Unloading and assembly system and process for injection molding apparatus

A process for forming an injection molded article from two complementary parts, said process comprising:

• providing an injection molding apparatus having a central mold member with at least one mold cavity in each of its two faces and two mating mold halfs each having a mold core element in a face;
• substantially simultaneously forming at least one first part and at least one complementary second part in said molding apparatus;
• and
• mating said at least one part with said at least one complementary second part in an internal region of said central mold member when said molding apparatus is in a mold closed position.

An apparatus for forming an assembled article from two injection molded parts, said apparatus comprising:

• means for substantially simultaneously forming a first injection molded part and a second complementary injection molded part;
• means for assembling said first and second parts into said article;
• said assembling means being located within said forming means;
• and
• means for unloading said first and second parts when said forming means is in a first portion of a molding cycle and for inserting said first and second parts into said assembling means when said forming means is in a second portion of said molding cycle.

An apparatus for forming an assembled article from two injection molded parts, said apparatus comprising:

• means for substantially simultaneously forming a first injection molded part and a second complementary injection molded part;
• means for assembling said first and second parts into said article;
• said assembling means being located within said forming means;
• means for unloading said first and second parts when said forming means is in a first portion of a molding cycle and for inserting said first and second parts into said assembling means when said forming means is in a second portion of said molding cycle;
• said forming means including a central mold member having two opposed faces;
• said assembling means comprising at least one port in each said face;
• said forming means further including two mold halfs with a first one of said mold halfs being positioned opposite a first face of said central mold member and a second one of said mold halfs being positioned opposite a second face of said central mold member;
• and
• said unloading and inserting means comprising a handling system pivotably mounted to each said mold half.

An apparatus for forming a plurality of assembled articles from a plurality of molded parts, said apparatus comprising:

• molding means for forming a plurality of first parts and a plurality of mating second parts during a single molding cycle;
• said molding means comprising first and second mold halfs each having a plurality of core elements and a central mold member positioned intermediate said mold halfs;
• said central mold member having a first face opposed to said first mold half and a second face opposed to said second mold half;
• each said face having a plurality of cavities aligned with said core elements on one of said first and second mold halfs;
• each said face further having a plurality of loading ports with the number of the ports being equal to the number of cavities therein, the loading ports in said first face being aligned with the loading ports in said second face;
• said first and second mold halfs and said central mold member moving relative to each other between a mold open position and a mold closed position during which said first and second parts are formed;
• and
• handling means for grasping said first and second parts during said mold open position, for removing said first and second parts from between respective ones of said mold halfs and said stack mold member, and for assisting in assembling said first parts to said second parts.

A system for unloading parts from an injection molding apparatus having a mold half and a mating mold member, said system comprising:

• means for contacting and removing said parts from between said mold half and said mating mold member;
• means for driving said contacting and removing means;
• said driving means comprising at least one rotatable member supporting said contacting and removing means mounted to said mold half and gear means affixed to said at least one rotatable member;
• said driving means further comprising a cam plate attached to said mating mold member and a movable block mounted to said mold half;
• and
• said movable block having rack means contacting said gear means and a cam follower for contacting said cam plate;
• whereby movement between said mold half and said mating mold member causes relative movement between said cam follower and said cam plate which in turn causes movement of said block member and said rack means so as to cause rotation of said gear means, said at least one rotatable member and said contacting and removing means.

An apparatus for forming an assembled article from two injection molded parts, said apparatus comprising:

• means for substantially simultaneously forming a first injection molded part and a second complementary injection molded part;
• means for assembling said first and second parts into said article;
• said assembling means being located within said forming means;
• said forming means including a central mold member having two opposed faces;
• said assembling means including an internal region of said central mold member wherein said first injection molded part is mated with said second injection molded part;
• and
• at least one internal chute assembly within said central mold member for transporting assembled articles away from said mold member.