Systems and methods for mobile and/or modular manufacturing

• US 8,543,434 B2
• Filed: 05/27/2008
• Issued: 09/24/2013
• Est. Priority Date: 05/25/2007
• Status: Active Grant

• Current Assignee: Amcor Rigid Plastics USA Incorporated (Amcor Plc)
• Original Assignee: Ecovision Technologies, LLC
• Inventors: Gaiser, Karin S.
• Primary Examiner(s): Sterrett, Jonathan G
• Assistant Examiner(s): Anderson, Folashade
• Application Number:
  US12/127,402
• Publication Number:
  US 20120274000A1
• Time in Patent Office: 1,946 Days
• Field of Search: 425/556, 425/564, 425/572, 705/7.11
• US Class Current: 705/7.11
• CPC Class Codes: B23P 19/04 for assembling or disassembling parts
• CPC Class Codes: B29C 2045/2683 Plurality of independent mould cavities in a single mould
• CPC Class Codes: B29C 45/26 Moulds
• CPC Class Codes: B29C 45/40 Removing or ejecting moulded articles
• CPC Class Codes: B29K 2105/253 Preform
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

Systems and methods for manufacturing that are scaleable and de-scaleable based upon the production requirements of the customer'"'"'s manufacturing facility. Systems and methods for mobile and/or modular manufacturing positioned at or near a customer'"'"'s production facility that are scaleable and de-scaleable based upon the production requirements of the customer'"'"'s manufacturing facility. The systems and methods of manufacturing may include identifying a customer'"'"'s production requirements at the customer'"'"'s production facility, designing a manufacturing cell based upon the identified production requirements, delivering components for the manufacturing cell to a location at or near the customer'"'"'s production facility, assembling the components to form the manufacturing cell at the location, and training operational personnel to operate the manufacturing cell. The systems and methods may comprise using a modular preform mold system.

Claims

1. A method of manufacturing, comprising:

identifying a customer'"'"'s production requirements at the customer'"'"'s production facility;

designing a manufacturing cell based upon the identified production requirements;

delivering components for the manufacturing cell to a location at or near the customer'"'"'s production facility;

assembling the components to form the manufacturing cell at the location, wherein the manufacturing cell comprises;

a modular preform mold system comprising;

a plurality of preform core side modules having a plurality of preform mold cores,

a core side clamp plate connectable to a moving platen of an injection mold machine and operable to receive the plurality of preform core modules, individually or simultaneously,

a plurality of preform cavity side modules having a plurality of preform mold cavities disposed therein, each one of the plurality of preform cavity side modules corresponding to and operable to engage a respective one of the plurality of core side modules to form a plurality of preform molds having a respective preform design wherein the plurality of preform molds are of one or more unique preform designs, and wherein the number of cavity side modules and corresponding core side modules is adjustable,

a plurality of ejector housing assemblies for connecting the plurality of core side modules to an ejector platen of the injection mold machine, each one of the plurality of ejector housing assemblies corresponding to a respective one of the plurality of core side modules,

a manifold and valve gate assembly connectable to a stationary platen of an injection mold machine and operable to receive the plurality of preform cavity modules and place the plurality of preform mold cavities in fluid communication with an injector of the injection mold machine,

wherein the manifold and valve gate assembly is operable to uniformly control the injection of fluidized plastic into each of the plurality of preform molds in fluid communication with the manifold and valve gate assembly whereby a plurality of unique preform designs may be formed simultaneously while using a single injection mold machine, and

training operational personnel to operate the manufacturing cell.

2. The method according to claim 1, wherein the manufacturing cell comprises an injection mold machine.

3. The method according to claim 2, wherein the injection mold machine comprises a preform injection mold machine.

4. The method according to claim 3, wherein modular preform mold system connects to the preform injection mold machine.

5. The method according to claim 1, wherein the step of identifying the customer'"'"'s production requirements comprises an interview of one or more of the customer'"'"'s personnel to assist in defining the customer'"'"'s production requirements.

6. The method according to claim 1, wherein the step of training operational personnel to operate the manufacturing cell comprises training the operational personnel at a Provider'"'"'s facilities.

7. The method according to claim 1, wherein the step of training operational personnel to operate the manufacturing cell comprises training the operation personal on the assembled manufacturing cell'"'"'s equipment at the Customer'"'"'s production facility.

8. The method according to claim 1, further comprising monitoring one or more parameters of the manufacturing cell remotely.

9. The method according to claim 1, wherein the manufacturing cell comprises a base systems section and a first phase production section.

10. The method according to claim 9, further comprising assembling a second phase production section based upon increased customer production requirements.

11. The method according to claim 10, further comprising assembling a third phase production section based upon increased customer production requirements.

12. The method according to claim 9, further comprising assembling one or more phase production sections based upon increased customer production requirements.

13. The method according to claim 12, further comprising disassembling the one or more phase production sections based upon decreased customer production requirements.

14. The method according to claim 13, further comprising disassembling the manufacturing cell based upon decreased customer production requirements.

15. The method according to claim 14, further comprising removing the manufacturing cell and the one or more phase production sections from the customer'"'"'s production facility.

16. The method according to claim 1, wherein the manufacturing cell is mobile and/or modular.

17. A method according to claim 1, further comprising capturing scrap plastic materials, regrinding the scrap plastic materials, and reusing the ground plastic material for production of new products.

18. A method of preform manufacturing, comprising:

identifying a customer'"'"'s preform production requirements at the customer'"'"'s production facility;

designing a preform injection mold manufacturing cell based upon the identified preform production requirements;

delivering components for the preform injection mold manufacturing cell to a location at or near the customer'"'"'s production facility;

assembling the components to form the preform injection mold manufacturing cell at the location, wherein the manufacturing cell is adjustable in number of preform molds of or more unique preform designs, assembly of the manufacturing cell comprising;

attaching a core side clamp plate to a moving platen of a single injection mold machine, the first clamp plate adapted to receive from one to six preform core side modules, individually or simultaneously, wherein each preform core side module comprises a plurality of preform mold cores;

engaging the preform core side modules with the respective mating preform cavity side modules to form a plurality of preform molds; and

attaching a manifold and valve gate assembly to a stationary platen of the single injection mold machine, the manifold and valve gate assembly adapted to receive from one to six respective preform cavity side modules, individually or simultaneously, wherein each preform cavity side module comprises a plurality of preform mold cavities, and the plurality of mold cores of the preform core side modules are adapted to insert within the plurality of preform mold cavities of the respective preform cavity side modules, wherein the manifold and valve gate assembly is operable to uniformly control the injection of fluidized plastic into each of the plurality of preform molds in fluid communication with the manifold and valve gate assembly, whereby a plurality of unique preform designs may be formed simultaneously while using only a single injection mold machine.