1. A hot runner nozzle for delivering melt to a mold cavity, the hot runner nozzle comprising:

an inner nozzle insert defining an inner flow passage;

a middle nozzle insert disposed around the inner nozzle insert,

the intermediate nozzle insert and the inner nozzle insert defining an intermediate flow channel; and

an outer nozzle insert disposed around the middle nozzle insert, the outer nozzle insert and the middle nozzle insert defining an outer flow passage,

the intermediate nozzle insert and the inner nozzle insert cooperate to define an intermediate outlet,

at least one of the inner nozzle insert and the intermediate nozzle insert further defines at least one orifice disposed upstream of the intermediate outlet, the at least one orifice being arranged in fluid connection with at least one of the inner flow channel and the outer flow channel.

2. The hot runner nozzle of claim 1, wherein, in use, when delivering the melt to the mold cavity:

a first melt stream of a first polymeric material flows through and exits the inner flow channel and the outer flow channel;

a second melt stream of a second polymeric material flows through the intermediate flow channel; and

at least a portion of the second melt stream passes from the intermediate flow channel through the at least one orifice to at least one of the inner flow channel and the outer flow channel.

3. The hot runner nozzle according to claim 2, wherein:

the intermediate nozzle insert defining the at least one orifice; and is

When in use, at least a portion of the second melt stream passes from the intermediate flow channel through the at least one orifice to the outer flow channel.

4. The hot runner nozzle according to claim 3, wherein the at least one orifice comprises:

a first plurality of apertures defined along a first line extending longitudinally along the intermediate nozzle insert; and

a second plurality of orifices defined along a second line extending longitudinally along the intermediate nozzle insert, the first line and the second line being separate from one another.

5. The hot runner nozzle according to claim 2, wherein:

the inner nozzle insert defining the at least one orifice; and is

When in use, at least a portion of the second melt stream passes from the intermediate flow channel through the at least one orifice to the inner flow channel.

6. The hot runner nozzle according to claim 5, wherein the at least one orifice comprises:

a first plurality of apertures defined along a first line extending longitudinally along the inner nozzle insert; and

a second plurality of orifices defined along a second line extending longitudinally along the inner nozzle insert, the first line and the second line being separate from one another.

7. The hot runner nozzle according to any one of claims 2 to 6 wherein the mold cavity is for defining, in use, a molded article having a core layer and a skin layer surrounding the core layer, the core layer being formed of the second polymeric material flowing through the intermediate flow channel, the core layer having a non-uniform radial thickness about a longitudinal axis of the molded article.

8. The hot runner nozzle according to claim 1, wherein the at least one orifice includes a plurality of orifices fluidly connecting the intermediate flow channel with at least one of the inner flow channel and the outer flow channel.

Background

Molding is a method of forming a molded article from a molding material by using a molding system. Various molded articles can be formed by using a molding process (e.g., an injection molding process). One example of a molded article that can be formed from, for example, polyethylene terephthalate (PET) material is a preform that can be subsequently blown into a beverage container (e.g., a bottle, etc.). In other words, the preform is an intermediate product that is then processed by a stretch blow molding process into a final shaped container (as one example). During stretch blow molding, the material of the preform exhibits certain properties (e.g., stretch ratio, which depends on reheat temperature, etc.).

It will be appreciated that a typical preform is circularly symmetric about its longitudinal axis. Some of the final shaped molded articles are also circularly symmetric. For example, beverage containers (bottles) for still or foamed beverages are substantially symmetrical about their longitudinal axis (e.g., when standing on a shelf). Other final shaped containers are not circularly symmetric. Examples of such non-circularly symmetric final shaped containers include, but are not limited to: containers for household cleaning liquids (e.g., glass cleaning liquids, toilet bowl cleaning liquids, etc.), containers for personal care products (shampoos, conditioners, etc.), and the like.

Blow molding a symmetric preform into an asymmetric container can cause challenges related to the structure and/or stretch blow molding process, such as a weaker wall where the preform has been maximally expanded.

Some preforms (and thus the final shaped containers) are made from a single molding material. For example, the preforms described above for stretch blow molding into beverage containers for still or foamed beverages are typically made from a single material of PET. PET is well suited for these applications. However, PET is not ideally suited for other applications. In this regard, for certain applications, no single material is a viable option (either because it lacks certain properties or because it is not commercially viable). Accordingly, it is also known to make multi-material preforms in which another material (often referred to as a "core material") is added and "sandwiched" between inner and outer layers of one or more other materials.

For example, certain materials may be selected as the core layer to enhance oxygen impermeability (e.g., barrier materials such as EVOH or PGA), enhance light impermeability, and the like.

Disclosure of Invention

The object of the present invention is to ameliorate at least some of the inconveniences of the prior art.

Without wishing to be bound by any particular theory, embodiments of the present technology are developed based on the developer's recognition that the geometry of the core/barrier layer may help to selectively control stretching or blowing of the final shaped container. Developers have also recognized that controlled non-uniform geometry of the core layer can be used for aesthetic purposes, including producing selective color changes in the final shaped container.

In accordance with a first broad aspect of the present technique, there is provided a molded article suitable for subsequent blow molding into a final shaped container. The article comprises a neck portion; a gate portion; and a body portion extending between the neck portion and the gate portion, at least a majority of the body portion having an overall shape that is symmetrical about a body axis extending longitudinally through a center of the body portion, at least the body portion including an inner outer layer and an outer layer of a first polymeric material; and a core layer of a second polymeric material disposed between at least a portion of the inner and outer layers, the core layer having a radial thickness that is selectively varied to control non-uniform blow molding of the molded article into the final shaped container.

In some embodiments of the molded article, the rate of thermal crystallization of the first polymeric material is substantially less than the rate of thermal crystallization of the second polymeric material; and the second polymeric material comprises at least one of a strain crystallizable homopolymer, copolymer, and blend of polyethylene terephthalate (PET).

In some embodiments of the molded article, at least a majority of the neck portion is comprised of the first polymeric material and is free of the second polymeric material.

In some embodiments of the molded article, the second polymeric material has a substantially higher intrinsic viscosity than the first polymeric material.

In some embodiments of the molded article, the radial thickness of the core layer varies about the body axis.

In some embodiments, the core layer has a localized region of increased radial thickness.

In some embodiments of the molded article, the radial thickness of the core layer has an asymmetrical annular form about the body axis.

In some embodiments of the molded article, the radial thickness of the core layer has a symmetrical annular form about the body axis.

In some embodiments of the molded article, the core layer has a semi-annular core layer.

In some embodiments of the molded article, the core layer varies in radial thickness in the axial direction.

In some embodiments of the molded article, the core layer is interrupted such that the radial thickness of the core layer is reduced to zero at least one location; and the inner outer layer and the outer layer are in contact at least one location.

In some embodiments of the molded article, the molded article further comprises a transition portion extending between the neck portion and the body portion; and wherein the transition portion comprises a transition inner layer and a transition outer layer of the first polymeric material; and a transitional core layer of a second polymeric material disposed between at least a portion of the inner outer layer and the outer layer.

In some embodiments of the molded article, the transition core layer is interrupted such that the radial thickness of the transition core layer is reduced to zero at least one location.

In accordance with another broad aspect of the present technique, there is provided a molded article suitable for subsequent blow molding into a final shaped container. The molded article includes a neck portion; a gate portion; and a body portion extending between the neck portion and the gate portion, at least the body portion comprising an inner outer layer and an outer layer of a first polymeric material; and a core layer of a second polymeric material disposed between at least a portion of the inner outer layer and the outer layer, the first polymeric material having a thermal crystallization rate substantially less than a thermal crystallization rate of the second polymeric material, the second polymeric material comprising at least one of a strain crystallizable homopolymer, copolymer, and blend of polyethylene terephthalate (PET).

In accordance with yet another broad aspect of the present technique, there is provided a molded article suitable for subsequent blow molding into a final-shaped container. The molded article includes a neck portion; a gate portion; and a body portion extending between the neck portion and the gate portion, at least the body portion comprising an inner outer layer and an outer layer of a first polymeric material; and a core layer of a second polymeric material disposed between the inner outer layer and at least a portion of the outer layer, the second polymeric material having a substantially higher intrinsic viscosity than the first polymeric material.

In accordance with yet another broad aspect of the present technique, there is provided a molded article suitable for subsequent blow molding into a final-shaped container. The molded article includes a neck portion; a gate portion; and a body portion extending between the neck portion and the gate portion, at least a majority of the body portion having an overall shape that is symmetrical about a body axis extending longitudinally through a center of the body portion, at least the body portion including an inner outer layer and an outer layer of a first polymeric material; and a core layer of a second polymeric material disposed between at least a portion of the inner and outer layers, the core layer having a radial thickness that is selectively varied to produce a change in color distribution in the final shaped vessel.

In some embodiments, the first polymeric material has a first color; and the second polymeric material has a second color different from the first color.

In some embodiments, the radial thickness of the core layer varies about the body axis.

In some embodiments, the radial thickness of the core layer has an asymmetric annular form about the body axis.

In some embodiments, the core layer has a localized region of increased radial thickness.

According to yet another broad aspect of the present technique, there is provided a hot runner nozzle for delivering melt to a mold cavity. The hot runner nozzle includes an inner nozzle insert defining an inner flow passage; an intermediate nozzle insert disposed about the inner nozzle insert, the intermediate nozzle insert and the inner nozzle insert defining an intermediate flow channel; and an outer nozzle insert disposed about the middle nozzle insert, the outer nozzle insert and the middle nozzle insert defining an outer flow channel, the middle nozzle insert and the inner nozzle insert cooperating to define a middle outlet, at least one of the inner nozzle insert and the middle nozzle insert further defining at least one orifice disposed upstream of the middle outlet, the at least one orifice being disposed in fluid connection with at least one of the inner flow channel and the outer flow channel.

In some embodiments, in use, a first melt stream of a first polymeric material flows through and out of the inner and outer flow channels as the melt is delivered to the mold cavity; a second melt stream of a second polymeric material flows through the intermediate flow channel; and at least a portion of the second melt stream passes from the intermediate flow channel through the at least one orifice to at least one of the inner flow channel and the outer flow channel.

In some embodiments, the intermediate nozzle insert defines at least one orifice; and in use, at least a portion of the second melt stream passes from the intermediate flow channel through the at least one orifice to the outer flow channel.

In some embodiments, the at least one orifice comprises a first plurality of orifices defined along a first line extending longitudinally along the intermediate nozzle insert; and a second plurality of orifices defined along a second line extending longitudinally along the intermediate nozzle insert, the first and second lines being separated from one another.

In some embodiments, the inner nozzle insert defines at least one orifice; and in use, at least a portion of the second melt stream passes from the intermediate flow channel through the at least one orifice to the inner flow channel.

In some embodiments, the at least one orifice comprises a first plurality of orifices defined along a first line extending longitudinally along the inner nozzle insert; and a second plurality of orifices defined along a second line extending longitudinally along the inner nozzle insert, the first and second lines being separated from one another.

In some embodiments, the mold cavity is for defining, in use, a molded article having a core layer and a skin layer surrounding the core layer, the core layer being formed of a second polymeric material flowing through the intermediate flow channel, the core layer having a non-uniform radial thickness about a longitudinal axis of the molded article.

In some embodiments, the at least one orifice comprises a plurality of orifices fluidly connecting the intermediate flow channel with at least one of the inner flow channel and the outer flow channel.

According to yet another broad aspect of the present technique, there is provided a hot runner nozzle for delivering melt to a mold cavity. The hot runner nozzle includes: an inner nozzle insert defining an inner flow passage, the inner flow passage including an inner outlet; an intermediate nozzle insert disposed about the inner nozzle insert, the intermediate nozzle insert and the inner nozzle insert defining an intermediate flow passage, the intermediate flow passage including an intermediate outlet; and an outer nozzle insert disposed around the middle nozzle insert, the outer nozzle insert and the middle nozzle insert defining an outer flow channel, the outer flow channel including an outer outlet, the inner nozzle insert being formed such that the middle outlet has a non-uniform cross-section.

In some embodiments, the mould cavity is for defining, in use, a moulded article having a core layer and a skin layer surrounding the core layer, the core layer being formed from material flowing through the intermediate flow passage, the material having a non-uniform radial thickness about the axis.

In some embodiments, the inner outlet, the intermediate outlet, and the outer outlet are immediately adjacent to one another.

In some embodiments, the inner nozzle insert is formed such that the intermediate outlet extends only partially around a longitudinal axis of the hot runner nozzle.

In some embodiments, the inner nozzle insert has an outer surface that partially defines the intermediate flow channel; and the outer surface has an elliptical form with the center of the elliptical form surface offset from the longitudinal axis of the hot runner nozzle.

In some embodiments, the inner outlet and the outer outlet are arranged concentrically.

In some embodiments, the intermediate outlet is disposed between a portion of the concentrically arranged inner and outer outlets.

In some embodiments, in use, a first melt stream of a first polymeric material flows through and out of the inner and outer flow channels when the melt is transferred into the mold cavity; a second melt stream of a second polymeric material flows through and out of the intermediate flow channel, the second polymeric material forming a core layer of a molded product produced from the melt in the mold cavity; and the first melt stream and the second melt stream intersect at a junction region.

In some embodiments, the mold cavity is for defining, in use, a molded article having a core layer and a skin layer surrounding the core layer, the core layer being formed of a second polymeric material flowing through the intermediate flow channel, the core layer having a non-uniform radial thickness about a longitudinal axis of the molded article.

According to yet another broad aspect of the present technique, there is provided a hot runner nozzle for delivering melt to a mold cavity. The hot runner nozzle includes an inner nozzle insert defining an inner flow passage; an intermediate nozzle insert disposed about the inner nozzle insert, the intermediate nozzle insert and the inner nozzle insert defining an intermediate flow channel; and an outer nozzle insert disposed about the intermediate nozzle insert, the outer nozzle insert and the intermediate nozzle insert defining an outer flow channel, a flow of material through the intermediate flow channel being non-uniformly distributed about a longitudinal axis of the hot runner nozzle when the hot runner nozzle is in use, the flow non-uniformity being due to surfaces of the intermediate nozzle insert and the inner nozzle defining the intermediate flow channel, a mold cavity for defining, in use, a molded article, the molded article having a core layer and a skin layer surrounding the core layer, the core layer being formed of material flowing through the intermediate flow channel, the core layer having a non-uniform radial thickness about the longitudinal axis of the molded article.

These and other aspects and features of non-limiting embodiments of the present technology will become apparent to those skilled in the art upon review of the following description of specific non-limiting embodiments of the present technology in conjunction with the accompanying figures.

Embodiments of the present technology each have at least one, but not necessarily all, of the above objects and/or aspects. It should be appreciated that some aspects of the present technology that arise from an attempt to achieve the above objectives may not meet this objective and/or may meet other objectives not specifically recited herein.

Additional and/or alternative features, aspects, and advantages of embodiments of the present technology will become apparent from the following description, the accompanying drawings, and the appended claims.

Drawings

This patent or application document contains at least one drawing executed in color. Copies of this patent or patent application publication with color drawing(s) will be provided by the office upon request and payment of the necessary fee.

Embodiments of the present technology (including alternatives and/or variations thereof) may be better understood with reference to the detailed description of non-limiting embodiments along with the following drawings, in which:

FIG. 1 is a cross-sectional view of a multi-layer preform as known in the prior art;

FIG. 2 is a top view schematic diagram of an injection molding machine that may be adapted to produce embodiments of non-limiting embodiments of the present technique;

FIG. 3A is a longitudinal cross-sectional view of a multi-layer preform in accordance with one embodiment of the present technique;

FIG. 3B is a horizontal cross-sectional view of the multi-layer preform of FIG. 3A taken along line 3B-3B of FIG. 3A;

FIG. 4A is a longitudinal cross-sectional view of a multi-layer preform in accordance with another embodiment of the present technique;

FIG. 4B is a horizontal cross-sectional view of the multi-layer preform of FIG. 4A taken along line 4B-4B of FIG. 4A;

FIG. 5A is a longitudinal cross-sectional view of a multi-layer preform in accordance with yet another embodiment of the present technique; FIG. 5B is a horizontal cross-sectional view of the multi-layer preform of FIG. 5A taken along line 5B-5B of FIG. 5A;

FIG. 6A is a longitudinal cross-sectional view of a multi-layer preform in accordance with yet another embodiment of the present technique; FIG. 6B is a horizontal cross-sectional view of the multi-layer preform of FIG. 6A taken along line 6B-6B of FIG. 6A;

FIG. 6C is a front elevational view of a blow molded product blow molded from the preform of FIG. 6A;

FIG. 7A is a longitudinal cross-sectional view of a multi-layer preform in accordance with yet another embodiment of the present technique;

FIG. 7B is a front elevational view of a blow molded product blow molded from the preform of FIG. 7A;

FIG. 8A is a longitudinal cross-sectional view of a multi-layer preform in accordance with yet another embodiment of the present technique;

FIG. 8B is a horizontal cross-sectional view of the multi-layer preform of FIG. 8A taken along line 8B-8B of FIG. 8A;

FIG. 8C is a front elevational view of a blow molded product blow molded from the preform of FIG. 8A;

FIG. 9A is a longitudinal cross-sectional view of a multi-layer preform in accordance with yet another embodiment of the present technique;

FIG. 9B is a horizontal cross-sectional view of the multi-layer preform of FIG. 9A taken along line 9B-9B of FIG. 9A;

FIG. 9C is a front elevational view of a blow molded product blow molded from the preform of FIG. 9A;

FIG. 10 is a longitudinal cross-sectional view of a multi-layer preform in accordance with yet another embodiment of the present technique;

FIG. 11 is a longitudinal cross-sectional view of a multi-layer preform in accordance with yet another embodiment of the present technique;

FIG. 12 is a cross-section of a hot runner nozzle (the cross-section being taken along an operational axis of the hot runner nozzle) suitable for implementing embodiments of the present technique;

FIG. 13 is a cross-section of the hot runner nozzle of FIG. 12 taken along line 13-13 of FIG. 12, the hot runner nozzle being configured for producing preforms having a core radial thickness that does not vary about an operating axis;

FIG. 14 is a cross-section of the hot runner nozzle of FIG. 12 taken along line 13-13 of FIG. 12, the hot runner nozzle being configured to produce preforms having a core layer radial thickness that varies about an operating axis;

15A-15D illustrate the sequence of valve stem repositioning to selectively undulate the core layer, the repositioning of the valve stem serving to form the shape of the core layer, in some non-limiting embodiments of the present technique;

FIG. 16A is a photograph produced by a backlit optical comparator of a cross-section of another non-limiting embodiment of a molded article according to the present techniques;

FIG. 16B is a line drawing representation of the cross-section of FIG. 16A;

fig. 16C is a bottom plan view photograph of the molded article of fig. 16A;

FIG. 16D is a line drawing representation of the photograph of FIG. 16C;

FIG. 17 is a cross-section of another embodiment of a hot runner nozzle (the cross-section being taken along an operational axis of the hot runner nozzle) suitable for implementing embodiments of the present technique;

FIG. 18 is a perspective view of a middle nozzle insert of the hot runner nozzle of FIG. 17;

FIG. 19 is a side view of another embodiment of an intermediate nozzle insert of a hot runner nozzle, the nozzle insert and hot runner nozzle being suitable for practicing embodiments of the present invention;

FIG. 20 is a cross-sectional view of the middle nozzle insert of FIG. 19 taken along line 20-20 of FIG. 19;

FIG. 21 is a perspective view of the intermediate nozzle insert of FIG. 19;

FIG. 22 is a side view of an intermediate nozzle insert of yet another embodiment of an intermediate nozzle insert of a hot runner nozzle, the nozzle insert and hot runner nozzle being suitable for practicing embodiments of the present technique;

FIG. 23 is a cross-sectional view of the middle nozzle insert of FIG. 22 taken along line 23-23 of FIG. 22;

FIG. 24 is a side view of yet another embodiment of an intermediate nozzle insert of a hot runner nozzle, the nozzle insert and hot runner nozzle being suitable for practicing embodiments of the present technique;

FIG. 25 is a cross-sectional view of the middle nozzle insert of FIG. 24 taken along line 25-25 of FIG. 24;

FIG. 26 is a cross-section of yet another embodiment of a hot runner nozzle (the cross-section being taken along an operational axis of the hot runner nozzle) suitable for implementing embodiments of the present technique;

FIG. 27 is a cross-sectional view of an intermediate nozzle insert of the hot runner nozzle (the cross-section being taken along the operational axis of the hot runner nozzle) illustrating various orifice embodiments;

FIGS. 28 and 29 are perspective views of an embodiment of an inner nozzle insert of a hot runner nozzle suitable for practicing embodiments of the present technique;

FIG. 30 is a bottom plan view of the inner nozzle insert of FIG. 28; and

FIG. 31 is a cross-sectional view of the inner nozzle insert of FIG. 28 disposed in a hot runner nozzle, taken along line 31-31 of FIG. 30.

Detailed Description

Referring to fig. 1, a cross-section of a molded article 50, particularly a multi-layer preform 50, manufactured by a molding machine known in the art is depicted. The prior art multi-layer preform 50 is described herein to provide a general structure of a molded article suitable for subsequent blow molding; the details of the molded article according to the present technology will be described in more detail below.

The multi-layer preform 50 is manufactured by an injection molding machine 100 described below with reference to fig. 2. It is contemplated that the multi-layer preform 50 may be manufactured by another type of molding machine (e.g., extrusion blow molding, transfer blow molding, etc.).

Multi-layer preform 50 is comprised of neck portion 32, gate portion 36 (i.e., "base"), and body portion 34 extending between neck portion 32 and gate portion 36. Gate portion 36 is associated with a generally spherical shape terminating in vestige portion 38. Of course, the gate portion 36 may be implemented in another form factor (e.g., generally conical, frustoconical, etc.). The body portion 34 of the multi-layer preform 50 is formed of three layers. As described below, portions of the body portion 34 may be formed from more or fewer layers, depending on the embodiment.

On the outside, the body portion 34 has an outer skin 20 and an inner outer skin 25. The skin layers 20, 25 may be made of various materials. For example, in a multi-layer preform 50 for making a beverage container, the skin layers 20, 25 are made of virgin polyethylene terephthalate (PET), which is FDA approved for contact with food. It is contemplated that skin layers 20, 25 may be made of a variety of other materials, including any suitable polymer resins and thermoplastics, as will be appreciated by those skilled in the art.

The multi-layer preform 50 has a cavity identification number 15 imprinted on the skin 25. Although the lumen identification number 15 is shown as being located in the neck 32, this need not be the case in alternative embodiments of the present technique. In alternative embodiments, cavity identification number 15 may be located anywhere within gate portion 36 or body portion 34. Note that the cavity identification number 15 may be omitted entirely.

As will be described below, each cavity 118 of the one or more mold cavities 118 of the injection molding machine 100 has a cavity origin insert that stamps a cavity identification number 15 for each cavity 118, each cavity identification number 15 being unique to each cavity 118.

The skin layers 20, 25 surround the core layer 40. The core layer 40 is typically made of a different material or a different state of the same material than the skin layers 20, 25. At the tip of the preform 50, the core layer 40 begins at the leading edge 42. At the bottom end of the preform 50 (commonly referred to as the "gate portion"), the core layer 40 terminates at a trailing edge 44 (i.e., the "open dome"). In other non-limiting embodiments not shown, the core layer may extend around the entire gate portion (i.e., "potting"). As described below, the core layer 40 serves to impart different properties, such as increased rigidity, to the preform 50. In some embodiments, the core layer 40 may act as a barrier layer in the final blow molded container blown from the preform 50. In such a case, the barrier layer may help prevent transmission of, for example, oxygen or light to the interior of the blow-molded container. The core layer 40 may also be made from any of a variety of suitable thermoplastics and polymer resins as understood by those skilled in the art. It is contemplated that the core layer 40 may also contain various additives, colorants, or performance modifiers to affect different properties of the multilayer preform 50.

Referring to FIG. 2, which illustrates a non-limiting embodiment of the injection molding machine 100, the injection molding machine 100 may be adapted to manufacture molded articles in accordance with embodiments of the present technique. It should be understood, however, that in alternative non-limiting embodiments, the injection molding machine 100 may include other types of molding systems, such as, but not limited to, compression molding systems, compression injection molding systems, transfer molding systems, metal molding systems, and the like.

As seen in fig. 2, the injection molding machine 100 includes a fixed platen 102 and a moving platen 104. In some embodiments of the present technique, the injection molding machine 100 may include a third non-moving platen (not shown). Alternatively or additionally, the injection molding machine 100 may include a turret block, a rotating cube, a turntable, and the like (none shown, but known to those skilled in the art).

The injection molding machine 100 further includes an injection unit 106 for plasticizing and injecting a molding material. The injection unit 106 may be implemented as a single stage or a two stage injection unit. The injection molding machine 100 may include two instances of the injection unit 106, each instance for preparing and injecting a different type of molding material, namely a first molding material and a second molding material.

In operation, the moving platen 104 is moved toward and away from the stationary platen 102 by means of stroke cylinders (not shown) or any other suitable device. For example, through the use of tie bars 108, 110 (typically, there are four tie bars 108, 110 in the injection molding machine 100) and a tie bar clamping mechanism 112, and, typically, an associated hydraulic system (not shown) generally associated with the tie bar clamping mechanism 112, a clamping force (also referred to as a closure or mold closure tonnage) may be generated within the injection molding machine 100. It will be appreciated that clamp tonnage may be generated using alternative means, such as using a post-based clamping mechanism, a toggle clamp device (not shown), or the like.

The first mold half 114 may be associated with the fixed platen 102 and the second mold half 116 may be associated with the moving platen 104. In the non-limiting embodiment of FIG. 2, the first mold half 114 includes one or more mold cavities 118. As will be appreciated by those skilled in the art, the one or more mold cavities 118 may be formed by using a suitable mold insert (e.g., a mold cavity insert, a gate insert, etc.) or any other suitable device. Thus, the first mold half 114 may generally be considered a "mold half cavity".

The second mold half 116 includes one or more mold cores 120 that are complementary to the one or more mold cavities 118. As will be appreciated by those skilled in the art, one or more mold cores 120 may be formed by using suitable mold inserts or any other suitable device. As such, the second mold half 116 may generally be considered a "mold half core. Even though not shown in fig. 2, the first mold half 114 may be further associated with a melt distribution network, commonly referred to as a hot runner, for distributing molding material from the injection unit 106 to each of the one or more mold cavities 118. The melt distribution network includes one or more hot runner nozzles, which will be described in more detail below.

Furthermore, the second mold half 116 is provided with a neck ring (not shown) to produce a preform having a neck 32. The second mold half 116 is provided with a cavity origin insert for imprinting the cavity identification number 15 on the multi-layer preform 50.

The first mold half 114 may be coupled to the stationary platen 102 by any suitable means, such as suitable fasteners (not shown) or the like. The second mold half 116 may be coupled to the moving platen 104 by any suitable means, such as suitable fasteners (not shown) or the like. It should be appreciated that in alternative non-limiting embodiments of the present technique, the positions of the first mold half 114 and the second mold half 116 may be reversed, as such, the first mold half 114 may be associated with the moving platen 104 and the second mold half 116 may be associated with the fixed platen 102. In alternative non-limiting embodiments of the present technique, the stationary platen 102 need not be stationary and may move relative to other components of the injection molding machine 100.

FIG. 2 shows the first mold half 114 and the second mold half 116 in a so-called "mold open position" in which the moving platen 104 is generally positioned away from the stationary platen 102, and thus the first mold half 114 is generally positioned away from the second mold half 116. For example, in the mold-open position, a molded article (not shown) may be removed from the first mold half 114 and/or the second mold half 116. In a so-called "mold closed position" (not shown), the first mold half 114 and the second mold half 116 are pushed together (by virtue of movement of the moving platen 104 toward the stationary platen 102) and cooperate to define (at least partially) a molding cavity (not shown) into which molten plastic (or other suitable molding material) may be injected, as known to those skilled in the art.

It should be appreciated that one of the first and second mold halves 114, 116 may be associated with a plurality of additional mold elements, such as one or more guide pins (not shown) and one or more guide sleeves, which cooperate to assist in aligning the first and second mold halves 114, 116 in the mold closed position, as known to those skilled in the art.

The injection molding machine 100 may further include a robot 122 operatively coupled to the fixed platen 102. Those skilled in the art will readily appreciate how the robot 122 is operatively coupled to the fixed platen 102, and therefore will not be described in any detail herein. The robot 122 includes a mounting structure 124, an actuation arm 126 coupled to the mounting structure 124, and a take-off plate 128 coupled to the actuation arm 126. The transfer plate 128 includes a plurality of molded article receptacles 130.

Generally, the plurality of molded article receptacles 130 are used to remove molded articles from the one or more mold cores 120 (or the one or more mold cavities 118) and/or to perform post-mold cooling of the molded articles. In the non-limiting example shown herein, the plurality of molded article receptacles 130 comprises a plurality of cooling tubes for receiving a plurality of molded preforms. It should be expressly understood, however, that the plurality of molded article receptacles 130 may have other configurations. The exact number of the plurality of molded article receptacles 130 is not particularly limited.

A side entry robot 122 is schematically illustrated in fig. 2. However, it should be understood that in alternative non-limiting embodiments of the present technique, the robot 122 may be of the top-entry type. It should also be clearly understood that the term "robot" is meant to include structures that perform a single operation, as well as structures that perform multiple operations.

The injection molding machine 100 further includes a post-mold treatment device 132 operably coupled to the moving platen 104. Those skilled in the art will readily appreciate how the post-mold treatment device 132 is operably coupled to the moving platen 104, and therefore will not be described in any detail herein. The post-mold treatment device 132 includes a mounting structure 134 for coupling the post-mold treatment device 132 to the moving platen 104. The post-mold treatment device 132 further includes a plenum 129 coupled to the mounting structure 134. A plurality of processing pins 133 are connected to the plenum 129. The number of disposal pins within the plurality of disposal pins 133 generally corresponds to the number of receptacles within the plurality of molded article receptacles 130.

The injection molding machine 100 further includes computer-implemented apparatus 140 (also referred to herein as a controller 140) configured to control one or more operations of the injection molding machine 100. The controller 140 includes a human machine interface (not separately numbered) or simply HMI. The HMI for the controller 140 may be implemented in any suitable interface. For example, the HMI of the controller 140 may be implemented in a multi-function touch screen. An example of an HMI that can be used to implement a non-limiting embodiment of the present technology is in commonly owned U.S. Pat. No. 6,684,264, the contents of which are incorporated herein by reference in their entirety.

Those skilled in the art will appreciate that the controller 140 may be implemented using pre-programmed hardware or firmware elements (e.g., Application Specific Integrated Circuits (ASICs), electrically erasable programmable read-only memories (EEPROMs), etc.) or other related components. In other embodiments, the functions of the controller 140 may be implemented using a processor having access to a code memory (not shown) that stores computer readable program code for operation of the computing device, in which case the computer readable program code may be stored on a medium that is fixed, tangible, and directly readable by various network entities (e.g., a removable diskette, CD-ROM, fixed hard disk, USB drive), or the computer readable program code may be stored remotely but transmittable to the controller 140 via a modem or other interface device (e.g., a communications adapter) connected to a network (including, but not limited to, the Internet) via a transmission medium, which may be a non-wireless medium (e.g., an optical or analog communications line) or a wireless medium (e.g., a microwave, Infrared or other transmission schemes), or a combination thereof.

In an alternative non-limiting embodiment of the present technology, the HMI need not be physically attached to the controller 140. In fact, the HMI for the controller 140 may be implemented as a separate device. In some embodiments, the HMI may be implemented as a wireless communication device (e.g., a smartphone) that is "paired" or otherwise communicatively coupled to the controller 140.

The controller 140 may perform a number of functions including, but not limited to, receiving control instructions from an operator, controlling the injection molding machine 100 based on operator control instructions or preset control sequences stored within the controller 140 or elsewhere within the injection molding machine 100, acquiring one or more operating parameters associated with the molding system, and the like.

Various non-limiting embodiments of molded articles according to the present techniques will be discussed with reference to fig. 3A through 11. It should be noted that in the prior art preform 50, the core layer 40 is continuous along the main portion of the preform 50 and is circularly symmetric about the longitudinal axis, with similarly symmetric trailing and leading edges 42, 44. In contrast, embodiments of the molded articles or preforms of the present technology have a core layer with some selectively introduced asymmetry to affect blow molding characteristics during subsequent blow molding of the preform, resulting in blow molded articles with different structural features. Broadly speaking, embodiments of the present technology contemplate selecting the geometry of the core layer such that particular material behavior is affected during processing of the preform (e.g., by stretch blow molding, etc.).

Referring to fig. 3A-3B, a molded article 300 in accordance with one embodiment of the present technique will be described. The molded article 300 (also referred to as a multi-layer preform 300) is manufactured by the injection molding machine 100 described above. In other non-limiting embodiments in accordance with the present techniques, it is contemplated that the multi-layer preform 300 may be manufactured by another type of molding machine.

Multi-layer preform 300 is comprised of a neck portion 332, a gate portion 336, and a body portion 334 extending between neck portion 332 and gate portion 336. The body portion 334 of the multi-layer preform 300 is formed of three layers. A majority of body portion 334 has an overall shape that is symmetrical about an axis 310 extending longitudinally through the center of body portion 334, as shown in fig. 3A.

On the outside, the body portion 334 has an outer skin 320 and an inner skin 325. The skin layers 320, 325 may be made from a variety of materials, including any suitable polymer resins and thermoplastics, as will be appreciated by those skilled in the art. The body portion 334 also has a core layer 340 disposed between at least a portion of the skin layers 320, 325. Core layer 340 is also comprised of any suitable polymer resin or thermoplastic, but is selected to be a different material than skin layers 320, 325.

As shown in fig. 3A-3B, at least a majority of the neck 332 is constructed of the first polymeric material and is free of the second polymeric material. It is contemplated that in alternative non-limiting embodiments of the present technique, at least a majority of the neck 332 may be comprised of the second polymeric material, and in some embodiments, free of the first polymeric material.

The preform 300 has a radial thickness of the core layer 340 that varies about the axis 310 for the purpose of facilitating asymmetric blow molding and the resulting final product (as is the case with selectively controlling material behavior during post-processing of the preform 300). It should be noted that the thicknesses of skins 320, 325 vary about axis 310 such that the overall shape of body portion 334 remains substantially symmetrical. The radial thickness 390 at a point about the axis 310 (see fig. 3A) is less than the radial thickness 391 at a point opposite the radial thickness 390. As shown in fig. 3B, the radial thickness of the core layer 340 has an asymmetric annular form about the body axis 310.

Variation in the radial thickness of the core layer 340 about the shaft 310 can be achieved by adjusting the design of the hot runner nozzle used to make the preform 300. Referring to FIG. 12, a cross-section of a hot runner nozzle 1200 mated with a gate insert 1202 is shown (the cross-section is taken along an operational axis of the hot runner nozzle 1200 and the gate insert 1202).

The hot runner nozzle 1200 includes a nozzle body 1204. Nozzle body 1204 includes a first nozzle insert 1206, a second nozzle insert 1208, and a third nozzle insert 1210. A nozzle flow channel for conveying molding material is defined at least in part by first nozzle insert 1206, second nozzle insert 1208, and third nozzle insert 1210.

More specifically, defined in nozzle body 1204 is a primary nozzle channel 1212 of a first material that receives the first material used to form inner outer skin 325 and outer skin 320.

The branches of the first material primary nozzle channel 1212 include: (i) a first material inner passage 1214 (defined in first nozzle insert 1206) and (ii) a first material outer passage 1216 (defined by second nozzle insert 1208 and third nozzle insert 1210).

First material inner channel 1214 and first material outer channel 1216 both convey the first material, which will ultimately define inner outer skin 325 and outer skin 320, respectively.

A second material nozzle passageway 1218 is also defined between the first nozzle insert 1206 and the second nozzle insert 1208. The second material nozzle channel 1218 is configured to receive a second material that will define the core layer 340.

All of first material inner channel 1214, first material outer channel 1216, and second material nozzle channel 1218 deliver their respective molding materials (i.e., first material and second material) toward gate region 1220 (defined at the interface between hot runner nozzle 1200 and gate insert 1202), and ultimately to molding cavity 1222 of the mold.

Hot runner nozzle 1200 further includes a valve stem 1224, the valve stem 1224 configured to control a flow of molding material into a gate area 1220 and a molding cavity 1222 of a mold.

More specifically, the valve stem 1224 is under the control of the controller 140. The controller 140 reciprocates the valve stem 1224 between a fully open position as shown in fig. 12 (where all of the first and second materials can flow through the first material inner passage 1214, the first material outer passage 1216, and the second material nozzle passage 1218 toward the molding cavity 1222 via the gate area 1220) and a fully closed position (where the valve stem 1224 blocks the gate area 1220 such that none of the first and second materials flow through any of the first material inner passage 1214, the first material outer passage 1216, and the second material nozzle passage 1218 toward the molding cavity 1222 via the gate area 1220).

In some non-limiting embodiments of the present technology, the controller 140 may control the valve stem 1224 to one or more stop positions between the fully open position and the fully closed position of the valve stem 1224. In some embodiments of the present technology, by controlling the valve stem 1224 to one or more stop positions between the fully open position and the fully closed position of the valve stem 1224, the controller 140 may control the relative volumetric flow rates of the first material and the second material during various portions of the molding cycle.

Referring to FIG. 13, a cross-section of hot runner nozzle 1200 taken along line 1300 of FIG. 12 is shown. Hot runner nozzle 1200 of fig. 13 is configured for use in manufacturing preforms having a radial thickness of core layer 340 that does not vary about axis 310.

Referring to fig. 14, which shows a modified version of hot runner nozzle 1200, the modified version of hot runner nozzle 1200 is configured to produce preforms having a radial thickness of core layer 340 that varies about axis 310. Note that in the illustration of fig. 14, the shape of the first nozzle insert 1206 is adapted to produce a cross-sectional shape of the flow passage that is asymmetrical about the axis 310.

Specifically, the outer surface of first nozzle insert 1206 (partially defining second material nozzle channel 1218) has an elliptical form, wherein the center of the elliptical form surface is offset from the longitudinal axis of hot runner nozzle 1200. It is contemplated that the surface of the first nozzle insert 1206 may have a different form.

Additionally or alternatively, the shape and/or arrangement of the core layer 340 may be selectively controlled by the positioning of the valve stem 1224. Referring to fig. 15A through 15D, a sequence of repositioning the valve stem 1224 to selectively undulate the core layer 340 is shown.

In the fig. 15A illustration, valve stem 1224 is shown in a fully open position wherein all of the first material and second material may flow through first material inner passage 1214, first material outer passage 1216, and second material nozzle passage 1218 toward molding cavity 1222 via gate region 1220. It should be noted that the actual flow of the first and second materials is controlled by the controller 140 by commanding the associated injection unit 106.

In the fig. 15B illustration, the valve stem 1224 is shown in a partially closed position wherein the valve stem 1224 blocks the flow of molding material through the first material inner passage 1214 while allowing the respective molding material to flow completely through the second material nozzle passage 1218 and through the first material outer passage 1216. Such positioning of the valve stem 1224 allows, for example, biasing the positioning of the core layer 340 toward the inner skin of the preform and/or controlling the thickness of the core layer 340.

In the fig. 15C illustration, the valve stem 1224 is shown in another partially closed position wherein the valve stem 1224 blocks the flow of molding material through the first material inner passage 1214 and partially throttles the flow of molding material through the second material nozzle passage 1218 while allowing the flow of molding material through the first material outer passage 1216. Such positioning of the valve stem 1224 allows, for example, biasing the positioning of the core layer 340 further toward the inner skin of the preform and/or controlling the thickness of the core layer 340.

In the fig. 15D illustration, valve stem 1224 is again shown in a fully open position, wherein all of the first and second materials may flow through first material inner passage 1214, first material outer passage 1216, and second material nozzle passage 1218 toward molding cavity 1222 via gate region 1220. Such positioning of the valve stem 1224 allows, for example, repositioning the core layer 340 toward a middle of the preform and/or controlling the thickness of the core layer 340.

In some embodiments, the first and second materials are selected such that the thermal crystallization rate of the first polymeric material is substantially less than the thermal crystallization rate of the second polymeric material. In some other embodiments, the second polymeric material has a substantially higher intrinsic viscosity than the first polymeric material. These embodiments will be discussed in more detail below with reference to fig. 10 and 11.

In any such embodiment, the different blow molding characteristics of the two different materials of the skin layers 320, 325 and the core layer 340, in combination with the non-uniformity of the core layer thickness, allow the preform 300 to be blow molded in a selectively varying manner. For example, a relatively large portion of the radial thickness 391 of the preform 300 may travel a relatively large path during the stretch blow molding process.

With reference to fig. 4A-4B, a multi-layer preform 400 in accordance with another non-limiting embodiment of the present technique will be described. The multi-layer preform 400 is manufactured by the injection molding machine 100 described above. In other non-limiting embodiments in accordance with the present technique, it is contemplated that the multi-layer preform 400 may be manufactured by another type of molding machine.

The multi-layer preform 400 includes a body portion 434 formed of three layers; the remainder of the preform 400 is substantially similar to the preform 300 described above, and therefore need not be repeated here.

On the outside, the body portion 434 has an outer skin 420 and an inner outer skin 425. The skin layers 420, 425 may be made from a variety of materials, including any suitable polymer resins and thermoplastics, as will be appreciated by those skilled in the art. The body portion 434 also includes a core layer 440 disposed between the skin layers 420, 425. Core layer 440 is also comprised of any suitable polymer resin or thermoplastic, but is selected to be a different material than skin layers 420, 425.

As shown, the radial thickness of the core layer 440 varies about the body axis 410. It should be noted that the thickness of the skins 420, 425 also varies about the body axis 410 such that the overall shape of the body portion 434 remains substantially rotationally symmetric. In this illustrated embodiment, the core layer 440 has a symmetrical annular form about the body axis 410, as shown in fig. 4B, although the radial thickness of the core layer 440 varies about the axis 410.

Control of the shape and/or arrangement of core layer 440 may be implemented similarly to the shape and/or arrangement of core layer 340, through the design of the hot runner nozzle and/or control of the valve stem 1224 of the hot runner nozzle.

Variation in the radial thickness of the core layer 440 about the shaft 410 can be achieved by adjusting the design of the hot runner nozzle used to make the preform 400. One non-limiting embodiment of such a hot runner nozzle design including an intermediate nozzle insert 1608 is described in more detail below with reference to fig. 24 and 25.

With reference to fig. 5A-5B, a multi-layer preform 500 in accordance with another non-limiting embodiment of the present technique will be described. The multi-layer preform 500 is manufactured by the injection molding machine 100 described above. In other non-limiting embodiments in accordance with the present techniques, it is contemplated that the multi-layer preform 500 may be manufactured by another type of molding machine.

The multi-layer preform 500 includes a body portion 534 formed of three layers; the remainder of the preform 500 is substantially similar to the preform 300 described above, and therefore need not be repeated here.

As with the preform 300, the body portion 534 has an outer skin 520 and an inner outer skin 525, both skins 520, 525 being made of the first material. The body portion 534 also has a core layer 540 composed of a second material selected from materials different from the skin layers 520, 525. In this embodiment, the core layer 540 is a semi-annular core layer, wherein the radial thickness of the core layer 540 varies about the body axis 510. The skin layers 520, 525 contact a portion of the body portion 534 where the radial thickness of the core layer 540 becomes zero.

Control of the shape and/or arrangement of core layer 540 may be implemented similarly to the shape and/or arrangement of core layer 340, through the design of the hot runner nozzle and/or control of the valve stem 1224 of the hot runner nozzle.

Variation in the radial thickness of the core layer 540 about the shaft 510 can be achieved by adjusting the design of the hot runner nozzle used to make the preform 500. One non-limiting embodiment of such a nozzle design for the hot runner 1900 is described in more detail below with reference to fig. 28-31.

With reference to fig. 6A-6C, a multi-layer preform 600 in accordance with another non-limiting embodiment of the present technique will be described. The multi-layer preform 600 is manufactured by the injection molding machine 100 described above. In other non-limiting embodiments in accordance with the present technique, it is contemplated that the multi-layer preform 600 may be manufactured by another type of molding machine.

The multi-layer preform 600 includes a body portion 634 formed of three layers; the remainder of the preform 600 is substantially similar to the preform 300 described above, and therefore need not be repeated here.

The body portion 634 of the preform 600 includes a transition portion 635 extending between the neck portion 632 and the body portion 634. The transition 635 includes a transitional inner layer 625 and a transitional outer layer 620 of a first polymeric material. The transition 635 also includes a transition core layer 640 of a second polymeric material disposed between at least a portion of the layers 620, 625. In the illustrated embodiment, the second polymeric material is stiffer such that thicker portions of core layer 640 expand less than thinner portions of core layer 640 during the same blow molding process.

Broadly speaking, a non-limiting embodiment of preform 600 contemplates placement of only the second polymeric material in transition 635. A small portion of the core layer of the body portion of preform 600 is also circumferentially varied, as described in other non-limiting embodiments herein.

An example of a blow molded product 601 made from the preform 600 is shown in fig. 6C. The transition portion 675 of the product 601 has a portion that expands less during blow molding, with the core layer 640 being thicker and expanding more when the core layer 640 is thinner.

Control of the shape and/or arrangement of core layer 640 may be implemented similarly to the shape and/or arrangement of core layer 340, through the design of the hot runner nozzle and/or control of the valve stem 1224 of the hot runner nozzle.

Referring to fig. 7A-7B, a multi-layer preform 700 in accordance with another non-limiting embodiment of the present technique will be described. The multi-layer preform 700 is manufactured by the injection molding machine 100 described above. In other non-limiting embodiments in accordance with the present technique, it is contemplated that the multi-layer preform 700 may be manufactured by another type of molding machine.

The multi-layer preform 700 includes a body portion 734 formed from three layers; the remainder of the preform 700 is substantially similar to the preform 300 described above, and therefore need not be repeated here.

As with the preform 300, the body portion 734 has an outer skin 720 and an inner outer skin 725, both skins 720, 725 being made of the first material. The body portion 734 also has a core layer 740 that is constructed of a second material selected from materials different from the skin layers 720, 725.

In this embodiment, the radial thickness of the core layer 740 is substantially uniform about the body axis 710. The radial thickness of the core layer 740 of the preform 700 instead varies along the axial direction defined by the axis 710. An example of a blow molded product 701 made from a preform 700 is shown in fig. 7B. As with preform 600, the thicker portion of core material expands less than the thinner portion during blow molding. The thicker portion of the core layer 740 thus results in a tighter portion on the blow molded product 701.

Control of the shape and/or arrangement of core layer 740 may be implemented similarly to the shape and/or arrangement of core layer 340, through the design of the hot runner nozzle and/or control of the valve stem 1224 of the hot runner nozzle.

With reference to fig. 8A-8C, a multi-layer preform 800 in accordance with another non-limiting embodiment of the present technique will be described. The multi-layer preform 800 is manufactured by the injection molding machine 100 described above. In other non-limiting embodiments in accordance with the present techniques, it is contemplated that the multi-layer preform 800 may be manufactured by another type of molding machine.

The multi-layer preform 800 includes a body portion 834 formed of three layers; the remainder of the preform 800 is substantially similar to the preform 300 described above, and therefore need not be repeated here.

As with the preform 300, the body portion 834 has an outer skin 820 and an inner outer skin 825, both skins 820, 825 being made of the first polymeric material. The body portion 834 also has a core layer 840 composed of a second material selected from materials different from the skin layers 820, 825.

The core layer 840 is an interrupted layer 840. The interrupted layer 840 is composed of a plurality of cores 841; the layers 820, 825 meet at a location where the radial thickness of the core layer 840 is reduced to zero (between the core layers 841).

In fig. 8C a blow molded product 801 made from a preform 800 is shown. The core 841 forms ribs on the blow molded product 801.

Control of the shape and/or arrangement of interrupted core layer 840 may be implemented similarly to the shape and/or arrangement of core layer 340 by any of the design of the hot runner nozzle (by adding structure that creates the interrupted shape of interrupted core layer 840) and/or the valve stem 1224 controlling the hot runner nozzle.

With reference to fig. 9A-9C, a multi-layer preform 900 in accordance with another non-limiting embodiment of the present technique will be described. The multi-layer preform 900 is manufactured by the injection molding machine 100 described above. In other non-limiting embodiments in accordance with the present techniques, it is contemplated that the multi-layer preform 900 may be manufactured by another type of molding machine.

The multi-layer preform 900 includes a body portion 934 formed of three layers; the remainder of the preform 900 is substantially similar to the preform 300 described above, and therefore need not be repeated here.

The body portion 934 of the preform 900 includes a transition portion 935 extending between the neck portion 932 and the body portion 934. The transition portion 935 includes a transition inner layer 925 and a transition outer layer 920 of a first polymeric material. The transition 935 further includes a transition core layer 940 of a second polymeric material disposed between at least a portion of the layers 920, 925. The core layer 940 is an interrupted layer 940. The interrupted layer 940 is made up of a plurality of cores 941; the layers 920, 925 make contact at a location where the radial thickness of the transition core layer 940 is reduced to zero (between cores 941).

In fig. 9C a blow molded product 901 made from the preform 900 is shown. Similar to the blow molded product 801, the core 941 is ribbed on the blow molded product 901.

Control of the shape and/or arrangement of the interrupted core layer 940 can be implemented similarly to the shape and/or arrangement of the core layer 340 by any of the design of the hot runner nozzle (by adding structure that creates the interrupted shape of the interrupted core layer 940) and/or the control of the valve stem 1224 of the hot runner nozzle.

Referring to fig. 10, a molded article 1000 in accordance with another non-limiting embodiment of the present technique will be described. The molded article 1000 (also referred to as a multi-layer preform 1000) is manufactured by the injection molding machine 100 described above. In other non-limiting embodiments in accordance with the present techniques, it is contemplated that the multi-layer preform 1000 may be manufactured by another type of molding machine.

Preform 1000 includes a neck portion 1032, a body portion 1034 and a gate portion 1036 as described with respect to preform 50. Body portion 1034 includes skin layers 1020 and 1025 and core layer 1040. Although the core layer 1040 is shown as a rotationally symmetric core form of the preform 50, it is contemplated that the core layer 1040 may be implemented in any of the forms of fig. 3 a-9 a.

Both the inner outer skin 1020 and the outer skin 1025 are formed from a first polymeric material that is a non-strain hardening material. The material of the skin layers 1020, 1025 may be selected from, but not limited to, High Density Polyethylene (HDPE) and polypropylene (PP).

Core layer 1040 is formed from a second, different polymeric material. In this embodiment, the first and second materials are selected such that the thermal crystallization rate of the first polymeric material is substantially less than the thermal crystallization rate of the second polymeric material. In particular, core layer 1020 is made of a strain hardening material, which may include, but is not limited to, homopolymers, copolymers, and blends of strain crystallizable polyethylene terephthalate (PET). By including a strain-hardened material as the core layer 1040, the preform 1000 may utilize a non-strain-hardened material, which may have preferred aesthetic and cost characteristics, while the strain-hardened core layer 1040 provides the strength lacking in the skin layers 1020, 1025.

In this non-limiting embodiment, neck 1032 is also made of a non-strain hardened material, although in some non-limiting embodiments it is contemplated that neck 1032 may be made of the same material as core layer 1040, or even a third different material.

Control of the shape and/or arrangement of core layer 1040 may be implemented similarly to the shape and/or arrangement of core layer 340, through the design of the hot runner nozzle and/or control of the valve stem 1224 of the hot runner nozzle.

Referring to fig. 11, a molded article 1100 in accordance with another non-limiting embodiment of the present technique will be described. The multi-layer preform 1100 is manufactured by the injection molding machine 100 described above. In other non-limiting embodiments in accordance with the present technique, it is contemplated that the multi-layer preform 1100 may be manufactured by another type of molding machine.

Preform 1100 includes neck portion 1132, body portion 1134 and gate portion 1136 as described with respect to preform 50. Body portion 1134 includes skin layers 1120 and 1125 and core layer 1140. Although the core 1140 is shown as a rotationally symmetric core form of the preform 50, it is contemplated that the core 1140 may be implemented in any of the forms of fig. 3 a-9 a.

Both inner outer skin layer 1120 and outer skin layer 1125 are formed from a first polymeric material. Core layer 1140 is formed from a second, different polymeric material. In this embodiment, the first and second materials are selected such that the second polymeric material has a substantially higher intrinsic viscosity than the first polymeric material. In some non-limiting embodiments, the first polymeric material may be PET and the second polymeric material may be selected from, but not limited to, PP, Polyethylene (PE), HDPE, and nylon.

In this non-limiting embodiment, the neck 1132 is made of a low viscosity material, although in some non-limiting embodiments it is contemplated that the neck 1032 may be made of the same material as the core layer 1140, or even a third different material.

Control of the shape and/or arrangement of core layer 1140 may be implemented similarly to the shape and/or arrangement of core layer 340, through the design of the hot runner nozzle and/or control of the valve stem 1224 of the hot runner nozzle.

Referring to fig. 16A-16D, a molded article 1300 in accordance with yet another non-limiting embodiment of the present technique will be described. A molded article 1300, and in particular a multi-layer preform 1300, is manufactured by the above-described injection molding machine 100 using a hot runner nozzle 1400 shown in fig. 17 and 18 (described in more detail below). In other non-limiting embodiments in accordance with the present techniques, it is contemplated that the multi-layer preform 1300 may be manufactured by another type of molding machine.

Preform 1300 includes a neck portion (not shown), a body portion 1334 and a gate portion 1336 as described with respect to preform 50. Body portion 1334 includes skin layers 1320 and 1325 and core layer 1340. Both inner outer layer 1320 and outer layer 1325 are formed of a first polymeric material, also referred to as a skin material. The material of the skin layers 1320, 1325 may be selected from, but is not limited to, High Density Polyethylene (HDPE) and polypropylene (PP).

Core layer 1340 is formed from a second, different polymeric material, also referred to as a core material. In this embodiment, the second polymeric material has a different color than the first polymeric material, but the second polymeric material may be selected to have any desired material type, material characteristics, material quality, material type (i.e., virgin or recycled), and the like. As can be seen in the image of the experimentally produced preform 1300 shown in fig. 16C, the core layer 1320 is made of a violet material, while the first polymeric material is typically a translucent material. In some embodiments, the first polymeric material may be a different color than the second polymeric material, rather than no color. The first and second polymeric materials can each be made from, but are not limited to, homopolymers, copolymers, and blends of polyethylene terephthalate (PET). It is contemplated that different polymeric materials, which may have different physical, aesthetic, and/or cost characteristics, may be used for the core layer 1340 and/or the skin layers 1320, 1325.

The core layer 1340 includes localized regions of increased radial thickness (see fig. 16a and 16 b). Due to the increased radial thickness of the purple core layer, purple color is more present, and the preform 1300 (and its final formed container) is colored differently in localized areas of greater thickness. Specifically, in the illustrated embodiment, the core layer includes two wider localized regions 1342 and two narrower localized regions 1344. Outer skin 1320 also has localized areas of thinner material in corresponding areas of outer skin 1320. Because of the localized areas of the thicker core layer 1340 and the thinner skin layer 1320 around the longitudinal axis of the preform 1300, the purple material core layer 1340 creates four longitudinally extending stripes in the preform 1300, which can be seen from the outside of the preform 1300. It should be noted that in alternative non-limiting embodiments of the present technique, there may be more or less localized areas of the thicker core layer 1340 and the thinner skin layer 1320. Likewise, all local areas of the thicker core layer 1340 and the thinner skin layer 1320 may have the same dimensions — smaller or larger.

In some other non-limiting embodiments of the preform 1300, the core layer 1340 may comprise a strain-hardening material or a material of different viscosity, such as described above for other embodiments of preforms according to this technique. In such embodiments, the stretching and blowing of the preform into the final shaped container may be controlled, at least in part, by the different thicknesses of the localized regions of the core layer 1340.

With reference to fig. 17 and 18, the hot runner nozzle 1400 used to produce the preform 1300 will now be described in more detail. Although the use of hot runner nozzle 1400 will be described with respect to the formation of preform 1300, it is also contemplated that hot runner nozzle 1400 may be used to produce different embodiments of molded articles and multi-layer preforms.

Hot-runner nozzle 1400 includes an inner nozzle insert 1406 (also referred to as first nozzle insert 1406), an intermediate nozzle insert 1408 (also referred to as second nozzle insert 1408), and an outer nozzle insert 1410 (also referred to as third nozzle insert 1410). The inner nozzle insert 1406 defines an inner flow passage 1414 therein. The inner nozzle insert 1406 and the middle nozzle insert 1408 define a middle flow passage 1418 therebetween. Intermediate nozzle insert 1408 and outer nozzle insert 1410 define an outer flow passage 1416 therebetween. Although not specifically illustrated, the hot runner nozzle 1400 is further mated with a valve stem (not shown), similar to the nozzle 1200 and valve stem 1224 described above. The hot runner nozzle 1400 defines a longitudinal axis 1402, which is generally the operational axis of the nozzle 1400.

Both inner flow channel 1414 and outer flow channel 1416 convey a first polymeric material that ultimately defines inner skin 1325 and outer skin 1320, respectively, for preform 1300. The intermediate flow channels 1418 are configured to receive a second polymeric material that will define the core layer 1340. The middle nozzle insert 1408 and the inner nozzle insert 1406 further cooperate to define a middle outlet 1420 of the middle flow passage 1418, wherein a majority of the second polymeric material flows through the middle outlet 1420 when the hot runner nozzle 1400 is in use.

Intermediate nozzle insert 1408 also defines four orifices disposed upstream of intermediate outlet 1420 and spaced from intermediate outlet 1420. Specifically, middle nozzle insert 1408 has two apertures 1433 spaced 180 degrees apart about axis 1402, and two apertures 1435 disposed between each aperture 1433 and equidistant from each aperture 1433. The orifices 1433, 1435 are arranged to provide a fluid connection between the intermediate flow channel 1418 and the outer flow channel 1416.

When the intermediate flow channel 1418 is fluidly connected to the outer flow channel 1416 upstream of the intermediate outlet 1420 via the orifices 1433, 1435, the distribution of the core material relative to the outer skin material is altered in a localized region downstream of the orifices 1433, 1435. When in use, at least a portion of the second polymeric material (i.e., core layer material) melt stream passing through intermediate flow channels 1418 enters outer flow channels 1416 through apertures 1433, 1435.

The core material passing through the apertures 1433, 1435 then forms the localized regions 1342, 1344 of increased radial thickness shown in fig. 16A-16D. The portions of core material passing from the intermediate flow channels 1418 and into the outer flow channels 1416 are typically joined together again in the preform 1300, with the separate flows of core material forming a greater thickness core layer 1340 at this point. As such, in the localized regions corresponding to the locations of the orifices 1433, 1435, a portion of the core layer material also displaces a portion of the skin layer material in the outer flow channels 1416, as can be seen in the figure. As can be seen in cross-section, the larger apertures 1433 allow for more core material to pass through, followed by the smaller apertures 1435, resulting in a greater increase in the radial thickness of the core layer 1340.

It is contemplated that the middle nozzle insert 1408 may define more or fewer apertures 1433, 1435 depending on the particular implementation or application. Some of these variations are explored in the following sections of the specification. Similarly, the arrangement, size, and orientation of the apertures 1433, 1435 may vary, as will be explored in further embodiments of hot runner nozzles and nozzle inserts.

With reference to fig. 19-21, another non-limiting embodiment of a hot runner nozzle design will now be described, which specifically includes an intermediate nozzle insert 1508, for producing at least some of the preform designs presented above. Although not specifically illustrated, intermediate nozzle insert 1508 may be used in place of intermediate nozzle insert 1408 in hot runner nozzle 1400.

In this non-limiting embodiment, the middle nozzle insert 1508 includes a total of 20 orifices for fluidly connecting the middle flow channel to the outer flow channel. The middle nozzle insert 1508 defines four circular, horizontally disposed apertures 1530, the apertures 1530 being disposed along each of four longitudinally extending lines, each line of apertures 1530 being equidistant from its adjacent lines about the axis of operation. Middle nozzle insert 1508 further defines four smaller circular apertures 1532 arranged around the bottom of middle nozzle insert 1508.

By controlling the flow rate, it is also contemplated that the degree of core layer radial thickness variation can be controlled. For example, varying the flow rate through a particular cycle may produce additional variations in the local core radial thickness in the machine direction.

With reference to fig. 22 and 23, another non-limiting embodiment of a hot runner nozzle design, specifically an intermediate nozzle insert 1558, will now be described for producing at least some of the preform designs presented above. Although not specifically illustrated, intermediate nozzle insert 1558 may be used in place of intermediate nozzle insert 1408 in hot runner nozzle 1400.

In a non-limiting embodiment of the intermediate nozzle insert 1558, the hot runner nozzle includes a total of 20 orifices for fluidly connecting the intermediate flow channel to the outer flow channel. The intermediate nozzle insert 1508 defines four circular apertures 1580, the apertures 1530 being arranged along each of four longitudinally extending lines, each line of apertures 1530 being equidistant from its adjacent lines about the axis of operation. The apertures 1580 are arranged at various angles, with the apertures 1580 typically being oriented at a substantial angle to a horizontal line down the operating axis. Similar to intermediate nozzle insert 1508, intermediate nozzle insert 1558 further defines four smaller circular apertures 1582 disposed around a bottom portion of intermediate nozzle insert 1558.

As can be seen in this non-limiting embodiment, the apertures 1580 need not all be arranged at the same angle relative to the operational axis. The apertures 1580 also need not be equally spaced, as can be seen from at least the top two apertures 1580 along each longitudinal line. It is contemplated that intermediate nozzle insert 1558 may include more or fewer orifices, depending on the particular embodiment.

With reference to fig. 24 and 25, another non-limiting embodiment of a hot runner nozzle design, in particular an intermediate nozzle insert 1608, for producing at least some of the preform designs presented above, including at least the preform 400 illustrated in fig. 4A and 4B, will now be described in more detail.

In a non-limiting embodiment of the intermediate nozzle insert 1608, the hot runner nozzle includes two apertures 1630. Each orifice 1630 is in the form of a curved slot that allows the core material to pass from the middle flow channel into the inside of the outer flow channel.

As shown in fig. 4A and 4B, the resulting core layer is slightly thickened along a wide portion of the core layer circumference.

In some embodiments, the aperture 1630 may be larger or smaller than shown. It is also contemplated that intermediate nozzle insert 1608 may include additional apertures, which may be in the form of apertures 1630 or in a different form. It is also contemplated that, for some embodiments, the apertures 1630 may be defined in the inner nozzle insert rather than the intermediate nozzle insert 1608.

Referring to fig. 26, an illustrative example of a hot runner nozzle 1700 for manufacturing at least some of the preform designs presented above will now be described.

Hot runner nozzle 1700 includes an inner nozzle insert 1706 (also referred to as a first nozzle insert 1706), an intermediate nozzle insert 1708 (also referred to as a second nozzle insert 1708), and an outer nozzle insert 1710 (also referred to as a third nozzle insert 1710). Inner nozzle insert 1706 defines an inner flow passage 1714 therein. The inner nozzle insert 1706 and the middle nozzle insert 1708 define a middle flow channel 1718 therebetween. Intermediate nozzle insert 1708 and outer nozzle insert 1710 define an outer flow channel 1716 therebetween. Although not specifically illustrated, the hot runner nozzle 1700 is further mated with a valve stem (not shown), similar to the nozzle 1200 and valve stem 1224 described above. Hot runner nozzle 1700 defines a longitudinal axis 1702, which is generally the operating axis of nozzle 1700.

Both internal flow channels 1714 and external flow channels 1716 deliver a first polymeric material that will ultimately define the internal and external outer skins, respectively, of the molded article produced by hot runner nozzle 1700. The intermediate flow channels 1718 are configured to receive a second polymeric material that will define a core layer of the molded article.

Inner nozzle insert 1706 also defines four orifices disposed upstream of and spaced apart from the outlet of inner nozzle insert 1706. Specifically, inner nozzle insert 1706 has four apertures 1730. The orifices 1730 are arranged to fluidly connect the inner flow channel 1714 to the intermediate flow channel 1718.

Similar to the hot runner nozzles described above, hot runner nozzle 1700, when used, produces a molded article having a core layer with a localized region of modified radial thickness. In this embodiment, a portion of the material flowing through the inner flow passages 1714 will turn toward the intermediate flow passages 1718, displacing a portion of the core material. This results in a local region of reduced radial thickness of the core layer. It is contemplated that inner nozzle insert 1706 may define more or fewer apertures 1730 therein.

Referring to fig. 27, an illustrative example of a middle nozzle insert 1800 has different, non-limiting orifice embodiments. While shown on the intermediate nozzle insert 1800, it is also contemplated that each example orifice may be implemented with an internal nozzle insert, such as in a non-limiting embodiment of the hot runner nozzle 1700.

As described at least with respect to nozzle inserts 1408, 1508, 1558, 1608, and 1706, orifices developed in the present technology allow a portion of the core layer material to enter an inner flow channel or an outer flow channel from an intermediate flow channel upstream and offset from a main outlet for the material. In this way, a molded article is produced having a core layer with localized regions of increased radial thickness. Further, a portion of the core material may displace a portion of the skin material around the localized area.

The apertures used may be of different forms depending on various factors. These factors may include, but are not limited to: the nature of the particular material used in the skin layer, core layer, or both; different cycle parameters of the nozzle when in use; and the desired amount of change in the radial thickness of the core layer.

In some embodiments, the apertures may be generally cylindrical and angled, such as apertures 1802 and 1804. In some embodiments, the aperture may be substantially cylindrical and substantially parallel to the axis of operation, such as the aperture 1806. Depending on the details of the embodiment, the aperture may be curved, such as aperture 1808. In some embodiments, the orifice may expand to be larger as the orifice extends away from the intermediate flow passage, such as orifice 1810 (with substantially linear walls) or orifice 1812 (with curved walls). Similarly, in some embodiments, the apertures may become narrower as they extend away from the intermediate flow channel, such as aperture 1814 (with substantially linear walls) or aperture 1816 (with curved walls).

The selection of one or more of the orifices 1802-1816 described above may depend on various factors, including the extent to which the core is to be altered, e.g., or the core material passing through the outer flow channel is to penetrate the outer skin or closer to the surface of the preform being manufactured. It is also contemplated that the orifice may be further varied, such as by having a larger or smaller diameter than shown. The relative spacing, orientation, and location of the different apertures may further vary according to particular embodiments. During use, it is also contemplated that any of the rod position, injection speed and injection timing, as well as other process variables, may be controlled to affect different preforms being manufactured. It should be noted that various methods may be utilized to form the orifice including, for example, electro-discharge machining and 3D printing of the nozzle insert, although fabrication of the present technology is not meant to be so limited.

These are non-limiting examples of different orifices that may be defined in at least one of the intermediate nozzle insert and the inner nozzle insert, but other different forms may also be implemented. According to embodiments, one or both of the intermediate nozzle insert and the inner nozzle insert may comprise as few as one aperture up to a plurality of apertures. It is also contemplated that in some embodiments, multiple forms of apertures 1802-1816 (or other forms) may be implemented in a single embodiment.

Additionally, the shape and/or arrangement of the preform core layer manufactured using the hot runner nozzle or insert 1400, 1508, 1558, 1608, 1700, or 1800 may be selectively controlled by the positioning of the valve stem 1224, as described above.

With reference to fig. 28-31, another non-limiting embodiment of a hot runner nozzle 1900, specifically an internal nozzle insert 1906, will now be described for producing at least some of the preform designs presented above.

The hot runner nozzle 1900 includes an inner nozzle insert 1906, an intermediate nozzle insert 1908, and an outer nozzle insert 1910. The inner nozzle insert 1906 defines an inner flow passage 1914 therein, the inner flow passage 1914 including an outlet 1922. The inner nozzle insert 1906 and the intermediate nozzle insert 1908 define an intermediate flow channel 1918 therebetween. Intermediate nozzle insert 1908 and outer nozzle insert 1910 define an outer flow channel 1916 therebetween. The inner nozzle insert 1906 and the middle nozzle insert 1908 further cooperate to define a middle outlet 1920, with at least the core layer material passing through the middle outlet 1920. The outer nozzle insert 1910 also defines an outlet 1924, with at least the outer skin material passing through the outlet 1924. Hot runner nozzle 1900 also defines a longitudinal axis 1902, which is generally the axis of operation of nozzle 1900.

As can be seen in the figures, the inner nozzle insert 1906 is formed such that the intermediate outlet 1920 has a non-uniform cross-section. As the core material flows from hot runner nozzle 1900, in use, a molded article produced using hot runner nozzle 1900 will have a core of non-uniform radial thickness about axis 1902 through non-uniform intermediate outlet 1920. As one non-limiting example, the preform 500 shown in fig. 5A and 5B may be produced using a hot runner nozzle 1900. The core layer 540 of the preform 500 extends only partially around the circumference of the preform 500, corresponding to part of the intermediate flow channels 1918.

As shown, the intermediate outlet 1920 and the outer outlet 1924 are immediately adjacent to one another. Specifically, the inner outlet 1922 and the outer outlet 1924 are concentrically arranged. Due to the form of the inner nozzle insert 1906, as will be discussed in more detail below, the intermediate outlet 1920 extends only partially around the axis 1902 of the hot runner nozzle 1900 and is disposed only between a portion of the concentrically arranged inner and outer outlets 1922, 1924.

The inner nozzle insert 1906 has two general surface forms, as shown in fig. 28 and 29. The first surface form 1940 matches the form of the inner surface of the middle nozzle insert 1908. When the inner nozzle insert 1906 is disposed in the hot runner nozzle 1900, the second surface form 1942 is spaced apart from an inner surface of the middle nozzle insert 1908 to define the middle flow channel 1918. In the region of surface form 1940, there is no core material flow because the inner nozzle insert 1906 is in contact with the middle nozzle insert 1908. Thus, as can be seen in the preform 500, the core layer 540 extends around only a portion of the circumference of the preform 500.

In some non-limiting embodiments, it is contemplated that portions of the passages 1916, 1918 may be modified to compensate for flow imbalances in the passages 1916, 1918 due to their non-uniform nature. For example, in some embodiments, the outer flow channels 1916 may be thinner in the portion around the axis defining the intermediate flow channels 1918, such that the total flow from the channels 1916, 918 has a similar or the same total flow as the portion of the nozzle 1900 not defining the intermediate flow channels 1918, and all flow is from the outer flow channels 1916 only. It is also contemplated that the form of the passages 1916, 1918 may be varied to equalize the pressure across the nozzle 1900 during use.

Broadly speaking, non-limiting embodiments of hot runner nozzles and nozzle inserts for delivering melt to the mold cavities described above are designed to deliver core layer material such that the molded articles produced in the mold cavities have a non-uniform radial thickness about the longitudinal axis of the molded articles. In particular, when a hot runner nozzle is used, the flow of material through the intermediate flow channel is non-uniformly distributed about the longitudinal axis of the hot runner nozzle. Flow non-uniformity is generally attributed to the surfaces of the inner nozzle and the intermediate nozzle insert defining the intermediate flow channel. In some of the above embodiments of the present technology, the surface defines an aperture through which the core material passes to create a locally increased core thickness. In other embodiments of the present technology, the surfaces form intermediate flow channels that do not extend uniformly about the hot runner nozzle axis, such that the core material is not distributed uniformly around the molded article.

It should be noted that even though the core layers shown in the various embodiments of the present technique are not completely encapsulated in (i.e., interrupted in) the gate portion of the preform, in alternative non-limiting embodiments of at least those preforms shown in fig. 3A, 4A, 8A, 10, 11, and 16A-D, the individual core layers may be completely encapsulated (i.e., continuous) in the gate portion of the preform.

The polymeric materials of any of the foregoing non-limiting embodiments for forming the multilayer article 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1300 may be selected wherein one polymeric material has a first color and another polymeric material has a second color so as to produce a change in color distribution in the final shaped container, wherein the color change is controlled by the selectively varying radial thickness of the core layer.

The polymeric materials of the foregoing non-limiting embodiments used to form the multilayer articles 300, 400, 500, 600, 700, 800, 900, 1000, 1100, 1300 may be selected or otherwise modified to resist delamination of the layers. In the case where two adjacent layers are formed of polymeric materials that are susceptible to delamination, an adhesive may be used to improve the adhesion between them. For example, a journal article entitled "Compatibilization Additives for Improving delamination Resistance of PET/Pa-MXD6 Multilayer co-injection Stretch Blow Molded Bottles (compatibility Additives for Improving the delamination Resistance of PET/Pa-MXD6 Multi layer decoration polyester films) published by the Society of Plastic Engineers (Society of Plastics Engineers) in Burley, Conn.S. and by Kris Akkapeaddi and Brian Lynch, assigned to Graham Packaging Company (Graham Packaging Company L.P.), and by Kris Akkap and Brian Lynch, Inc., and incorporated by reference, provides relevant teachings on providing adhesives. In a non-limiting example of a PET and HDPE interface, an adhesive may be provided, for example(trade mark of du Pont de Nemours, Wilmington, Del., USA),(trademark of Arkema S.A of Keron, France), or(trade mark of Honeywell International Inc. of Morris Plains, N.J.).

Modifications and improvements to the above-described embodiments of the present technology will be apparent to those skilled in the art. The foregoing description is exemplary rather than limiting in nature. Accordingly, the scope of the present technology is to be limited only by the scope of the following claims.

The description of the embodiments of the present technology provides only examples of the present technology, and these examples do not limit the scope of the present technology. It should be clearly understood that the scope of the present technology is defined only by the claims. The concepts described above may be adapted for specific conditions and/or functions, and may be further extended to a variety of other applications that are within the scope of the present technology.

Having thus described embodiments of the present technology, it will be apparent that modifications and enhancements are possible without departing from the concepts as described.