HK1081149A - Side shuttle apparatus and method for an injection molding machine - Google Patents

Description

Side shuttle for injection molding machine

no marking

Technical Field

The present invention relates to apparatus and methods for manipulating one or more molded articles within one or more mold cavities and/or on a mold core. And more particularly, to a side shuttle apparatus and method by which various in-mold operations, such as removing a plastic molded article from a mold cavity or a mold core, attaching a label to the plastic molded article, inserting various inserts into the mold cavity, capping a molded container, and the like, can be performed quickly and easily.

Background

In the field of injection molding, various operations are required to be performed on the plastic articles that have just been molded and are still located (or partially located) in the respective mold cavities (or on the respective mold cores). For example, it would be beneficial to provide various structures for the following purposes: for removing the molded article just molded, for adding product labels, for providing various structural inserts, for rotating or handling the molded article in some manner, inspecting the molded article with a display system, in-mold decorating (e.g., priming, painting), transferring the molded article from one molding location to another for further in-cavity molding (cavity molding), applying a barrier layer (e.g., oxygen detergent, etc.).

It would also be beneficial to provide structure for supporting pre-molding operations such as adjusting the mold or mold insert (e.g., heating and/or cooling the molding surface, applying mold release, cleaning the molding insert with dry ice cleaner, and vents). All of these operations require additional structure that can be incorporated onto the injection molding machine to perform one or more of these operations. Such structure may be an operative structure or tool assembly (tool) mounted on a general transport structure for moving the operative structure into and out of the forming area to perform its function. However, all of the additional structure adds complexity, weight, maintenance requirements, and slows the injection molding cycle.

For example, US4976603, US5518387 and US5709833 all disclose a so-called servo rotating slot ("SSC") configuration whereby a molded article is removed from a mold cavity by a tool assembly mounted to a rotating arm delivery structure that is rotated toward and away from the mold to remove the just-molded plastic article from the mold cavity. These SWC structures are typically mounted outside of the mold cavity. The operation of these rotary tools requires relatively more time to remove the molded article, thereby increasing the cycle time (i.e., additional time is required to open the mold wide enough to allow a large radius of rotation controlled by the rotating arm and/or the molded article thereon).

The so-called end of the side insertion robot/tool arm ("EOAT") mechanism is another variation of the transport structure for moving the tool assembly over the surface of the mold for some post-forming operation. This transfer structure and tool assembly are located outside of the mold, usually in the vicinity of the injection molding machine, and therefore the injection molding machine is associated with drawbacks in size and weight because the tool assembly is sized to service the entire mold surface (i.e., must cover the entire mold surface), and it has a robust and relatively large structure to accommodate the tool assembly with a relatively long translational stroke.

US patent US5527173 discloses a molding apparatus comprising an operative structure in the form of a carrier plate for receiving a molded article and holding an insert to be incorporated into the molded article and, in addition, for transferring the insert onto a mold core prior to molding. The carrier plate is intended to be mounted for use on a typical side-entry robot.

Us patent RE33237 discloses an improved carrier plate for cooperation with an injection molding machine for processing hollow plastic articles in a mold cavity. In addition, when considering the construction and operation of a side-entry robot, the proposed configuration includes a platen-mounted robot having a pneumatically or servo-driven tool assembly plate drive, in addition to a carrier plate for the mold alignment apparatus.

US patents US4616992, US4679997 and US4784592 are examples of known apparatuses for placing labels in blow moulds of blow moulding machines. These devices include a transport assembly mounted on a side-insertion robot that uses suction cups or grippers to transfer labels and/or blow molded articles. However, these patents do not disclose a slide transfer structure that can be advantageously installed inside a mold.

US patent US5520876 discloses a method and an apparatus for injection moulding plastic cups, in which a label-shaped wrapping sheet is incorporated. The label holder and handling device are a unitary structure that is rotatably connected to the core half. This patent does not disclose a slide conveying structure that can be advantageously mounted inside the mold.

US patents 4351630 and US4340352 disclose devices for capping caps or lids in moulds. The apparatus comprises a finger mounted inside the mould which slides between the two mould parts in the open position, during which it comes into contact with a part of the moulded article or the lid, causing the part or the lid to rotate about a hinge and rapidly close the lid. This patent does not disclose a slide transfer structure that can be compactly installed inside the mold.

Co-assigned to the present applicant, U.S. patent application No. 10/243002 filed on 9/13/2002, discloses an apparatus and method for removing a molded article from a mold and folding the hinged molded article in the mold using a rotating arm mechanism. However, this application does not disclose a slide conveying structure that can be advantageously mounted inside a mold.

There is a need for a new type of transfer structure and associated tooling assembly and/or method for performing various post-mold operations on freshly formed plastic articles that reduces cycle time, size and weight constraints, and provides great flexibility in the types of post-mold operations that can be performed.

Disclosure of Invention

An advantage of the present invention is to provide a side shuttle adapted to fit within a mold and a method of using the same, wherein the apparatus is capable of translating over the mold surface in order to position the tool assembly on the apparatus relative to the mold cavity/core (or an auxiliary station, such as a drop groove) for various pre-and post-mold operations; and the method overcomes the problems of the prior art injection molding machines. The term "side" is not limited to the direction of motion of the reciprocating structure. I.e. the shuttle structure may be moved horizontally within a horizontally disposed mold and may be moved vertically within a vertically disposed mold. In this way, the shuttle structure will move in a direction substantially parallel to the common surface of the cavity and core faces.

According to a first aspect of the present invention, a side shuttle structure and/or steps of a molding machine are provided. Wherein a shuttle plate has a portion that is always located inside the perimeter of the first mold half of the molding machine; a guide assembly adapted to be coupled to the first mold half and also adapted to guide the shuttle plate for linear movement over the molding surface of the first mold half; a drive adapted to linearly drive the shuttle plate such that the shuttle plate moves linearly only over the molding surface of the first mold half; an operating structure is coupled to the shuttle plate and adapted to: (i) removing the molded article from the core or from the cavity, (ii) performing a further operation on at least one of (iia) the molded article located in/on the mold structure of the first mold half and (iib) the mold structure of the first mold half.

According to a second aspect of the present invention, the following structures and/or steps are provided. Wherein one of the molded article workpiece setting devices comprises a plate adapted to be coupled to the mold section. The plate includes a workpiece setting device adapted to set a workpiece onto at least one of the mold core and the mold cavity. A drive structure is coupled to the mold section and is adapted to drive the plate such that (i) the plate is driven in only one or more coplanar linear directions and (ii) the workpiece placement device places the workpiece on at least one of the mold core and the mold cavity.

According to a third aspect of the present invention, the following structures and/or steps are provided. Wherein the means for covering the molded article comprises a plate adapted to be coupled to the mold sections and further comprises a covering device adapted to at least partially cover the molded article on the mold core or in the mold cavity. The plate further includes a molded article removal apparatus adapted to remove the molded article from at least one of the mold core and the mold cavity. Drive structure is adapted to be coupled to the mold sections and to drive the plates so that (i) the plates are driven only in one or more coplanar linear directions and (ii) the covers of the molded articles on the mold cores or in the mold cavities are at least partially covered.

According to a fourth aspect of the present invention, the following structures and/or steps are provided. A method of manipulating a molded article within at least one of a mold cavity and a mold core of a molding machine, comprising the steps of: (i) opening at least one of the cavity plate and the core plate to expose the molded article; (ii) moving the shuttle element over a surface of at least one of the cavity plate and the core plate in only one or more linear co-planar directions to a position proximate the molded article; (iii) operating on the molded article while the molded article is at least partially within at least one of the mold cavity and the mold core; (iv) moving the shuttle element only in one or more coplanar linear directions from a position proximate to the molded article to a rest position where at least a portion of the shuttle element is within a perimeter of at least one of the cavity plate and the core plate; then, (v) closing at least one of the cavity plate and the core plate when said at least a portion of the shuttle element is within the perimeter of the at least one of the cavity plate and the core plate.

Drawings

The advantageous structure and/or function of the present invention will be more readily understood from the following detailed description of the preferred embodiments and the accompanying drawings. Wherein:

FIG. 1 is a schematic side view of an injection molding machine in which the servo side shuttle system of the present invention may be used.

FIG. 2 is a plan view of a first embodiment of the servo side shuttle system of the present invention.

Fig. 3 is a top view of a first embodiment of the present invention.

Fig. 4 is a side view of a first embodiment of the present invention.

Fig. 5 is another top view of the first embodiment of the present invention.

Fig. 6 is another side view of the first embodiment of the present invention.

Fig. 7 is a top view of an alternative embodiment of the first embodiment of the present invention.

Fig. 8 is a top view of the alternative embodiment of fig. 7.

Fig. 9 is a plan view of a core plate of another alternative embodiment of the first embodiment of the present invention.

FIG. 10 is a plan view of the cavity plate of the alternate embodiment of FIG. 9.

Fig. 11 is a drop-down detail view of the alternative embodiment of fig. 9.

Fig. 12 is another drop-in detail view of the alternative embodiment of fig. 9.

FIG. 13 is a schematic plan view of a mold core and mold cavity joined together in accordance with another alternative embodiment of the first embodiment of the present invention.

Fig. 14 is a top view of the alternative embodiment of fig. 13.

Fig. 15 is a plan view of yet another alternative embodiment of the first embodiment of the present invention.

Fig. 16a is a plan view of yet another alternative embodiment of the first embodiment of the present invention, and fig. 16b is a close-up schematic plan view of yet another alternative embodiment of the first embodiment of the present invention.

Fig. 17 is a plan view of a second embodiment of the present invention.

Fig. 18 is a top view of the second embodiment.

Fig. 19 is another top view of the second embodiment.

Fig. 20 is yet another top view of the second embodiment.

Fig. 21 is a plan view of a third embodiment of the present invention.

Fig. 22 is a detailed schematic diagram of the third embodiment.

Fig. 23 is a top view of the third embodiment.

Detailed Description

1. Introduction to the design reside in

The invention will now be described with respect to embodiments in which a plastic injection molding machine includes a mold having an internally mounted side shuttle assembly for a number of in-mold operations including the handling of finished molded articles. These forming operations may be performed in molds such as single-sided molds, stack molds, tertiary and quaternary molds, and the like. The invention can also be used in virtually any other forming process, such as stamping, die casting, metal forming, etc., or wherever an effective formed article handling structure is useful.

As a brief overview to aid in understanding the detailed description that follows, preferred embodiments include a shuttle plate connected to a first mold half by a guide for guiding the shuttle plate linearly across a molding surface of the first mold half. The shuttle plate is driven by suitable actuating means. The shuttle plate includes operating structure that allows various operations to be performed on the molded articles that have just been molded while still in their respective cavities or on their respective cores, or in the cavities or cores before or after the liquid plastic is injected into the cavities. For example, the shuttle plate may include a plurality of suction cups that are used to suck the molded article off of the mold core, linearly move the molded article, and lower the molded article into the drop cavity. Also, the operation structure may insert the label into the mold cavity and/or close the lid of the molded article left on the mold core before the plastic is injected into the mold cavity.

The shuttle plate is preferably located inside the mold halves, thus not only providing a small base, but also allowing a short distance for the shuttle plate to travel. This results in a lighter weight and compact structure which can be operated faster, which also shortens the cycle time.

A servo side shuttle system ("SSS") is adapted to translate (i.e., linearly move) its tool assembly along the face of the mold. The preferred internal mounting and associated short stroke of the servo side shuttle system provides a compact and relatively lightweight structure which again allows for faster cycling and/or allows for the handling of more cavitated (highher position) molds at a lower cost than SSC and side insertion robot/EOAT tools. Furthermore, the side shuttle, preferably mounted internally, improves the alignment of the tool assembly with the mold cavity (i.e., no loss due to robot-to-machine and/or mold-to-machine alignment) for handling the molded article and/or inserting the workpiece.

Three embodiments of the invention will be described below with respect to fig. 1-16b, 17-20 and 21-23. Fig. 2-16b illustrate the configuration of the servo side shuttle system for removing a formed plastic article from a mold, fig. 17-20 illustrate the configuration for closing and removing a cap on a formed plastic article from a mold, and fig. 21-23 illustrate in detail the configuration for placing a label in a mold cavity for subsequent placement on a formed plastic article. However, the side shuttle described herein may be used in other in-mold operations, such as inserting other formed or non-formed structures of plastic, composite materials, or metal into a mold cavity or onto a mold core before, during, or after an injection molding operation, inspecting the article with a vision system, in-mold decorating (e.g., priming, painting), pre-molding operations such as adjusting the mold or mold insert (e.g., heating and/or cooling the molding surface, applying mold release, cleaning the mold insert and vent with dry ice cleaner, transferring the molded article from one molding location to another for further in-cavity molding), applying a barrier (e.g., oxygen detergent), trimming or cutting the molded article, and the like. Further, any or all of the operations described above may be performed in any combination and in any order in order to shape and manipulate the article in a desired manner.

2. Structure of formed product processing tool

Fig. 1 illustrates an injection molding machine that includes a base 100, the base 100 housing various motors and control mechanisms (not shown) necessary to operate the body of the machine. The first mold portion 102 forms a mold cavity half and the second mold portion 104 forms a mold core half that is movable relative to the first mold portion. The first mold portion 102 includes a cavity plate 106 having a plurality of cavities 108. The second mold portion 104 has a core plate 110, the core plate 110 including a plurality of cores 112. Second mold portion 104 is slidably supported on upper and lower tie rods 114 and 116 and is caused to reciprocate therealong by a piston 118. The first mold portion 102 may be stationary or movable depending on the particular injection molding machine. The servo side shuttle tool 120 of the present invention is located on the second mold side 104. The side shuttle 120 removes the molded articles 122 from the core portion 104 and places them on the drop chute 124. The servo side shuttle tool preferably includes a servo motor 126, a drive shaft 128, respective linear/rack mechanisms 130, a shuttle plate 132, and respective suction elements 134.

Fig. 2 is a plan view of an embodiment for an injection molded plastic closure in a 4-level mold. Core plate 202 has a molding area 204 with 8 cores 206. A stripper ring 208 surrounds the mold core 206 and removes the molded article from the mold core 206 in a manner to be described below. Each support dowel 210 is used to align the core section 202 with a cavity section (not shown). Harmonic linkage (harmonic linkage)212 is used to open several molds in a stack mold configuration simultaneously.

Shuttle plates 214 and 216 are located on the left and right sides of core portion 202, respectively. Each shuttle plate has 4 arms extending over and covering the respective mold core 206. For purposes of explanation only, the left side of FIG. 2 shows shuttle plate 214 in an outer or closed position, while the right side of FIG. 2 shows shuttle plate 216 in an inner or open position. At an outer position, a portion of the shuttle plate extends outside the perimeter of core portion 202; and in the inner position the shuttle plate is located entirely within the core portion perimeter. However, as shown in FIG. 2, at least a portion of the shuttle plate is located within the perimeter of the core portion, whether in the open position or the closed position of the mold. Of course, each shuttle plate may comprise one or more flat elements, rectangular elements in cross-section, circular elements in cross-section, wires, cables, hinged elements, and may be made of metal, plastic, composite materials, and the like.

The servo motors 218 and 220 drive the shuttle plates 214 and 216, respectively, through respective drive shafts 222 and 224 and rack/linear guides 226, 228 and 230, 232. The servo motors 218 and 220, drive shafts 222 and 224, and rack/linear rails 226, 228 and 230, 232 are preferably coupled to the core and/or cavity plates. Each rack/linear guide preferably includes one or more linear bearings 234 and is constructed and arranged to guide the shuttle plate in linear movement relative to the mold surface of the core plate. Of course, any convenient drive/guide structure may be suitable for driving the shuttle plate.

Each shuttle plate is linearly driven across the surface of the core plate (and/or cavity plate) between an inner/open position (also referred to as a pick-up position) where the shuttle plate picks up the molded article from the core, and an outer/closed position (also referred to as a drop position) where the shuttle plate drops the molded article into the drop cavities 236 and 238. In fig. 2, a plurality of molded articles 240 are shown attached to shuttle plate 214 within drop mold cavity 236 and exiting from drop mold cavities 236 and 238. The servo motor may be replaced/supplemented by other drive mechanisms, such as a mechanical transmission, a pneumatic transmission, a hydraulic transmission, or a transmission that integrates the movement of the two mold halves when they are opened and closed. In addition, the side shuttle may be used to perform any desired operation on the molded article when the molded article is fully or partially on the mold core or within the mold cavity. For example, the label may be applied to the outer surface of a just-formed plastic container, while the container is still only partially withdrawn from the mold cavity.

Fig. 3 is a top view of the embodiment shown in fig. 2 showing the molds within the 4-stage mold in the closed position. The core plate 202 holds the individual mold cores 206, while the cavity plate 302 has a plurality of mold cavities 304. The molded article 240 is positioned between the mold core 206 and the mold cavity 304. The stripper plate 306 has a plurality of stripper rings 208 that remove each molded article 240 from each mold core 206 when the mold opening mechanism moves the core plate 202 away from the cavity plate 302. The first hot runner plate 308 and the second hot runner plate 310 hold a hot runner 312 in a known manner. Each pick-up position on shuttle plates 214 and 216 includes two suction members 316, 317 and 318, 319, respectively. These suction cups are used to pick up the molded article 240 from the mold core 206. However, many alternatives to suction cups may be used, such as vacuum slots, mechanical grippers, adhesive layers, electrostatic attraction/repulsion, magnetic attraction/repulsion, and the like.

Shuttle plates 214 and 216 are driven by servo motors 218 and 222 to move linearly between core 206 and drop slots 236 and 238. Once in the drop cavity, the vacuum is broken and/or an interference protrusion is arranged to lower the molded article 240 into the drop cavity. Drive gears 320 are used to transfer motion from drive shafts 222, 224 to rack/linear rails 226, 228 and 230, 232, respectively. In fig. 3, the first and second mold portions are symmetrical about line a-a, and the details of the second mold portion are not discussed further below. Similarly, the first and second die sets are symmetrical about line B-B, and the details of the second die set are not discussed further below.

Fig. 4 is a side view of the embodiment shown in fig. 2, showing the mold halves in a closed position. The figure shows a servo motor 218, core plate 202, mold core 206, cavity plate 302, hot runner plates 308, 310, and hot runner 312. A second harmonic linkage 402 is used to transfer motion between the pairs of core/cavity plates to ensure that the mold plates open/close at the proper timing. Since the respective mold halves are closed in this figure, the shuttle plate is not visible. This advantageous feature allows the shuttle mechanism to be completely contained within the contour of each of the closed mold halves, thereby keeping the footprint of the molding machine to a minimum. The narrow gap between the core and cavity plates provides sufficient "parking" space for the rack/linear guide structure and shuttle plates when the mold plates are in the closed position.

Fig. 5 is a top view of the embodiment shown in fig. 2, showing the mold halves in an open position. At this position, the shuttle plates 214, 216 are moved internally to a position where their suction cups 317, 317 and 318, 319 can pick up the molded article 240 from the mold core 206. Note that: there is a thin gap (e.g., about 50mm) between the open core plate 202 and the cavity plate 302. The rack/linear guide arrangement 226, 228 and 230, 232 and shuttle plates 214, 216 are adapted to move within this narrow gap to pick up a molded article 240 from the mold core 206, retract to a drop-in position, and then drop the molded article 240 into the drop chutes 236, 238. This narrow gap means that the mold halves do not have to be opened so much that removal of the molded article is effected. Fig. 5 also shows that linear bearings 234 are widely disposed on opposite sides of the drop die slot 236 to provide a wide range of linear bearing support for the rack/linear guide 228.

Fig. 6 is a side view of the embodiment shown in fig. 2, showing the core plate 202 and the cavity plate 302 in an open position.

Fig. 7 shows the alternative embodiment of fig. 2 in a stack mold where the molded article 240 is stripped from the shuttle cups 316, 318 into the drop mold slots 236, 238 by a U-shaped stripper bar 702 (part of the mold). With the release bar 702, the molded article 240 can be removed from the suction cup without any vacuum grooves and vacuum control structures. The stripper bar 702 also forms a portion of the drop chutes 236, 238 when the mold is closed and serves to guide the molded article into the drop chute, thereby eliminating possible interference between the falling molded article and the suction cup.

Fig. 8 shows the alternative embodiment of fig. 7 in an open position. The shuttle plates 214, 216 have been driven internally to position their suction cups 316, 318 adjacent the molded article 240 being prepared for picking up the molded article 240 from the mold core 206.

Fig. 9 is a plan view of core plate 202 in another alternative embodiment of fig. 2. In this alternative embodiment, shuttle plates 214, 216 comprise relatively narrow rectangular plates, each holding 4 vacuum plates 902. Each vacuum plate 902 has 3 vacuum ports 904 for grasping the molded article 240 by vacuum force. Vacuum line 906 delivers air at a lower pressure to vacuum port 904. To grasp or release the molded article 240 as desired, a vacuum source (not shown) and control structure (e.g., a processor, solenoid, etc.) control the vacuum to grasp or release the molded article 240 as desired. The stripper plate piston 908 moves the stripper plate in a known manner to remove the molded article 240 from the mold core 206. In this alternative embodiment, each of the mold cavities 236, 238 has a movable portion 236a, 238a that moves with the core plate 202 and a stationary portion 236b, 238b that remains stationary with respect to the core plate 202.

FIG. 10 is a plan view of the cavity plate 302 in the alternative embodiment shown in FIG. 9. Note that the various cut-outs 1002 form spaces for the gears of the shuttle plate drive mechanism to rest when the mold halves are closed.

Fig. 11 is a close-up view of a drop-down detail of the alternative embodiment shown in fig. 9, showing the mold halves in an open position. The hot runner plate is adjacent to a cavity plate 302 that holds a cavity 304. The core plate 202 holds the core 206 and moves relative to the cavity plate 302. The stripper plate 306 moves the stripper ring 208, which in this figure, the stripper ring 208 is in a clamped position (solid lines) and an unclamped position (dashed lines). As each mold half is opened, the shuttle plate 216 moves from left to right to position its vacuum port 904 to pick up the molded article 240 to be stripped from the mold core 240 with the stripper ring 208; while the shuttle 216 (and the attached molded article 240) moves from right to left (supported by bearings 234) to a position above the drop cavity 238a and the mold halves are closed again (with the plastic molded article), the closing action of the mold causes the stripper bar 702 to remove the molded article 240 from the suction cup 316 and lower it into the drop cavity 238 a. Dashed lines 1102 and 1104 represent the outer limits of the gears that drive shuttle plate 216. Dashed lines 1106 represent vacuum tube fittings and dashed lines 1108 represent vacuum tubes for picking up the molded article 240 from the mold core 206.

Fig. 12 is a close-up view of a drop-down detail of the alternative embodiment of fig. 9, showing the mold halves in a closed position. This figure clearly illustrates how the stripper bar 702 pushes the molded article 240 off of the shuttle plate vacuum port 904 and down onto the drop cavity 238 a. Note that: the stripper bar 702 forms a portion of the drop chute so that it properly positions the molded article 240 on the drop chute 238a as the molded article drops through the drop chute. It is also noted that the shuttle mechanism is properly fitted within the vertical gap between the mold halves.

Fig. 13 is another alternative embodiment of fig. 2. For illustrative purposes only, the left half of FIG. 13 shows a plan view of the mold core showing the molded article 240 transferred to the side shuttle plates 1306, 1308; while the right half of fig. 13 is a plan view of the mold cavity, showing the molded article 240 transferred to the drop mold cavities 1302, 1304. In this alternative embodiment, each servomotor drives two shuttle plates, thereby acting on two rows of mold cavities. Of course, this alternative embodiment could be extended so that each servomotor could drive three or more shuttle plates. This alternative embodiment also allows two shuttle plates therein to be positioned inside the drop chute and the mold cavity.

More specifically, cavity plate 302 includes 16 mold cavities 304 and 4 mold chase (only mold chase 1302 and 1304 are shown for clarity). 4 shuttle plates are provided (again only shuttle plates 1306 and 1308 are shown for clarity), one corresponding to a row of mold cavities. The servomotor 218 drives two shuttle plates 1306, 1308 through the drive shaft 222, rack/linear guide 228, 228 and gear 320. The shuttle plates 1306, 1308 are simultaneously driven in the direction of black arrow C to lower the molded article 240 into the two respective drop mold cavities. A servomotor, not shown, drives the other two shuttle plates in the direction of arrow D in a similar manner to lower the molded article 240 onto the drop cavities 1302, 1304.

Fig. 14 is a top view of the embodiment shown in fig. 13. In the lower half of the figure, the mold halves are shown in an open position, and four drop slots 1302, 1304, 1312, and 1324 are also shown. The shuttle plates 1306, 1308 are moved horizontally between respective pick-up positions to respective drop positions to drop the molded article 240 into the drop cavity. In the upper part of the figure, the respective mold halves are shown in the open position for explanatory purposes only. Note that: the core portion 202 and the cavity portion 302 have cut-out portions that are used to retain the shuttle plates and their drive mechanisms when the respective mold halves are closed.

Fig. 15 is a top view of yet another alternative embodiment of fig. 2. In this alternative embodiment, the stacks of mold cavities are offset or staggered from each other, thereby allowing adjacent rows of molded articles 240 to be transferred to the same drop slots 236, 238 to minimize the size of the mold, also saving space on the machine and further reducing the footprint of the machine. Servomotor 1502 drives shuttle plates 1504 and 1508 in the direction of arrow D, while servomotor 1503 drives shuttle plates 1506 and 1510 in the direction of arrow E. The drives of the servo motors 1502 and 1503 are synchronized so that the molded articles 240 from alternate rows of cavities are lowered into the same drop cavity. In this manner, only two stripper grooves 236, 238 are required to eject the molded article 240 from the four rows of mold cavities or cores. This "compresses" the four rows of cavities into two rows of output. Note that: this configuration allows all of the rack/linear guide structure to be positioned within the perimeter of the cavity plate 302.

Fig. 16A is a plan view of yet another alternative embodiment of fig. 2. In this alternative embodiment, there is no staggering between rows of mold cavities 304, but shuttle plates 1602 and 1604 are driven diagonally (arrow F) to a lowering position above the same drop slot 1606 to compress adjacent rows of molded articles 240. This diagonal drive is accomplished by driving respective helical drive shafts 1612 and 1614 in the vertical direction indicated by arrow G by servomotors 1608 and 1610 and moving in the horizontal direction indicated by arrow H by rack/linear guides 226 and 228. This configuration allows two rows of shaped articles to be simultaneously lowered into the same drop cavity. Thus, the driving is performed in more than one coplanar linear direction. Of course, this alternative embodiment could be deployed with each servomotor driving multiple shuttle plates.

Fig. 16b is a side view of yet another alternative embodiment of fig. 2 for treating a shaped article (e.g., a cup) having a relatively long, shallow draft. Shuttle plate 1602 includes a clamp 1616 that receives and traps (trap) the molded article 240, either during a mold closing stroke or when pushed by a stripper ring (not shown). Shuttle plate 1602 then moves gripper 1616 in the direction of arrow 16A, where it is positioned over drop die slot 236. The clamp stroke (or intermediate stroke) causes the push rod 1618 to engage the molded article 240 in the direction indicated by arrow 16B, thereby releasing the molded article 240 into the drop slot 236.

3. Structure of cover closing tool

FIG. 17 is a plan view of a second embodiment of the servo side shuttle of the present invention. In this embodiment, the servo side shuttle is used for another in-mold operation, such as capping and/or snapping the cap onto the formed plastic container. Although this embodiment is directed to a double shuttle plate, double row cavity embodiment, any of the alternative embodiments of FIG. 2 described above may be used in this embodiment.

In fig. 17, the servomotors 218, 220 drive respective drive shafts 222, 224, rack/linear guides 226, 228, 230, and shuttle plates 1702, 1704 in a manner substantially similar to that described with respect to fig. 2. The shaped article (not shown) is lowered in the direction of arrow I into two drop cavities (also not shown) for ejection. Movement of shuttle plates 1702 and 1704 in the direction of arrow J causes each cap to partially or fully close onto molded article 240 on mold core 206, as described in more detail below with respect to fig. 18.

Fig. 18 is a top view of the embodiment shown in fig. 17, showing the mold halves closed. Core plate 202 includes mold cores 206, each of which is shown with suitable molding structures 207, such as dowels (dowels), core caps (core caps), retainer screws, cooling channels, and the like. The cavity plate 302 includes a plurality of mold cavities 306, each of which includes suitable molding structures 307, such as cooling channels, injection nozzles, hot runners, and the like. In the upper right portion of the figure, the shuttle plate 1704 is shown positioned above the drop mold trough 238 with the suction cup 316 just unfastened from the molded article 240. Note that: the molded article 240 includes a body 240a and a closed lid 24 b.

Fig. 19 is a top view of the embodiment of fig. 17 showing the mold halves open. Note that: as shuttle 1702 moves in the direction of arrow K, portions of the shuttle (described in more detail below) contact the edge of cover 240b and rotate the cover in a counterclockwise direction to a position at an angle of about 90 to the main portion of molded article body 240 a. The molded article 240 is then peeled from the core 206 onto the suction cup 316 and the shuttle 1702 is linearly moved to the drop position, the cover 240b is gripped by the clamp structure (described in more detail below), and the molded article 240 is dropped onto the drop chute 236.

Fig. 20 is an enlarged view of the embodiment of fig. 17, in which the cavity plate 302 and the core plate 202 are in an open position. The configuration of fig. 20 may operate in at least two alternative embodiments. In the # 1 alternative embodiment, a pickup protrusion 2002 is coupled to shuttle plate 1702, which picks up the edge of cover 240b and rotates it to a 90 ° position as shuttle plate 1702 moves in the direction of arrow K. Then, the knock-out ring 2004 is moved upward, and the main body 240a of the molded article is brought into contact with the telescopic suction cup 2006. When the shuttle plate 1702 is retracted in the direction of arrow L, the mold bars 2008 mounted to the cavity plate 302 push the cap from the 90 ° position to about 175 ° (from its initial fully open position). Thereafter, when the mold halves are closed again, the clamp protrusions 2010, also mounted on the cavity plate 302, snap over the cover 240b with the fork-like protrusions shown in the drawings. This same mold closing action also removes the molded article 240 from the suction cup 2006 and lowers it into the drop cavity 236. Of course, the position of the pick-up projection may be varied to cover the lid in any desired position, preferably one between about 90 ° and about 175 °. The clamp protrusion 2010 may also include an actuator for applying an auxiliary clamping force to the cover 240 b.

In the 2# alternative embodiment of fig. 20, the pickup projection 2003 is located to the right of the suction cup 2006, so that movement of the shuttle plate 1702 in the direction of arrow K causes the cover 240b to rotate clockwise to a position of about 175 °. Then, when the mold release ring 2004 pushes the molded article 240 onto the telescopic suction cup 2006, the lid 240b is caught and the shuttle plate moves in the direction of the arrow L to lower the molded article 240 into the drop mold cavity 236. It is also possible that the cover will not be bitten when the suction cup 2006 grasps the molded article 240, in which case the clamp protrusion 2010 can be used to bite into the cover 240b before the molded article is lowered into the drop cavity 236.

4. Structure of tool for labelling in mould

Fig. 21 is a plan view of a third embodiment of the invention in which a shuttle plate is used to place labels into the mold cavities before molten plastic is injected into the mold cavities. Although this embodiment is directed to a double shuttle plate, double row cavity embodiment, any of the alternative embodiments of FIG. 2 described above may be used in this embodiment. In the preferred stack mold, servo motors 218, 220 drive shafts 222, 224 which in turn drive rack and pinion mechanisms 226, 228, 230, 232 which move curved shuttle plates 2102 and 2104 into an open mold. Here, a vacuum receiving shaft and/or suction cup on each shuttle plate receives a molded article 240 from the mold cavity 206. Each shuttle plate 2102, 2104 is then removed from the mold and the take-up shaft transfers the molded article to a vacuum belt transfer mechanism (not shown) or a drop box. When the shuttle plates 2102, 2104 are in the outer position (when the respective mold halves are closed again), a floating plate 2106 coupled to each shuttle plate (in a manner to be described in detail below) moves over the workpiece container 2108 and picks up the workpiece for subsequent transfer into the mold cavity.

In this embodiment, the workpiece comprises a label to be affixed to the exterior of the formed plastic container in the manner described below. However, the workpiece may comprise other materials, such as a container lid, a shaped insert, a temperature sensitive element, an electrical circuit, a battery, a filter, a diaphragm, etc., or any other device that may be useful in a finished product. The workpiece container 2108 preferably includes 4 vacuum ports 2110 for holding labels within the container. The workpiece may be inserted into the mold cavity (or mold core) before, after, or between injections of different layers (or other structures) of the molded article.

Figure 22 is a detailed schematic of the embodiment of figure 21 showing each floating plate 2106 comprising an upper plate 2106a and a lower plate 2106 b. For purposes of explanation only, the upper half of fig. 22 shows the mold in a closed state with the side shuttling plates resting, while the lower half of fig. 22 shows the mold in an open state with the side shuttling plates in a pick/transfer position. In the open position of the mold illustrated in the lower half of the figure, floating plates 2106a, b are interposed between mold core 206 and mold cavity 304. The upper half of fig. 22 shows how the shuttle and float plates are safely positioned in the rest position when the respective mold halves are closed. The stack of labels 2112 is held within the container 2108 by vacuum, static electricity, gravity, or any other suitable mechanism.

Fig. 23 is a detailed view of the structure of fig. 22. In fig. 22, the core plate 202 and cavity plate 302 are in the open position of the mold with the molded article 240 on the mold core 206 and it is about to be removed from the mold core by the stripper ring 208. Floating plates 2106a, 2106b are mounted on opposite sides of shuttle plate 2102 using shaft 2302 and sleeve 2304 so that the plates "float" in the direction of arrow M. Springs 2306 (or any other biasing means) are positioned between the upper surface of shuttle plate 2102 and the lower surface of float plate 2106a in the manner shown to urge each float plate back to a rest position with molded article handling plate 2106a biased away from the shuttle plate. In operation, the molded article 240 being demolded by the stripper ring 208 is grasped by the suction cups 2308, and the demolding action on the molded article 240 pushes the floating plates 2106a, 2106b toward the mold cavity 304 and positions the label 2310 at a predetermined location. Thereafter, the label is released from suction cup 2309 onto the bottom surface (or other desired surface location, e.g., side surface) of mold cavity 304, stripper ring 208 is retracted, floating plates 2106a, 2106b return to their rest position, and the shuttle plate is retracted to the lowered position of the molded article. The stripping action may be alternately coupled between the floating plates 2106a, 2106b by pins (not shown) engaging the stripper ring 208. The label may be held in place within mold cavity 304 by vacuum grooves 2312 or other holding means (e.g., electrostatic charge).

In summary, as the stripper ring 208 ejects the molded article 240, it moves the floating plates 2106a, 2106b downward until the lower floating plate 2106b reaches the bottom of the molded article, and the label 2310 held by the suction cup 2309 can be transferred to the mold while the previously molded article 240 is transferred to the suction cup 2308. When the float plates 2106a, 2106b return to the rest position, the primary shuttle plate 2102 retracts from the mold, the molded article 240 is discharged into the drop mold cavity, and the label 2310 is loaded onto the suction cup 2309, thereby preparing the shuttle plate for the next cycle.

5. Operation of

The operation of the various structures of the present invention has been described above. The overall operation of the one-shot forming operation of the preferred embodiment is briefly described below.

The method comprises the following steps:

1. injecting molten plastic into the mold cavity;

2. opening the mold;

2.1. moving the shuttle assembly to a pick-up position;

2.2. ejecting/transferring the shaped article to a side shuttle;

2.2.1. (alternative) workpiece (e.g. label) transfer;

2.2.2. (alternative) intermediate mould fully/partially closed to affect transfer/operation of steps;

2.3. moving the tool assembly to a lowering position, which may be the same or different from the resting position;

3. closing the mold;

3.1. removing the molded article from the side shuttle;

(alternative) picking up a workpiece (e.g. a label).

6. Advantages of the invention

The servo side shuttle system shortens cycle time, increases the number of mold cavities that can be used, reduces investment, and improves positioning accuracy. In particular:

(1) the in-mold treatment/labeling of the molded article requires less time because the shuttle plate is inside the mold and therefore travels a shorter distance than a robotic plate that must completely exit the molding area. Furthermore, when there are multiple servo side shuttle plates on one mold surface (e.g., the entire horizontal run is driven by two side shuttle plates, a left side shuttle plate and a right side shuttle plate), the cycle time can also be reduced.

(2) The internal treatment of the shaped article between the mould cavity and the drop chute with the servo side shuttle is a substantially linear movement and requires a shorter opening stroke than the internal treatment of the shaped article with the servo rotary chute, where the shaped article is treated over a large arc, thus requiring more space between the two mould halves.

(3) For example, in the case of a conventional roto-trough rotary molded article, the opening stroke required for an 8.5 "lid may exceed the 10" to 12 "arc of rotation, while for the same molded article, the SSS may require only a 2" to 3 "stroke, thereby greatly reducing cycle time by reducing the time required for the molding stroke.

(4) By having the motion of the core-side stripper plate/ejector interact with the shuttle plate to transfer the workpiece into the mold, the actuator and associated control feedback is eliminated, thereby saving cost and reducing weight, the reduction in weight and the simplification of the controller (no signal lag time for the tool plate actuator) provide the potential for reduced cycle time.

(5) Due to the size, weight, positioning accuracy and associated stability of the robot arm, known in-mold labeling systems can be considered limited to only 2 x 4 active chambers, while servo-side shuttle plates can handle 2 x 8 or even more chambers, since the in-mold mounting is not only stable, but the shorter stroke distance and lighter weight of the shuttle plate (i.e. no actuators on the plate) makes the structure lighter and more compact. Furthermore, conventional stand-alone in-mold labeling systems have poor precision due to the relative motion of the robot/former/mold, and the present invention contemplates in-mold mounting (i.e., securing everything within the mold) to improve operational precision.

(6) The technique is not limited to in-mold labeling but may have more general use for placing inserts into mold cavities.

(7) The method of operation of the side shuttle plate maintains the orientation of the molded article as it is processed from the mold cavity to the drop chute, which may be advantageous for post-molding operations such as stacking/packing. In addition, the internal mounting of the side shuttle plates and their inherent alignment accuracy provide precise orientation and placement of the molded inserts (e.g., labels).

7. Conclusion

Thus, a servo side shuttle apparatus and method are described that can perform various operations on molded articles in a mold that will significantly reduce the cycle time and cost of producing molded articles.

Any of the U.S. and foreign patent documents cited above are hereby incorporated by reference into the detailed description of the preferred embodiments.

The various components shown in outline or designated by blocks in the attached drawings are all well-known in the molding arts, and their specific construction and operation are not critical to the operation or best mode for carrying out the invention.

While the invention has been described with respect to what is presently considered to be the preferred embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. On the contrary, the invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.

Claims (89)

1. A side shuttle for a molding machine, comprising:

a shuttle plate having a portion always located inside the perimeter of the first mold half of the molding machine;

a guide assembly adapted to be coupled to the first mold half and adapted to guide the shuttle plate for linear movement over the molding surface of the first mold half;

a drive adapted to linearly drive said shuttle plate so that said shuttle plate moves linearly only over the molding surface of the first mold half; and

an operating structure coupled to the shuttle plate adapted to: (i) removing the molded article from the core or from the cavity, (ii) performing a further operation on at least one of (iia) the molded article located in/on the mold structure of the first mold half and (iib) the mold structure of the first mold half.

2. The apparatus of claim 1 wherein the operation structure is adapted to perform other operations on the plastic injection molded article positioned on the mold core of the first mold half.

3. The apparatus of claim 1 wherein the operation structure is adapted to perform another operation on the molded article on the core of the first mold half.

4. The apparatus of claim 1, wherein the operation structure is adapted to perform another operation on the molded article positioned within the mold cavity of the first mold half.

5. The apparatus of claim 1, wherein the manipulation structure is adapted to perform other manipulations on the mold cavity of the first mold half.

6. The apparatus of claim 1 wherein the operation structure is adapted to perform other operations on the core of the first mold half.

7. The apparatus of claim 1, wherein the operating structure comprises a structure adapted to remove a molded article from a mold cavity of the first mold half.

8. The apparatus of claim 1 wherein the operating structure comprises structure adapted to remove the molded article from the mold core of the first mold half.

9. The apparatus of claim 1, wherein the operating structure is adapted to position the workpiece within the cavity of the first mold half.

10. The apparatus of claim 9 wherein the operating structure is adapted to position a label into a mold cavity of the first mold half.

11. The apparatus of claim 1 wherein the operating structure is adapted to position the workpiece on a core of the first mold half.

12. The apparatus of claim 1, wherein the operating structure is adapted to move the lid over the molded article.

13. The apparatus of claim 1, wherein the operative structure is adapted to dispose an insert into the molded article.

14. The apparatus of claim 1, further comprising a first floating plate and a second floating plate on opposite sides of the shuttle plate.

15. The apparatus of claim 1 wherein said shuttle plate has a portion that is always positioned within the second mold half of the molding machine.

16. The apparatus of claim 1, further comprising a plastic injection molding machine.

17. A demolding device for a molded article, comprising:

a plate adapted to be coupled to the mold sections, the plate including a demolding apparatus adapted to pick up a molded article from at least one of the mold core and the mold cavity;

drive structure adapted to be coupled to the mold sections and adapted to drive the plate such that (i) the plate is driven in only one or more coplanar linear directions and (ii) the demolding apparatus removes the molded article from at least one of the mold core and the mold cavity.

18. An apparatus according to claim 17, wherein the plate comprises a plurality of shuttle plates, each shuttle plate being coupled to the mold section such that a portion of each shuttle plate is always located within the perimeter of the mold section.

19. The apparatus of claim 18, further comprising a drop mold cavity adapted to receive a molded article from each of said plurality of shuttle plates.

20. The apparatus of claim 18, wherein at least one of said plurality of shuttle plates is always completely within the perimeter of the mold sections.

21. The apparatus of claim 17, wherein said drive structure comprises:

a servo motor;

a drive shaft coupled to the servo motor;

a gear coupled to the drive shaft; and

a linear guide coupled between the drive shaft and the shuttle plate and driven by a gear.

22. The apparatus of claim 17 wherein the mold sections comprise at least one of (i) a core plate having a plurality of cores thereon and (ii) a cavity plate having a plurality of cavities thereon, and wherein the shuttle plate comprises a plurality of arms for accessing the plurality of cores or the plurality of cavities.

23. The apparatus of claim 22, further comprising:

a suction cup coupled to each of the arms; and

a vacuum tank for supplying low pressure air to the suction cup.

24. A molded article workpiece setting device comprising:

a plate adapted to be coupled to the mold sections, the plate including a workpiece setting device adapted to set a workpiece onto at least one of the mold core and the mold cavity; and

a drive structure adapted to be coupled to the mold sections and adapted to drive the plate such that (i) the plate is driven in only one or more coplanar linear directions and (ii) the workpiece placement device places the workpiece on at least one of the mold core and the mold cavity.

25. The apparatus of claim 24 wherein said workpiece disposing means comprises label disposing means adapted to dispose labels onto the interior surface of the mold cavity.

26. The apparatus of claim 25 wherein said label applying means includes a label attracting element for grasping a label.

27. The apparatus of claim 26, further comprising a floating plate device having:

a first float plate on the first side of the plate having a molded article attracting element for picking up a just molded article from the mold core;

a second float plate on the second side of the plate having a label attracting element for grasping a label;

biasing structure between said plate and at least one of said first and second floating plates, said biasing structure permitting said first and second floating plates to move in a direction perpendicular to a plane of said plate when the mold core and mold cavity are moved relative to each other.

28. The apparatus of claim 27 wherein the drive structure is adapted to move in a first direction to move (i) the molded article attracting member to a position adjacent a recently molded article on the mold core and (ii) the label attracting member holding the label to a position adjacent the mold cavity, and wherein after removal of the molded article from the mold core, the drive structure is movable in a second direction to move (iii) the molded article attracting member to a position at which the recently molded article is to be ejected from the mold and (iv) the label attracting member to a position adjacent the label supply position.

29. The apparatus of claim 28 further comprising retaining structure located adjacent the mold cavity for retaining the label in the mold cavity after clamping.

30. A capping apparatus for a shaped article, comprising:

a plate adapted to be coupled to the mold sections, the plate including a capping device adapted to at least partially cap the molded article on the mold core or in the mold cavity, the plate including a molded article ejection device adapted to remove the molded article from the mold core or mold cavity; and

drive structure adapted to be coupled to the mold sections and adapted to drive the plate such that (i) the plate is driven in only one or more coplanar linear directions and (ii) a cover of a molded article on the mold core or in the mold cavity is at least partially covered.

31. The apparatus of claim 30 wherein the molded article comprises a plastic injection molded article positioned on the mold core when the drive structure drives the plate to close the cap, wherein the cap covers an angle of between about 90 ° and about 175 ° with respect to the injection molding position.

32. The apparatus of claim 31 wherein said molded article removal device comprises a suction element for removing the molded article from the mold core and said capping device comprises a tab element secured to said plate on one side of said suction element.

33. The apparatus of claim 32 wherein said drive structure drives said plate in a direction to place the molded article adjacent the molded article ejection location after said suction element removes the molded article from the mold core.

34. The apparatus of claim 33, further comprising a capping structure coupled to the mold that further caps the molded article when the drive structure drives the plate in the direction to place the molded article adjacent the ejection location of the molded article.

35. The apparatus of claim 34, further comprising a cover member coupled to the mold tool and adapted to bite into a cover over the molded article when the mold cavity is closed relative to the mold core.

36. An injection molding machine comprising:

a cavity plate having a plurality of cavities;

a core plate having a plurality of cores;

a driver for opening or closing the cavity plate and the core plate relative to each other;

injection structure for injecting molten plastic into said plurality of mold cavities;

a molded product discharge structure for discharging a molded product from the injection molding machine; and

and shuttle means linearly movable between the core plate and the cavity plate when the core plate and the cavity plate are separated by a predetermined gap, the shuttle means for ejecting a plurality of molded articles from the plurality of mold cavities or the plurality of mold cores, the shuttle means being located at least partially within the perimeter of the cavity plate when the core plate and the cavity plate are in the closed position.

37. The injection molding machine of claim 36, further comprising:

a driver to and from the device; and

a coupling structure for transmitting a driving force from said shuttle device driver to said shuttle device, the structure causing said shuttle device to move only in respective linear directions which are coplanar.

38. An injection molding machine according to claim 36, further comprising a plurality of floating plate apparatuses, each apparatus coupled to the corresponding shuttle apparatus, each floating plate apparatus comprising:

a molded article grasping structure on an upper surface of said float plate apparatus for grasping a molded article from a corresponding mold core;

a molded article grasping structure on a lower surface of said float plate apparatus for placing a workpiece in a corresponding mold cavity; and

biasing structure which allows said floating plate to move in a direction perpendicular to the linear direction of said shuttle apparatus to thereby pick up a molded article from a corresponding mold core and place a workpiece in a corresponding mold cavity.

39. An injection molding machine according to claim 36, further comprising a capping structure coupled to each of said shuttle devices for capping the molded article when the molded article is located in the corresponding mold cavity or the corresponding mold core.

40. The injection molding machine of claim 36, further comprising a plurality of openings in at least one of the core plate and the cavity plate for positioning said plurality of shuttles inwardly of the periphery of the cavity plate when the core plate and the cavity plate are in the closed position.

41. A shuttle structure for a molding machine, comprising:

a plurality of shuttle members, each of which is engageable with a portion of the mold and is operable to remove a molded article from the mold core or from the mold cavity;

a shuttle guide structure that is engageable to the portion of the mold and that limits movement of each of the plurality of shuttle elements to only respective linear directions that are coplanar, the respective linear directions of the coplanar being substantially parallel to a surface of the mold; and

a shuttle drive structure that may (i) be coupled to the mold section, (ii) drive each of the plurality of shuttle elements in respective linear directions that are coplanar only, (iii) when the mold is in the closed position, cause each of the plurality of shuttle elements to dwell at a location where at least a portion of each of the plurality of shuttle elements is within a perimeter of the mold section.

42. A side shuttle for a molding machine, comprising:

a shuttle member having a portion always located inside the perimeter of the first mold half of the molding machine, the shuttle member being shuttled between the first mold half and the second mold half when the first mold half and the second mold half are in the open position;

a guide member coupled to the first mold half for guiding the shuttle member to linearly move on the molding surface of the first mold half;

a drive member adapted to linearly drive the shuttle member so that the shuttle member moves only linearly over the molding surface of the first mold half; and

an operating member coupled to the shuttle member that is capable of (i) removing the molded article from the mold core or from the mold cavity, (ii) performing other operations on at least one of (iia) the molded article located in/on the mold structure of the first mold half and (iib) the mold structure of the first mold half.

43. An apparatus according to claim 42, wherein the operation device performs a further operation on the plastic molded article located in the mold cavity of the first mold half.

44. The apparatus of claim 42 wherein said operating means performs another operation on the molded article on the core of the first mold half.

45. The apparatus of claim 42 wherein the operation component performs another operation on the molded article positioned within the cavity of the first mold half.

46. An apparatus according to claim 42, wherein the operative component performs other operations on the mold cavity of the first mold half.

47. The apparatus of claim 42 wherein said operating means performs other operations on the core of the first mold half.

48. An apparatus according to claim 42, wherein the operating means comprises mold removal means for removing the molded article from the cavity of the first mold half.

49. An apparatus according to claim 42, wherein the operative means comprises mold removal means for removing the molded article from the core of the first mold half.

50. The apparatus of claim 42 wherein said operative means comprises means for positioning the workpiece within the cavity of the first mold half.

51. An apparatus according to claim 50, wherein the operating means comprises means for placing a label into a cavity of the first mold half.

52. The apparatus of claim 42 wherein said operating means comprises means for positioning the workpiece on a core of the first mold half.

53. An apparatus according to claim 42, wherein the operating means comprises moving means for moving the lid over the shaped article.

54. An apparatus according to claim 42, wherein the operating means comprises means for disposing an insert into the shaped article.

55. The apparatus of claim 42, further comprising a first floating member and a second floating member on opposite sides of the shuttle member.

56. An apparatus according to claim 42, wherein the shuttle portion is always located inside the second mold half of the molding machine.

57. The apparatus of claim 1, wherein said molding machine comprises a plastic injection molding machine.

58. A method of operating a molded article in at least one of a mold cavity and a mold core of a molding machine, comprising the steps of:

opening at least one of the cavity plate and the core plate to expose the molded article;

moving the shuttle member in only one or more linear directions over a surface of at least one of the cavity plate and the core plate to a position proximate the molded article;

removing the molded article from at least one of the mold cavity and the mold core;

moving the shuttle element only in one or more linear directions from a position proximate to the molded article to a rest position where at least a portion of the shuttle element is within a perimeter of at least one of the cavity plate and the core plate; then the

Closing at least one of the cavity plate and the core plate when said at least a portion of the shuttle element is within the perimeter of the at least one of the cavity plate and the core plate.

59. The method of claim 58 wherein said step of removing molds performs a mold removal operation on a plastic injection molded article positioned on a core of a core plate.

60. The method of claim 58, wherein said step of removing performs a mold removal operation on a molded article positioned on a core of a core plate.

61. The method of claim 58, wherein said removing step performs a mold removal operation on the molded article located in the cavity of the cavity plate.

62. The method of claim 58, further comprising the step of performing other operations on the mold cavity of the first mold half.

63. The method of claim 58, further comprising the step of performing other operations on the mold core of the first mold half.

64. The method of claim 58, wherein said removing step removes the molded article from the cavity of the cavity plate.

65. The method of claim 58 wherein said removing step removes the molded article from a core of the core plate.

66. The method of claim 58, further comprising the step of disposing the workpiece into a cavity of a cavity plate.

67. A method according to claim 66 wherein said disposing step disposes the label into a cavity of a cavity plate.

68. The method of claim 66 wherein said disposing step disposes the workpiece on a core of a core plate.

69. The method of claim 58, further comprising the step of moving the cap over the shaped article.

70. The method of claim 58, further comprising the step of disposing an insert onto the shaped article.

71. The method of claim 58 wherein the removing step removes the molded article from the core of the core plate and the disposing step disposes the workpiece into the cavity of the cavity plate.

72. A method according to claim 58, wherein said shuttle plate portion is always located inside the second mold half of the molding machine.

73. The method of claim 58 wherein said molding machine comprises a plastic injection molding machine.

74. A molded article taking-out method comprising the steps of:

driving the shuttle plate in only one or more coplanar linear directions;

picking up the molded article from at least one of the mold core and the mold cavity with a mold removal apparatus coupled to the shuttle plate; then the

The shuttle plate is driven in only one or more coplanar linear directions to remove a molded article from at least one of the mold core and the mold cavity.

75. A method according to claim 74, wherein the shuttle plate is always located within the periphery of the core.

76. A method according to claim 75 wherein the mold sections comprise at least one of (i) a core plate having a plurality of cores thereon and (ii) a cavity plate having a plurality of cavities thereon, the shuttle plate comprising a plurality of arms for accessing the plurality of cores or the plurality of cavities, the second driving step comprising the step of driving the shuttle plate so that the arms of the shuttle plate are always located within the periphery of the cores.

77. The method of claim 76 wherein the grasping step comprises the step of grasping the molded article with a suction device coupled to each arm for grasping the molded article.

78. A method of setting a shaped article workpiece comprising the steps of:

driving the shuttle plate in only one or more coplanar linear directions;

setting the workpiece with a workpiece setting device coupled to the shuttle plate into at least one of: (i) a molded article on at least one of the mold core and the mold cavity, and/or (ii) at least one of the mold core and the mold cavity; then the

The shuttle plate is driven in only one or more coplanar linear directions to move the workpiece setting device to the workpiece pick-up position.

79. A method as recited in claim 78 wherein said workpiece setting device comprises a label setting device and said setting step comprises the step of setting labels onto interior surfaces of the mold cavities.

80. A method according to claim 79 wherein the label applying apparatus comprises a label attracting element and a molded article attracting element and the applying step comprises the step of applying the label with the label attracting element.

81. The method of claim 80 wherein the first driving step drives the shuttle plate in a first direction to move (i) the molded article attracting member to a position adjacent to the molded article just molded on the mold core and (ii) the label attracting member holding the label to a position adjacent to the mold cavity, and wherein after removing the molded article from the mold core, the second driving step drives the shuttle plate in a second direction to move (iii) the molded article attracting member to a position where the molded article just molded is to be ejected from the mold and (iv) the label attracting member to a position adjacent to the work pick-up position.

82. The method of claim 81 further comprising the step of retaining the label in the mold cavity after the mold is closed.

83. The method of claim 78 wherein the step of disposing comprises the step of removing the molded article from the mold core while disposing the label on the interior surface of the mold cavity.

84. The method of claim 78 further comprising the step of closing the mold core and mold cavity, wherein said step of closing comprises the step of causing the workpiece setting device to pick up the label from the label picking position.

85. A method of capping a shaped article comprising the steps of:

first, the shuttle plate is driven only in one or more coplanar linear directions; and during the first driving step, (i) at least partially capping the molded article on the mold core or in the mold cavity with a capping device coupled to the shuttle plate, and (ii) gripping the molded article on the mold core or in the mold cavity;

second, after the cover of the molded article is at least partially covered, the shuttle plate is driven only in one or more coplanar linear directions.

86. The method of claim 85, further comprising the steps of: during the second driving step, the partially covered lid of the molded article is further covered with a capping structure bonded to the mold.

87. The method of claim 86 wherein the molded article comprises a plastic injection molded article on a mold core and the partially capping step covers the cap at an angle of between about 90 ° and about 175 ° relative to the injection molding position.

88. A method according to claim 87, wherein the plate includes a suction element for removing the molded article from the core, and the partially capping step comprises the step of capping the lid with a tab element on a shuttle plate secured to one side of the suction element.

89. The method of claim 88 wherein after the suction element removes the molded article from the mold core, a second driving step drives the shuttle in a direction to place the molded article adjacent the molded article ejection location.