structure, that together surround said base blow-mold sub-assembly product cavity mold parting-line perimeter when end-butted, that each have two pivot connections, each of said two pivot connections being located in a different one of the elongate gutter plate segment end regions, that each have a gutter flash clamping surface opposing and spaced-apart from said cap blow-mold sub-assembly gutter flash clamping surface;
• two interior gutter plate segments that are each pivoted relative to said base blow-mold sub-assembly support structure and the product interior through-opening mold parting-line perimeter, that extend to the product interior through-opening mold parting-line perimeter and are separated from each other by an elongate bellows gap registering with said cap and base blow-mold sub-assembly elongate bellows void cavities, that each have two pivot connections each one of which is located adjacent a different end of the elongate bellows gap separating said gutter plate segments, that each have a gutter flash core clamping surface opposing and spaced-apart from said cap blow-mold sub-assembly interior gutter flash core clamping surface, and
• a bi-directional gutter plate segment drive that is carried by said base blow-mold sub-assembly support structure, that is co-operably connected to said base blow-mold sub-assembly exterior and interior gutter plate segments, and that is actuated to cause pivoting of each said base blow-mold sub-assembly exterior or interior gutter plate segment;
• said elongate gutter plate segment pivot connections and said interior gutter plate segment pivot connections each having a longitudinal pivot axis oriented normal to the plane of said base blow-mold sub-assembly product cavity mold cavity parting-line perimeter, and each said exterior elongate gutter plate segment pivot connection or said interior gutter plate segment pivot connection permitting its respective co-operating gutter plate segment to be translated linearly in directions parallel to the plane of said base blow-mold sub-assembly product cavity mold parting-line perimeter when separating integrally-attached surrounding gutter flash and interior gutter flash core from the blow-molded product progressively along said base blow-mold sub-assembly product cavity mold cavity parting-line perimeter and along said base blow-mold sub-assembly product interior through-opening mold parting-line perimeter while the blow-molded product is retained in the blow-mold assembly.

A blow-mold assembly for use in a blow-molding machine which processes a heated thermoplastic resin parison to form a blow-molded thermoplastic resin product having integrally attached gutter flash surrounding the product, and to progressively separate the surrounding gutter flash from the product while the product is retained in the blow-mold sub-assembly, and comprising:

• a cap blow-mold sub-assembly having a product cavity that is defined in-part by a mold parting-line perimeter, and that is surrounded by a cap blow-mold sub-assembly gutter flash clamping surface extending outwardly from said product cavity mold parting-line perimeter;
• a base blow-mold sub-assembly having a support structure, and having a product cavity that is carried by said support structure and that is defined in-part by a mold parting-line perimeter corresponding to said cap blow-mold sub-assembly product cavity mold parting-line perimeter;
• multiple base blow-mold sub-assembly elongate gutter plate segments that are each pivotable and movable relative to said base blow-mold sub-assembly support structure, that together surround said base blow-mold sub-assembly product cavity mold parting-line perimeter when end-abutted, that each have two, spaced-apart pivot connections each of which is positioned in a different one of the elongate gutter plate segment end regions, that each have a gutter flash clamping surface opposing and spaced-apart from said cap blow-mold sub-assembly gutter flash clamping surface;
• a controlled bi-directional gutter plate segment drive that is actuated to cause pivoting of each said elongate gutter plate segments in directions that do not intersect the plane of said base blow-mold sub-assembly product cavity mold parting-line perimeter to separate the product surrounding gutter flash from the product progressively along said base blow-mold sub-assembly product cavity mold parting-line perimeter;
• ejector pin elements provided in at least one of said base blow-mold assembly multiple elongate gutter plate segments;
• a multi-ramp slide member mounted on at least one of said elongate gutter plate segments;
• each ejector pin element engaging one ramp of said multi-ramp slide member;
• bi-directional ramp slide member actuator movable between one and another positions wherein said ejector pins are extended outwardly of said gutter flash clamping surface when said actuator is in said one said positions and wherein said ejector pins are retracted inwardly of said gutter flash clamping surface when said actuator is in said other positions.

A blow-mold assembly for use in a blow-molding machine which processes a heated thermoplastic resin parison to form a blow-molded thermoplastic resin product having integrally attached gutter flash surrounding the product, and to progressively separate the surrounding gutter flash from the product while the product is retained in the blow-mold sub-assembly, and comprising;

• a cap blow-mold sub-assembly having a product cavity that is defined in-part by a mold parting-line perimeter, and that is surrounded by a cap blow-mold sub-assembly gutter flash clamping surface extending outwardly from said product cavity mold parting-line perimeter;
• a base blow-mold sub-assembly having a support structure, and having a product cavity that is carried by said support structure and that is defined in-part by a mold parting-line perimeter corresponding to said cap blow-mold sub-assembly product cavity mold parting-line perimeter;
• multiple base blow-mold sub-assembly elongate gutter plate segments that are each pivotable and movable relative to said base blow-mold sub-assembly support structure, that together surround said base blow-mold sub-assembly product cavity mold parting-line perimeter when end-abutted, that each have two, spaced-apart pivot connections each of which is positioned in a different one of the elongate gutter plate segment end regions, that each have a gutter flash clamping surface opposing and spaced-apart from said cap blow-mold sub-assembly gutter flash clamping surface;
• a controlled bi-directional gutter plate segment drive that is actuated to cause pivoting of each said elongate gutter plate segments in directions that do not intersect the plane of said base blow-mold sub-assembly product cavity mold parting-line perimeter to separate the product surrounding gutter flash from the product progressively along said base blow-mold sub-assembly product cavity mold parting-line perimeter;
• at least one extensible and retractable spacer elements mounted in said base blow-mold sub-assembly support structure beneath said elongate gutter plate segments;
• a ramped slide member mounted in said base blow-mold sub-assembly having at least one ramp which receives said space elements;
• a bi-directional actuator operatively connected to said ramped slide member and movable between one and another positions wherein in said one position said spacer element is extended and engages said elongate gutter plate segment to define the space between said cap blow-mold sub-assembly gutter flash clamping surface and said gutter plate segment gutter flash clamping surface.

A blow-mold assembly for use in a blow-molding machine which processes a heated thermoplastic resin parison to form a blow-molded thermoplastic resin product having integrally attached gutter flash surrounding the product, and to progressively separate the surrounding gutter flash from the product while the product is retained in the blow-mold sub-assembly, and comprising:

• a cap blow-mold sub-assembly having a product cavity that is defined in-part by a mold parting-line perimeter, and that is surrounded by a cap blow-mold sub-assembly gutter flash clamping surface extending outwardly from said product cavity mold parting-line perimeter;
• a base blow-mold sub-assembly having a support structure, and having a product cavity that is carried by said support structure and that is defined in-part by a mold parting-line perimeter corresponding to said cap blow-mold sub-assembly product cavity mold parting-line perimeter;
• multiple base blow-mold sub-assembly elongate gutter plate segments that are each pivotable and movable relative to said base blow-mold sub-assembly support structure, that together surround said base blow-mold sub-assembly product cavity mold parting-line perimeter when end-abutted, that each have two, spaced-apart pivot connections each of which is positioned in a different one of the elongate gutter plate segment end regions, that each have a gutter flash clamping surface opposing and spaced-apart from said cap blow-mold sub-assembly gutter flash clamping surface;
• a controlled bi-directional gutter plate segment drive that is actuated to cause pivoting of each said elongate gutter plate segments in directions that do not intersect the plane of said base blow-mold sub-assembly product cavity mold parting-line perimeter to separate the product surrounding gutter flash from the product progressively along said base blow-mold sub-assembly product cavity mold parting line perimeter;
• at least one extensible and retractable crash pad element mounted in said base blow-mold sub-assembly support structure beneath said elongate gutter plate segments;
• a ramped slide member mounted in said base blow-mold sub-assembly having at least one ramp which receives one end of said crash pad element;
• a bi-directional actuator operatively connected to said ramped slide member and operable to move said ramped slide member between one and another positions wherein in said one position said crash pad element projects beyond said gutter plate segment gutter flash clamp surface to engage a cap blow-mold crash pad and in said another position said crash pad element is retracted to a position beneath said elongate gutter plate segment.