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Sleeve molding
| Details |
Inventors: Collette, Wayne N.; Krishnakumar, Suppayan M.;
Assignee: Continental PET Technologies, Inc. (Toledo, OH)
Primary Examiner: Ortiz; Angela
Assistant Examiner:
Attorney, Agent or Firm: Finnegan, Henderson, Farabow, Garrett & Dunner
Method and apparatus for making multilayer injection molded plastic articles. In one embodiment, a relatively thin inner sleeve layer is molded in a first mold cavity on a core, the first mold cavity being heated to maintain an outer surface of the inner sleeve layer at an elevated temperature, and the core and sleeve layer are transferred to a second mold cavity to mold a relatively thick outer layer over the sleeve layer while the outer surface is at the elevated temperature, where the elevated temperature is selected to provide melt adhesion between the inner sleeve and the outer layer during the second molding step. In another embodiment, a method of injection molding is provided in which a first thermoplastic material is used to form a first preform portion having an average percent crystallinity of at least about 30%, and a second thermoplastic material is injection molded to form a second preform portion which remains substantially amorphous. |
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DETAILED DESCRIPTION The present invention is directed to a method and apparatus for making a multilayer injection-molded plastic article, such as a preform, which is both cost-effective and enables control over the amounts of materials used in the various layers and/or portions of the article.
According to a method/embodiment of the invention, an inner sleeve is molded on a first core positioned in a first mold cavity.
The inner sleeve is only partially cooled before being transferred while still at an elevated temperature to a second mold cavity where an outer layer is molded over the inner sleeve.
By providing the inner sleeve in the second mold cavity at the elevated temperature, bonding between the inner sleeve and outer layer is enabled during the second molding step, such that layer separation is avoided in the final molded article.
The inner sleeve may comprise a full-length inner sleeve, extending substantially the full length of the article, or alternatively may comprise only an upper portion of the article, in which case the outer layer comprises a lower portion of the article and there is some intermediate portion in which the outer layer is bonded to the inner sleeve.
In one embodiment, a first thermoplastic material is used to make an inner sleeve which comprises a neck finish portion of the preform.
The first thermoplastic material is preferably a thermal resistant material having a relatively high T.
sub.
g, and/or forms a crystallized neck finish during the first molding step.
In contrast, a lower body portion of the preform is made of a second thermoplastic material having a relatively lower thermal resistance and/or lower crystallization rate compared to the first material, and forms a substantially amorphous body-forming portion of the preform.
In one example, by achieving crystallization in the neck finish during the first molding step, the initial and finish dimensions are the same so that the dimensional variations caused by the prior art post-molding crystallization step (and the expense thereof) are eliminated
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