Systems and methods for mobile and/or modular manufacturing

• US 9,481,058 B2
• Filed: 08/21/2013
• Issued: 11/01/2016
• Est. Priority Date: 05/25/2007
• Status: Active Grant

• Current Assignee: Amcor Rigid Plastics USA Incorporated (Amcor Plc)
• Original Assignee: Amcor Rigid Plastics USA Incorporated (Amcor Plc)
• Inventors: Gaiser, Karin S
• Primary Examiner(s): Hindenlang, Alison L
• Assistant Examiner(s): Luk, Emmanuel S
• Application Number:
  US13/972,528
• Publication Number:
  US 20130333189A1
• Time in Patent Office: 1,168 Days
• Field of Search: 425/190, 425/192.R
• US Class Current: 1/1
• 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 mold stack-up module comprising:

a core module comprising;

a core plate, and

a plurality of cores extending from the core plate, wherein the plurality of cores are positioned along the core plate in two or less rows and comprise a first row of cores positioned along the core plate and a second row of cores positioned adjacent to and staggered from the first row of cores along the core plate; and

a cavity module comprising;

a cavity plate, and

a plurality of shaped chambers disposed in the cavity plate, wherein the plurality of shaped chambers are positioned along the cavity plate in two or less rows and comprise a first row of shaped chambers disposed within the cavity plate and a second row of shaped chambers disposed within the cavity plate, adjacent to and staggered from the first row of chambers;

wherein the core module and cavity module matingly engage each other such that each one of the plurality of shaped chambers receives a respective one of the plurality of cores to form a respective mold chamber.

2. The mold stack-up module of claim 1, wherein the respective mold chamber defines a preform.

3. The mold stack-up module of claim 1, wherein:

the first row of cores comprises eight cores positioned along the core plate and the second row of cores comprises eight cores positioned adjacent to and staggered from the first row of eight cores along the core plate; and

the first row of shaped chambers comprises eight shaped chambers disposed within the cavity plate and the second row of chambers comprises eight shaped chambers disposed within the cavity plate, adjacent to and staggered from the first row of eight chambers.

4. The mold stack-up module of claim 3, wherein the first row of eight cores and second row of eight cores matingly engaged with the first row of eight shaped chambers and second row of eight shaped chambers, respectively, to form eight mold chambers and eight mold chambers, respectively.

5. A method of molding a plurality of preforms using a single plastic injection mold machine, the method comprising:

using one to six mold stack-up modules according to claim 1; and

forming sixteen to one hundred preforms having one to six distinct preform designs simultaneously.

6. A mold stack-up module kit, the kit comprising:

a first mold stack-up module for forming a first preform design, the first mold stack-up module comprising;

a first core module comprising;

a core plate, and

a plurality of cores extending from the core plate, wherein the plurality of cores are positioned along the core plate in two or less rows and comprise a first row of cores positioned along the core plate and a second row of cores positioned adjacent to and staggered from the first row of cores along the core plate, and

a first cavity module comprising;

a cavity plate, and

a plurality of shaped chambers disposed in the cavity plate, wherein the plurality of shaped chambers are positioned along the cavity plate in two or less rows and comprise a first row of shaped chambers disposed within the cavity plate and a second row of shaped chambers disposed within the cavity plate, adjacent to and staggered from the first row of chambers,

wherein the first core module and first cavity module matingly engage each other such that each one of the plurality of shaped chambers receives a respective one of the plurality of cores to form a respective mold chamber shaped to form the first preform design; and

a second mold stack-up module for forming a second preform design, the second mold stack-up module comprising;

a second core module comprising;

a core plate, and

a plurality of cores extending from the core plate, wherein the plurality of cores are positioned along the core plate of the second core module in two or less rows and comprise a first row of cores positioned along the core plate of the second core module and a second row of cores positioned adjacent to and staggered from the first row of cores along the core plate of the second core module, and

a second cavity module comprising;

a cavity plate, and

a plurality of shaped chambers disposed in the cavity plate, wherein the plurality of shaped chambers are positioned along the cavity plate of the second cavity module in two or less rows and comprise a first row of shaped chambers disposed within the cavity plate of the second cavity module and a second row of shaped chambers disposed within the cavity plate, adjacent to and staggered from the first row of chambers along the cavity plate of the second cavity module,

wherein the second core module and second cavity module matingly engage each other such that each one of the plurality of shaped chambers receives a respective one of the plurality of cores to form a respective mold chamber shaped to form the second preform design which is different than the first preform design.

7. The kit of claim 6, further comprising a third mold stack-up module for forming a third preform design, the third mold stack-up module comprising:

a third core module comprising;

a core plate, and

a plurality of cores extending from the core plate, wherein the plurality of cores are positioned along the core plate in two or less rows; and

a third cavity module comprising;

a cavity plate, and

a plurality of shaped chambers disposed in the cavity plate, wherein the plurality of shaped chambers are positioned along the cavity plate in two or less rows;

wherein the third core module and third cavity module matingly engage each other such that each one of the plurality of shaped chambers receives a respective one of the plurality of cores to form a respective mold chamber shaped to form the third preform design which is the same as or different than the first and second preform designs.

8. The kit of claim 7, further comprising a fourth mold stack-up module for forming a fourth preform design, the fourth mold stack-up module comprising:

a fourth core module comprising;

a core plate, and

a plurality of cores extending from the core plate, wherein the plurality of cores are positioned along the core plate in two or less rows; and

a fourth cavity module comprising;

a cavity plate, and

a plurality of shaped chambers disposed in the cavity plate, wherein the plurality of shaped chambers are positioned along the cavity plate in two or less rows;

wherein the fourth core module and fourth cavity module matingly engage each other such that each one of the plurality of shaped chambers receives a respective one of the plurality of cores to form a respective mold chamber shaped to form the fourth preform design which is the same as or different than the first, second, and third preform designs.

9. The kit of claim 7, wherein the third preform design is different than the first and second preform designs.

10. The kit of claim 8, wherein the first, second, third, and fourth preform designs are all different from each other.

11. A mold stack-up module comprising a core side module configured to matingly engage a respective cavity side module,

wherein the core side module comprises:

a plurality of outwardly extending cores arranged in a staggered conformation wherein each of the plurality of outwardly extending cores comprises a base end;

a core plate comprising apertures through which the base end of the plurality of outwardly extending cores are inserted such that the outwardly extending cores extend from a top surface of the core plate;

a plurality of core sleeves each comprising an aperture into which the outwardly extending cores are inserted, each of the plurality of core sleeves comprising a flange which abuts the core plate;

an ejector plate positioned upon the flanges of the core sleeves, the ejector plate comprising apertures through which the plurality of outwardly extending cores and core sleeves extend therethrough;

a wear plate positioned upon the ejector plate, the wear plate comprising apertures through which the plurality of outwardly extending cores and core sleeves extend therethrough;

a left and a right carrier plate positioned upon the wear plate comprising apertures through which the plurality of outwardly extending cores extend therethrough;

wherein the ejector plate is secured to both the left and the right carrier plate by a plurality of gibs positioned at opposite ends of the ejector plate;

thread splits comprising apertures through which the plurality of outwardly extending cores extend therethrough wherein the thread splits are connectable to the ejector plate;

a pair of y-cams, comprising a pair of return cams, positioned at opposite ends of the carrier plates;

wherein the core plate apertures, the ejector plate apertures, the left and the right carrier plate apertures, and the thread split apertures are all coaxially aligned; and

wherein the cavity side module comprises;

a cavity plate comprising a plurality of staggered apertures corresponding to the plurality of outwardly extending cores of the respective core side module; and

a plurality of cavity portions inserted into the staggered apertures and attached to the cavity plate, each cavity portion comprising a shaped chamber configured to receive the outwardly extending cores such that the mating of the shaped chamber and the outwardly extending core forms a preform mold comprising a mold chamber having a specific preform design.

12. The mold stack-up module of claim 11, wherein the cavity plate comprises sixteen staggered apertures disposed in two rows of eight.

13. The mold stack-up module of claim 12, wherein the core play comprises sixteen staggered apertures disposed in two rows of eight that correspond with the sixteen staggered apertures of the cavity plate.

14. The mold stack-up module of claim 11, wherein each cavity portion comprises baffle cavities.

15. A method of molding preforms on a single plastic injection mold machine, the method comprising:

forming a plurality of preforms having a first preform design using a first mold stack-up module, the first mold stack-up module comprising;

a first core module comprising;

a core plate, and

a plurality of cores extending from the core plate, wherein the plurality of cores are positioned along the core plate in two or less rows and comprise a first row of cores positioned along the core plate and a second row of cores positioned adjacent to and staggered from the first row of cores along the core plate, and

a first cavity module comprising;

a cavity plate, and

a plurality of shaped chambers disposed in the cavity plate, wherein the plurality of shaped chambers are positioned along the cavity plate in two or less rows and comprise a first row of shaped chambers disposed within the cavity plate and a second row of shaped chambers disposed within the cavity plate, adjacent to and staggered from the first row of chambers,

wherein the first core module and first cavity module matingly engage each other such that each one of the plurality of shaped chambers receives a respective one of the plurality of cores to form a respective mold chamber shaped to form the first preform design; and

forming a plurality of preforms having a second preform design using a second mold stack-up module, the second mold stack-up module comprising;

a second core module comprising;

a core plate, and

a plurality of cores extending from the core plate, wherein the plurality of cores are positioned along the core plate of the second core module in two or less rows and comprise a first row of cores positioned along the core plate of the second core module and a second row of cores positioned adjacent to and staggered from the first row of cores along the core plate of the second core module, and

a second cavity module comprising;

a cavity plate, and

a plurality of shaped chambers disposed in the cavity plate, wherein the plurality of shaped chambers are positioned along the cavity plate of the second cavity module in two or less rows and comprise a first row of shaped chambers disposed within the cavity plate of the second cavity module and a second row of shaped chambers disposed within the cavity plate, adjacent to and staggered from the first row of chambers along the cavity plate of the second cavity module,

wherein the second core module and second cavity module matingly engage each other such that each one of the plurality of shaped chambers receives a respective one of the plurality of cores to form a respective mold chamber shaped to form the second preform design, which is different than the first preform design.

16. The method of claim 15, further comprising forming a plurality of preforms having a third preform design using a third mold stack-up module, the third mold stack-up module comprising:

a third core module comprising;

a core plate, and

a plurality of cores extending from the core plate, wherein the plurality of cores are positioned along the core plate in two or less rows, and

a third cavity module comprising;

a cavity plate, and

a plurality of shaped chambers disposed in the cavity plate, wherein the plurality of shaped chambers are positioned along the cavity plate in two or less rows,

wherein the third core module and third cavity module matingly engage each other such that each one of the plurality of shaped chambers receives a respective one of the plurality of cores to form a respective mold chamber shaped to form the third preform design, which is the same as or different than the first and second preform designs.

17. The method of claim 16, further comprising forming a plurality of preforms having a fourth preform design using a fourth mold stack-up module, the fourth mold stack-up module comprising:

a fourth core module comprising;

a core plate, and

a plurality of cores extending from the core plate, wherein the plurality of cores are positioned along the core plate in two or less rows, and

a fourth cavity module comprising;

a cavity plate, and

a plurality of shaped chambers disposed in the cavity plate, wherein the plurality of shaped chambers are positioned along the cavity plate in two or less rows,

wherein the fourth core module and fourth cavity module matingly engage each other such that each one of the plurality of shaped chambers receives a respective one of the plurality of cores to form a respective mold chamber shaped to form the fourth preform design, which is the same as or different than the first, second, and third preform designs.

18. The method of claim 17, wherein the first, second, third, and fourth preform designs are all different from each other.