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Disclosed herein are methods and systems for forming a plurality of multiple layer plastic articles. The methods and systems utilize shooting pot technology in combination with a combination of thermal control elements and in some instances, specialized flow bore geometries to control a thermal prop

Disclosed herein are methods and systems for forming a plurality of multiple layer plastic articles. The methods and systems utilize shooting pot technology in combination with a combination of thermal control elements and in some instances, specialized flow bore geometries to control a thermal property and a flow parameter of selected polymeric material flowing through the system to mold the plurality of multiple layer plastic articles. Both the systems and methods are well suited for use to perform simultaneous flow injection or sequential flow injection to form the plurality of multiple layer plastic articles. The systems and methods described therein beneficially reduce the mold cavity pitch size for multiple layer molds used with systems having shooting pot technology to a mold cavity pitch size found on conventional monolayer molds to provide a plurality of multiple layer plastic articles having a cost similar to monolayer plastic articles.

대표청구항 ▼

What is claimed is: 1. A system for injection molding a plurality of multiple layer plastic articles, the system comprising, a mold having a plurality of cavities to mold a plurality of multiple layer plastic articles; a first material source to supply a first polymeric material for use in forming

What is claimed is: 1. A system for injection molding a plurality of multiple layer plastic articles, the system comprising, a mold having a plurality of cavities to mold a plurality of multiple layer plastic articles; a first material source to supply a first polymeric material for use in forming at least one layer of each of the plurality of multiple layer plastic articles; a second material source to supply a second polymeric material for use in forming at least one layer of each of the plurality of multiple layer plastic articles; a plurality of nozzles in communication with a portion of the mold to inject the first and second polymeric materials into each of the plurality of cavities; a plurality of shooting pots, each of the plurality of shooting pots having an ingress port to receive the first polymeric material, a reservoir to hold a volume of the first polymeric material, and an egress port to feed there through a selected volume of the first polymeric material held by the reservoir; a first set of flow channels configured to distribute the first polymeric material from the first material source to the ingress port of each of the plurality of shooting pots; a second set of flow channels configured to distribute the first polymeric material from the egress port of each of the plurality of shooting pots to each of the plurality of nozzles to feed each of the plurality of nozzles with a controlled volume shot of the first polymeric material; a third set of flow channels configured to distribute the second polymeric material from the second material source to each of the plurality of nozzles; and a plurality of thermal control elements configured to cooperatively control a temperature component of a portion of the system through which the second polymeric material flows, the temperature component of the portion of the system being controllable to control a thermal property and a flow parameter of the second polymeric material flowing through the portion of the system to provide a material flow stream of the second polymeric material at an outlet of each of the plurality of nozzles having a substantial uniform flow parameter. 2. The system of claim 1, wherein the first polymeric material forms one of an inner layer, an interior layer or an outer layer of each of the plurality of multiple layer plastic articles. 3. The system of claim 1, wherein the second polymeric material forms one of an inner layer, an interior layer or an outer layer of each of the plurality of multiple layer plastic articles. 4. The system of claim 1, wherein the plurality of shooting pots and the plurality of nozzles have a one to one relationship. 5. The system of claim 1, wherein the plurality of shooting pots in combination with the plurality of nozzles comprises, a first group of nozzles in communication with a first portion of the mold to inject the first and second polymeric materials into the plurality of cavities associated with the first portion of the mold; a second group of nozzles in communication with a second portion of the mold to inject the first and second polymeric materials into the plurality of cavities associated with the second portion of the mold; a first shooting pot having an ingress port to receive the first polymeric material, a reservoir to hold a volume of the first polymeric material, and an egress port to feed there through a selected volume of the first polymeric material held by the reservoir to feed each nozzle forming the first group of nozzles with a controlled volume shot of the second polymeric material; and a second shooting pot having an ingress port to receive the first polymeric material, a reservoir to hold a volume of the first polymeric material, and an egress port to feed there through a selected volume of the first polymeric material held by the reservoir to each nozzle forming the second group of nozzles with a controlled volume shot of the first polymeric material. 6. The system of claim 1, wherein the system sequentially injects the first polymeric material and the second polymeric material into each of the plurality of mold cavities to mold the plurality of multiple layer plastic articles. 7. The system of claim 1, wherein the system simultaneously injects the first polymeric material and the second polymeric material into each of the plurality of mold cavities to mold the plurality of multiple layer plastic articles. 8. The system of claim 1, wherein the plurality of thermal control elements are associated with the plurality of nozzles to control a temperature component of each of the plurality of nozzles, each of the plurality of thermal control elements being individually controllable to individually control the temperature component of each of the plurality of nozzles to control the thermal property and the flow parameter of at least the second polymeric material through each of the plurality of nozzles. 9. The system of claim 1, wherein the plurality of thermal control elements are associated with a group of nozzles selected from the plurality of nozzles to control a temperature component of the group of nozzles as a group, the plurality of thermal control elements being controllable as a group to control the temperature component of the group of nozzles to control the thermal property and the flow parameter of at least the second polymeric material through the group of nozzles. 10. The system of claim 1, wherein the plurality of thermal control elements are associated with each channel member of the third set of flow channels to control a temperature component of each channel member, each of the plurality of thermal control elements being individually controllable to individually control the temperature component of each channel member of the third set of flow channels to control the thermal property and the flow parameter of the second polymeric material through each channel member forming the third set of flow channels. 11. The system of claim 1, wherein the plurality of thermal control elements are associated with a group of channel members selected from the third set of flow channels to control a temperature component of the selected channel members as a group, the plurality of thermal control elements being controllable as a group to control the temperature component of the group of selected channel members to control the thermal property and the flow parameter of the second polymeric material through the group of selected channel members. 12. The system of claim 1, wherein the plurality of thermal control elements comprise elements selected from a heater element, a cooling element, an insulator element, or a thermal conduction element. 13. The system of claim 1, wherein the third set of flow channels comprises, a plurality of flow channels configured to distribute a shear heated portion of the second polymeric material amongst the plurality of channels to feed each of the plurality of nozzles with a material flow of the second polymeric material from the second material source, each material flow of the second polymeric material having a substantially uniform flow rate and a substantially uniform distribution of the shear heated second polymeric material at an ingress port of each of the plurality of nozzles. 14. A system for injection molding a plurality of multiple layer plastic articles, the system comprising, a mold having a plurality of cavities to mold a plurality of multiple layer plastic articles; a first material source to supply a first polymeric material for use in forming at least one layer of each of the plurality of multiple layer plastic articles; a second material source to supply a second polymeric material for use in forming at least one layer of each of the plurality of multiple layer plastic articles; a plurality of nozzles in communication with the mold to inject the first and second polymeric materials into the plurality of cavities; a first shooting pot having an ingress port to receive the first polymeric material, a reservoir to hold a volume of the first polymeric material, and an egress port to feed there through a selected volume of the first polymeric material held by the reservoir; a second shooting pot having an ingress port to receive the second polymeric material, a reservoir to hold a volume of the second polymeric material, and an egress port to feed there through a selected volume of the second polymeric material held by the reservoir to feed each of the plurality of nozzles with a controlled volume shot of the second polymeric material; a first set of flow channels configured to distribute the first polymeric material from the first material source to the ingress port of the first shooting pot; a second set of flow channels configured to distribute the first polymeric material from the egress port of the first shooting pot to each of the plurality of nozzles to feed each of the plurality of nozzles with a controlled volume shot of the first polymeric material; a third set of flow channels configured to distribute the second polymeric material from the second material source to the ingress port of the second shooting pot; a fourth set of flow channels configured to distribute the second polymeric material from the egress port of the second shooting pot to each of the plurality of nozzles to feed each of the plurality of nozzles with a volume shot of the second polymeric material; and a plurality of thermal control elements configured to cooperatively control a temperature component of a portion of the system through which at least one of the first and second polymeric materials flows, the temperature component of the portion of the system being controllable to control a thermal property and a flow parameter of at least one of the first and second polymeric materials flowing through the portion of the system to provide a material flow stream of at least one of the first and second polymeric materials at an outlet of each of the plurality of nozzles having a substantial uniform flow parameter. 15. The system of claim 14, wherein the first polymeric material forms one of an inner layer, an interior layer or an outer layer of each of the plurality of multiple layer plastic articles. 16. The system of claim 14, wherein the second polymeric material forms one of an inner layer, an interior layer or an outer layer of each of the plurality of multiple layer plastic articles. 17. The system of claim 14, wherein the system sequentially injects the first polymeric material and the second polymeric material into each of the plurality of mold cavities to mold the plurality of multiple layer plastic articles. 18. The system of claim 14, wherein the system simultaneously injects the first polymeric material and the second polymeric material into each of the plurality of mold cavities to mold the plurality of multiple layer plastic articles. 19. The system of claim 14, wherein the plurality of thermal control elements are associated with the plurality of nozzles to control a temperature component of each of the plurality of nozzles, each of the plurality of thermal control elements being individually controllable to individually control the temperature component of each of the plurality of nozzles to control the thermal property and the flow parameter of at least one of the first and second polymeric materials flowing through each of the plurality of nozzles. 20. The system of claim 14, wherein the plurality of thermal control elements are associated with a group of nozzles selected from the plurality of nozzles to control a temperature component of the selected nozzles as a group, the plurality of thermal control elements being controllable as a group to control the temperature component of the group of nozzles to control the thermal property and the flow parameter of at least one of the first and second polymeric materials flowing through the group of nozzles. 21. The system of claim 14, wherein the plurality of thermal control elements are associated with each channel member of the second set of flow channels to control a temperature component of each channel member, each of the plurality of thermal control elements being individually controllable to individually control the temperature component of each channel member of the second set of flow channels to control the thermal property and the flow parameter of the first polymeric material through each channel member forming the second set of flow channels. 22. The system of claim 14, wherein the plurality of thermal control elements are associated with selected channel members of the second set of flow channels to control a temperature component of the selected channel members as a group, the plurality of thermal control elements being controllable as a group to control the temperature component of the group of selected channel members to control the thermal property and the flow parameter of the first polymeric material through the group of selected channel members. 23. The system of claim 14, wherein the plurality of thermal control elements are associated with each channel member of the fourth set of flow channels to control a temperature component of each channel member, each of the plurality of thermal control elements being individually controllable to individually control the temperature component of each channel member of the fourth set of flow channels to control the thermal property and the flow parameter of the second polymeric material through each channel member forming the fourth set of flow channels. 24. The system of claim 14, wherein the plurality of thermal control elements are associated with selected channel members of the fourth set of flow channels to control a temperature component of the selected channel members as a group, the plurality of thermal control elements being controllable as a group to control the temperature component of the group of selected channel members to control the thermal property and the flow parameter of the second polymeric material through the group of selected channel members. 25. The system of claim 14, wherein the plurality of thermal control elements comprise elements selected from a heater element, a cooling element, an insulator element, or a thermal conduction element. 26. A system for injection molding a plurality of multiple layer plastic articles, the system comprising, a mold having a plurality of cavities to mold a plurality of multiple layer plastic articles; a first material source to supply a first polymeric material for use in forming at least one layer of each of the plurality of multiple layer plastic articles; a second material source to supply a second polymeric material for use in forming at least one layer of each of the plurality of multiple layer plastic articles; a plurality of nozzles in communication with a portion of the mold to inject the first and second polymeric materials into each of the plurality of cavities; a shooting pot having an ingress port to receive at least the second polymeric material, a reservoir to hold a volume of the second polymeric material, and an egress port to feed there through a selected volume of the second polymeric material held by the reservoir to feed each of the plurality of nozzles with a controlled volume shot of the second polymeric material; a first plurality of flow channels configured to distribute a shear heated portion of the first polymeric material amongst the plurality of channels to feed each of the plurality of nozzles with a material flow of the first polymeric material from the first material source, each material flow of the first polymeric material having a substantially uniform flow rate and a substantially uniform distribution of the shear heated first polymeric material at an ingress port of each of the plurality of nozzles, a second plurality of flow channels configured to distribute the second polymeric material from the second material source to the ingress port of each of the plurality of shooting pots; and a third plurality of flow channels configured to distribute the second polymeric material from the egress port of each of the plurality of shooting pots to each of the plurality of nozzles to feed each of the plurality of nozzles with the controlled volume shot of the second polymeric material from a related shooting pot. 27. In a system a method for injection molding a plurality of multiple layer plastic articles, the method comprising the steps of, injecting using, a shooting pot, a first polymeric material into a plurality of cavities of a mold to form a first layer of each of the plurality of multiple layer plastic articles; and injecting using a thermal balancing technique a second polymeric material into the plurality of cavities of the mold to form a second layer of each of the plurality of multiple layer plastic articles, wherein the thermal balancing technique controls a plurality of thermal control elements configured to cooperatively control a temperature component of a portion of the system through which the second polymeric material flows, the temperature component of the portion of the system being controllable to control a thermal property and a flow parameter of the second polymeric material flowing through the portion of the system to provide a material flow stream of the second polymeric material at an outlet of each of a plurality of nozzles having a substantial uniform flow parameter. 28. The method of claim 27, wherein the steps of injecting are performed in a sequential manner. 29. The method of claim 27, wherein the steps of injecting are performed in a simultaneous manner. 30. In a system a method for injection molding a plurality of multiple layer plastic articles, the method comprising the steps of, injecting using, a shooting pot, a first polymeric material into a plurality of cavities of a mold to form a first layer of each of the plurality of multiple layer plastic articles; and injecting using a thermal distribution technique a second polymeric material into the plurality of cavities of the mold to form a second layer of each of the plurality of multiple layer plastic articles, wherein the thermal distribution technique distributes a shear heated portion of the second polymeric material amongst a plurality of channels to feed each of a plurality of nozzles in the system with a material flow of the second polymeric material from a second material source, and wherein each material flow of the second polymeric material has a substantially uniform flow rate and a substantially uniform distribution of the shear heated second polymeric material at an ingress port of each of the plurality of nozzles. 31. The method of claim 30, wherein the steps of injecting are performed in a sequential manner. 32. The method of claim 30, wherein the steps of injecting are performed in a simultaneous manner. 33. In a system a method for injection molding a plurality of multiple layer plastic articles, the method comprising the steps of, injecting using, a shooting pot, a first polymeric material into a plurality of cavities of a mold to form a first layer of each of the plurality of multiple layer plastic articles; and injecting using a thermal distribution technique and a thermal balancing technique a second polymeric material into the plurality of cavities of the mold to form a second layer of each of the plurality of multiple layer plastic articles, wherein the thermal distribution technique distributes a shear heated portion of the second polymeric material amongst a plurality of channels to feed each of a plurality of nozzles in the system with a material flow of the second polymeric material from a second material source, each material flow of the second polymeric material has a substantially uniform flow rate and a substantially uniform distribution of the shear heated second polymeric material at an ingress port of each of the plurality of nozzles, and wherein the thermal balancing technique controls a plurality of thermal control elements configured to cooperatively control a temperature component of a portion of the system through which the second polymeric material flows, the temperature component of the portion of the system being controllable to control a thermal property and a flow parameter of the second polymeric material flowing through the portion of the system to provide a material flow stream of the second polymeric material at an outlet of each of a plurality of nozzles having a substantial uniform flow parameter. 34. The method of claim 33, wherein the steps of injecting are performed in a sequential manner. 35. The method of claim 33, wherein the steps of injecting are performed in a simultaneous manner. 36. The system of claim 1, wherein the third set of flow channels are configured to distribute the second polymeric material from the second material source directly to each of the plurality of nozzles. 37. The method of claim 30, wherein the plurality of channels directly feed each of the plurality of nozzles with the second polymeric material from the second material source. 38. The method of claim 33, wherein the plurality of channels directly feed each of the plurality of nozzles with the second polymeric material from the second material source.