Vertically added processing for blow molding machine

Abstract

A vertical additive processing system for use with a blow molding machine having a flow head from which a plastic parison is delivered to a mold and producing an article. The system has a servo-controlled accumulation technology (SCAT) unit including (a) an accumulator collecting plastic material when retracted and delivering plastic material when extended, and (b) an actuator directing the accumulator to retract and extend. The system further has a tooling unit including a bushing body adapted to engage the flow head, a distribution ring, a bushing cap, a central aperture defining a main parison flow path, and a distribution channel delivering plastic material received from the accumulator to the main parison flow path. The system still further has a material duct connecting the two units through which plastic material delivered by the SCAT unit is transported to and received by the tooling unit. Also disclosed is a related method.

What is claimed: 
     
         1 . A blow molding machine for producing an article from a plastic parison, the machine comprising:
 a flow head from which the parison is delivered to a mold;   a servo-controlled accumulation technology (or SCAT) unit including:
 an accumulator collecting plastic material when in a retracted position and delivering plastic material when in an extended position, and 
 an actuator directing the accumulator to retract and extend; 
   a tooling unit including a bushing body engaging the flow head, a distribution ring, and a bushing cap, the tooling unit having a central aperture defining a main parison flow path and a distribution channel delivering plastic material received from the accumulator to the main parison flow path; and   a material duct connecting the SCAT unit and the tooling unit through which plastic material delivered by the SCAT unit is transported to and received by the tooling unit.   
     
     
         2 . A vertical additive processing system for use with a blow molding machine producing an article from a plastic parison, the machine having a flow head from which the parison is delivered to a mold, the system comprising:
 a servo-controlled accumulation technology (or SCAT) unit including:
 an accumulator collecting plastic material when in a retracted position and delivering plastic material when in an extended position, and 
 an actuator directing the accumulator to retract and extend; 
   a tooling unit including a bushing body adapted to engage the flow head, a distribution ring, a bushing cap, a central aperture defining a main parison flow path, and a distribution channel delivering plastic material received from the accumulator to the main parison flow path; and   a material duct connecting the SCAT unit and the tooling unit through which plastic material delivered by the SCAT unit is transported to and received by the tooling unit.   
     
     
         3 . The vertical additive processing system according to  claim 2 , further comprising a control system directing the actuator and, in turn, the accumulator to add or remove plastic material to or from a targeted area on the article. 
     
     
         4 . The vertical additive processing system according to  claim 2 , wherein the tooling unit defines a top plane and has an exit in the top plane defined by the circumference of the central aperture and the height between the top plane and the distribution channel increases the velocity and pressure differentials at the exit which in turn increase the thickness of the parison at the location of the increased pressure and velocity. 
     
     
         5 . The vertical additive processing system according to  claim 2 , wherein the bushing cap, the bushing body, and the distribution ring are combined by one or more fasteners to create a seal preventing exit of the main parison flow and the plastic material from the tooling unit except through the central aperture. 
     
     
         6 . The vertical additive processing system according to  claim 2 , wherein the bushing cap and the distribution ring combine to form the distribution channel. 
     
     
         7 . The vertical additive processing system according to  claim 2 , wherein multiple distribution channels are configured to allow the plastic material to enter the mold at separate locations and wherein the bushing cap and the distribution ring combine to form a distribution runner configured to deliver the plastic material to each of the multiple channels simultaneously. 
     
     
         8 . The vertical additive processing system according to  claim 7 , wherein the distribution runner has a substantially U-shaped outer portion and two, mirror-image, substantially semi-circular inner portions, the inner and outer portions interconnected to form an integral distribution runner and a closed path for the plastic material. 
     
     
         9 . The vertical additive processing system according to  claim 2 , wherein the bushing cap has a diverge pin. 
     
     
         10 . The vertical additive processing system according to  claim 2 , wherein four distribution channels comprise two pair of distribution channels, the distribution channels of each pair separated by about 70 degrees and the pairs separated by about 110 degrees. 
     
     
         11 . A method for blow molding in a mold a plastic article having one or more vertical material distribution sections, the method comprising:
 providing a first material source;   providing a second material source;   placing a tooling unit between the second material source and the mold, the tooling unit including a distribution ring having an aperture configured to allow introduction of a first material from the first material source into the mold, and at least one channel configured to allow introduction of a second material from the second material source into the mold;   introducing the first material from the first material source into the mold; and   selectively introducing the second material from the second material source into the tooling unit to create predetermined vertical material distribution sections in the plastic article.   
     
     
         12 . The method according to  claim 11 , wherein the first material and the second material are the same. 
     
     
         13 . The method according to  claim 11 , wherein the first material and the second material are different. 
     
     
         14 . The method according to  claim 11 , wherein the first material source and the second material source are the same. 
     
     
         15 . The method according to  claim 11 , wherein the step of selectively introducing the second material includes collecting the second material in an accumulator when the accumulator is in a retracted position and introducing the second material when the accumulator is in an extended position. 
     
     
         16 . The method according to  claim 15 , wherein the step of selectively introducing the second material further includes directing the accumulator to retract and extend using an actuator. 
     
     
         17 . The method according to  claim 16 , wherein the step of selectively introducing the second material further includes controlling the actuator using a controller. 
     
     
         18 . The method according to  claim 11 , further comprising the step of increasing the velocity and pressure differentials at an exit of the tooling unit which in turn increases the thickness of the parison at the location of the increased pressure and velocity. 
     
     
         19 . The method according to  claim 11 , further comprising the steps of combining the first material and the second material and predetermining the height between a top plane defined by the tooling unit and the at least one channel to define the velocity of the combined materials. 
     
     
         20 . The method according to  claim 19 , wherein the height is between about 4 and 20 mm.