United States Patent [19]
`Abrams
`
`[11] Patent Number:
`[45] Date of Patent:
`
`4,783,056
`Nov. 8, 1988
`
`[76]
`
`[54] PROCESS FOR MAKING AN ASEPTIC VIAL
`AND CAP
`Inventor: Robert S. Abrams, 21 Marion Ave.,
`Albany, N.Y. 12203
`[21] Appl. No.: 928,475
`[22] Filed:
`Nov. 10, 1986
`Int. a.4 .............................................. B29C 45/04
`[51]
`[52] U.S. a ................................... 264/40.5; 264/40.1;
`264/328.1; 264/328.16; 264/238
`[58] Field of Search .................... 264/40.1, 328.1, 238,
`264/248,525,40.5,328.16; 53/167, 426, 561;
`215/1 C, 32; 156/69; 220/306
`References Cited
`U.S. PATENT DOCUMENTS
`2,991,500 7/1961 Hagen ....................................... 18/5
`3,537,676 1111970 Miller .................................. 425/468
`3,730,372 5/1973 Komendowski ...................... 215/32
`3,804,282 4/1974 Komendowski ...................... 215/32
`
`[56]
`
`4,134,511 1/1979 Deussen ................................ 215/32
`4,176,755 12/1979 Winchell ............................... 215/32
`4,340,352 7/1982 Hayberg .............................. 425/517
`4,351,630 9/1982 Hayberg et aI ..................... 425/517
`Primary Examiner-Jan H. Silbaugh
`Assistant Examiner-Allan R. Kuhns
`Attorney, Agent, or Firm-Burns, Doane, Swecker &
`Mathis
`[57]
`ABSTRACf
`A mold for forming the vial and cap and for seating the
`cap on the vial prior to ejecting the vial from the mold
`is provided and includes a frame for the mold, a first
`mold half arranged on the frame, and a second mold
`half movable arranged relative to the first mold half so
`as to form a mold cavity therebetween. The mold pro(cid:173)
`duces a vial and cap including smooth radii provided at
`several locations to facilitate the seating of the cap on
`the vial.
`
`12 aaims, 3 Drawing Sheets
`
`CLARIANTX 1016 Page 1
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`u.s. Patent Nov. 8, 1988
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`4,783,056
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`CLARIANTX 1016 Page 2
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`u.s. Patent Nov. 8, 1988
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`Sheet 2 of3
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`4,783,056
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`CLARIANTX 1016 Page 3
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`Sheet 3 of3
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`4,783,056
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`u.s. Patent Nov. 8, 1988
`r.:f q. 6
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`101
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`CLARIANTX 1016 Page 4
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`

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`1
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`4,783,056
`
`PROCESS FOR MAKING AN ASEPTIC VIAL AND
`CAP
`
`2
`failure of the second mold part to return to its initial
`position may be caused by the second mold part sticking
`to the vial cap, or other factors delaying the resetting of
`the second mold part. Other unidentified causes may
`BACKGROUND AND SUMMARY OF THE
`5 also contribute to the two mold parts striking each
`INVENTION
`other.
`Another problem with the mold is that gases mixed
`The present invention relates to a sealable vial and a
`with the molten plastic are not able to escape from the
`mold and a process for making the vial in the mold.
`mold cavity during the injection process. As a result,
`More particularly, the present invention relates to a
`sealable vial and cap and mold therefor, wherein the 10 the gases remain with the plastic and form bubbles or
`vial is sealed closed within the mold.
`weak spots in the molded vials.
`Vials of the type to which the present invention re-
`An additional problem with the molds is that ele-
`ments in the first part of the mold are partially separated
`lates are generally injection-molded plastic vials that
`have caps adapted to seal the vial closed with a substan-
`by a spring during the ejection of the vial from the
`tially hermetic seal. The cap mayor may not be inte- 15 mold. Because of the distance the elements are sepa-
`grally connected to the vial, but is preferably joined
`rated, excessive wear causes the spring to fail with an
`thereto with a small flange. It is important to maintain
`undesirable frequency
`the sterility of the interior of the vial prior to use. Ac-
`A further problem with the original mold is that the
`cordingly. in order to maintain the sterility of the inte-
`vial-ejecting poppet does not produce a strong enough
`rior of the vial the cap must be closed onto the vial 20 burst of air to always eject the vial from the mold.
`while the vial is in an aseptic environment.
`A further, serious problem with the vials encountered
`The vial itself is preferably formed from a thermo-
`during development of the present invention is that
`plastic material, and is essentially cylindrical in shape,
`with an integrally formed bottom. Such vials are used to
`during automated assembly, the vial cap does not al-
`collect samples, e.g., in the dairy industry. The caps are 25 ways seat itself properly on the vial. If the vial is not
`often sealed on to the vial after formation in a separate
`properly sealed closed while the vial is still in the mold,
`step. Under certain conditions, that step must be done
`sterility is not maintained. In certain situations, the cap
`under aseptic conditions and must ensure a tight, her-
`or vial is actually damaged during the seating process.
`metic seal between the cap and the vial
`In either case, the product is not usable.
`The cap includes a circular, flat center portion having 30 Applicant has continued to experiment and develop a
`a rim extending perpendicularly from the outer edge
`fully operational mold and a sealed vial made therein
`thereof. The rim is intended to fit over the upper edge
`which overcomes the deficiencies of Applicant's prior
`of the outer wall of the vial in a sealing manner. A ridge
`mold system.
`may be formed on the inside of the cap rim to enhance
`Accordingly, it is an object of the present invention
`the seal of the cap to the vial.
`35 to provide a vial with a cap that is able to be seated
`easily on the vial while the vial is in the mold.
`Applicant developed a concept for attempting to seat
`It is another object of the present invention to pro-
`the cap onto the vial while the vial is still within the
`mold. In this way, the heat of the molding process could
`vide a mold for the manufacture of vials and vial caps
`be utilized to maintain sterility during closing thereby
`wherein the cap may be seated on the vial by automated
`eliminating additional steps and reducing costs and time 40 means with a high degree of reliability while the vial is
`of production of finished sealed vials. In order to effect
`in the mold.
`It is yet another object of the present invention to
`sealing in the mold, Applicant designed a mold with
`several moving parts. A first part of the mold is de-
`provide in a mold for the manufacture of vials and vial
`signed to be separated from a main portion of the mold
`caps, an arrangement for preventing one portion of the
`in order to allow the vial to be closed by the cap and to 45 mold from striking and damaging another portion of the
`allow the vial to be ejected from the mold.
`mold.
`While the first part of the mold is separated from the
`Still another object of the present invention is to
`main portion, a second mold part rotates on pivots to
`provide a seal arrangement for a vial and vial cap that
`transfer the cap from its original position in the mold to
`does not significantly impede the seating of the cap onto
`a position where it is sealed closed on the vial. Once the 50 the vial.
`cap is positioned on the vial, the second mold part
`It is another object of the present invention to pro-
`swings back to its original position and the vial with the
`vide a mold for the manufacture of vials and vial caps
`cap seated thereon is then ejected from the main portion
`wherein gases released from the molten plastic are able
`of the mold, preferably by an air poppet located near
`the sprue gate.
`55 to escape from the mold during the injection process.
`After the second mold part has been returned to its
`It is still another object of the present invention to
`position the vial-ejecting poppet to maximize the effec-
`original position, and after the vial has been ejected
`from the mold, the first part of the mold is returned to
`tiveness of the air emitted therefrom.
`the main portion of the mold to await the beginning of
`Still yet another object of the present invention to
`60 alleviate stress on springs contained within the mold.
`a new cycle.
`It is still another object of the present invention to
`Applicant's initial. attempts at producing and using a
`provide a seal arrangement for a vial and vial cap that
`mold that seals the cap to the vial were not totally satis-
`has a high degree of reliability.
`factory. A particular problem with the mold for the
`manufacture of the vials is that occasionally the first
`In view of these objects, it was determined that if
`part of the mold is returned to the main portion of the 65 certain modifications were made to the experimental
`vial mold, some of which affect the shape of the vial,
`mold before the second part of the mold is completely
`reset. As a result, the first mold part strikes the second
`dramatic increases in product quality and improved
`part, damaging either or both of the mold parts. The
`mold operation resulted.
`
`CLARIANTX 1016 Page 5
`
`

`
`4,783,056
`
`4
`3
`vention is provided for making a vial 12 and cap 14. The
`Accordingly, in an effort to improve the quality of
`vial 12 and cap 14 are preferably injection-molded in the
`the vial and to increase the productivity of the mold,
`mold 10 from a thermoplastic material. The vial 12 may
`certain changes were made. These changes individually
`be integrally connected to the cap 14 by means of a tab
`and collectively have produced a mold, a process of
`operating the mold and a sealed vial that are markedly 5 or flange 16. Because the interior of the vial 12 is prefer-
`better and more consistent than Applicant's prior ef-
`ably maintained in a sterile condition, the mold 10 is
`forts. These changes include but are not limited to the
`adapted to seat the cap 14 onto the vial 12 in a sealing
`following:
`manner while the vial 12 is still in the mold 10.
`A radius was formed in the mold at the region of the
`With specific reference to FIG. 1, the mold 10 pri-
`top of the vial wall, the effect of the radius being to 10 marily includes a first mold part comprising an end
`plate or end mold part 18, an intermediate plate 20, and
`form a smooth transition between the vial interior wall
`and the end surface of the vial wall.
`a stripper plate or interior mold part 22, and a second
`The taper of the mold forming the interior of the vial
`mold part comprising a central portion 26 and a·flipper
`was changed from about f to about ~..
`or pivoting arm 28. The second mold part is arranged
`The tip of the annular seal within the vial cap was 15 on a mold frame 24.
`.
`rounded with a slight radius.
`The intermediate plate 20 is connected to the end
`The intersection between different regions in the
`plate 18 by means of bolts or other suitable fastening
`interior surface of the vial cap rim has been rounded
`means (not shown). When the mold 10 is in an original
`with a slight break.
`configuration, the stripper plate 22 is arranged between
`Vents have been added to the mold to allow gases 20 the intermediate plate 20 on one side and the frame 24,
`trapped within the molten plastic to escape.
`the central portion 26, and the flipper arm 28 on its
`The air poppet was rotated 90· so that the air stream
`other side.
`emitted therefrom is directed toward the vial.
`A press means (not shown) is provided to both hold
`In accordance with additional preferred embodi-
`all three plates 18,20,22 against the frame 24 with pres-
`ments of the present invention, a rack and pinion gear 25 sure during the injection process and to retract the end
`and intermediate plates 18,20 away from the frame 24
`system is used to pivot the second mold part for im-
`proved control. Further, a safety switch is used to indi-
`after the vial 12 has been injected. A bolt 30, threadedly
`cate when the second mold part is reset to avoid un-
`engaged with the stripper plate 22 is arranged with its
`wanted engagement of mold parts. In addition, exten-
`head 32 located within a chamber 34 in the end and
`sions of a press means are used, instead of springs, to 30 intermediate plates 18,20. A shoulder 36 of the chamber
`temporarily separate the stripper plate from the end
`34 is designed to engage the bolt head 32 after the end
`plate.
`and intermediate plates 18,20 have travelled about one
`While these features are illustrative, the various com-
`inch away from the stripper plate 22. The contacting of
`binations of features that comprise Applicant's inven-
`the bolt head 32 with the shoulder 36 prevents any
`tion are set out in the attached claims.
`35 further separation of the stripper plate 22 from the end
`and intermediate plates 18,20.
`BRIEF DESCRIPTION OF THE DRAWINGS
`It should be noted that specific dimensions used
`throughout this specification are exemplary and are
`Preferred embodiments of the present invention will
`only intended to illustrate relative sizes of the various
`be described in greater detail with reference to the
`accompanying drawings, wherein like members bear 40 elements and not in any way to limit the present inven-
`like reference numerals and wherein:
`tion to the particular disclosed dimensions or operating
`FIG. 1 i~ side view, in partial cross section of a first
`parameters.
`preferred embodiment of a mold according to the pres-
`A cavity 38 is formed within the plates 18,20,22, and
`a spring 40, such as a red die spring, is arranged within
`ent invention;
`FIG. 2 is a side view of a mold core used in the mold 45 the cavity 38 under compression when the mold 10 is
`depicted in FIG. 1;
`closed. The effect of the spring 40 is to apply a repulsive
`FIG. 3 is a side view of another mold core used in the
`force between the stripper plate 22 and the end and
`mold depicted in FIG. 1;
`intermediate plates 18,20.
`FIG. 4 is an enlarged view, in cross section of a por-
`Accordingly, when the press means is pulling the end
`tion of the mold core depicted in FIG. 3;
`50 and intermediate plates 18,20 away from the frame 24,
`FIG. 5 is a cross-sectional view of a vial and vial cap
`during the first inch of travel of the plates 18,20, the
`spring 40 will hold the stripper plate 22 against the
`according to the present invention;
`FIG. 6 is a side view of a flipper arm used in the mold
`frame 24 with a reducing force. After about one inch of
`depicted in FIG. 1;
`travel, the bolt head 32 will contact the chamber shoul-
`FIG. 7 is a top view of the flipper arm depicted in 55 der 36, and the stripper plate 22 will then be drawn by
`FIG. 6;
`the press means away from the frame 24.
`FIG. 8 is a side view of a poppet valve used in the
`If the separation distance between the stripper plate
`mold depicted in FIG. 1;
`22 and the intermediate plate 20 is substantially greater
`FIG. 9 is a side view of a portion of a second pre-
`than one inch, undesirable stresses are created in the
`ferred embodiment of a mold according to the present 60 spring 40. These stresses may lead to premature failure
`of the spring 40.
`invention; and
`FIG. 10 is a side view of a flipper arm used in the
`A rod 42 is fastened within the intermediate plate 20,
`second preferred embodiment of the present invention.·
`and extends through an opening 44 in the stripper plate
`22 and into a bore 46 located in the frame 24 of the mold
`65 10. The rod 42 maintains the plates 18,20,22 in align(cid:173)
`ment with each other and with the frame 24 of the mold
`10. Preferably, one such rod arrangement is provided in
`each corner of the mold 10.
`
`DETAILED DESCRIPTION OF THE
`PREFERRED EMBODIMENTS
`With reference to FIGS. 1 and 5, a first preferred
`embodiment of a mold 10 according to the present in-
`
`CLARIANTX 1016 Page 6
`
`

`
`4,783,056
`
`55
`
`5
`With reference now to FIGS. 1 and 2, a first core 48
`is mounted within the intermediate plate 20 so as to
`project through a first opening 50 in the stripper plate
`22 and into a recess within the central portion 26 of the
`mold 10. The first core 48 provides a mold surface for 5
`forming the interior wall 60 of the vial 12 during the
`molding process.
`With specific reference to FIG. 2, the first core 48 is
`preferably about 5.853" in length and has a first end 52
`that is adapted to engage with the intermediate plate 20. 10
`The second end 54 of the first core 48 is approximately
`3.276" in length and comprises the surface that actually
`forms the interior wall 60 of the vial 12. This second end
`64 has a recess 56 at the base thereof to accommodate
`the influx of molten plastic.
`Desirable mold efficiency and vial quality is obtained
`by providing the second end 54 of the core 48 with a
`diameter of about 1.097" at its base, and expanding
`slightly the diameter of the core 48 toward the first end
`52 with a taper of about ~ of a degree. The r taper 20
`facilitates withdrawing the core 48 from the vial 12
`without inadvertently pulling the vial 12 from the mold
`10 prior to seating the cap 14 thereon as will be ex(cid:173)
`plained in greater detail below.
`At a distance of about 3.276" from the second end 54 25
`there is an abrupt increase in the core diameter from
`1.177" to 1.229". At this abrupt increase, a smooth 90°
`radius 58 of about 0.026" is formed in the core 48.
`With reference now to FIG. 5, the radius 58 provides
`a smooth transition surface having a like radius of about 30
`0.026" from the interior wall 60 of the vial 12 to the
`upper edge 62 of the vial 12.
`Also provided at the top of the vial wall is an annular
`ridge 63 extending around the periphery of the vial 12.
`The ridge 63 and the smooth transition surface at the 35
`upper edge 62 of the vial form an annular region for
`interlocking with the cap 14. At the top of the ridge 63
`the outer diameter is about 1.248", compared with an
`outer wall diameter of about 1.225" adjacent the ridge
`63. The outer diameter of the ridge 63 is constant for 40
`about 0.033" at a first ridge surface 65. Adjacent the
`first ridge surface 65, a second ridge surface 67 tapers
`down to the outer wall of the vial 12 over a distance of
`about 0.030" at a 21° angle.
`With reference to FIGS. 1, 3, and 4, a second core 64 45
`is mounted within the intermediate plate 20 so as to
`project through a second opening 66 in the stripper
`plate 22. The base 68 of the second core 64 is located
`adjacent a flipper arm 28.
`The base 68 of the second core 64 comprises the mold 50
`surface that forms the interior surface 70 of the vial cap
`14. With specific reference to FIG. 4, a recess 72 is
`provided in the base 68 of the second core 64 for form(cid:173)
`ing an annular seal 74 projecting from the interior sur-
`face 70 of the vial cap 14.
`The seal 74 is provided with an inner edge 75 and an
`outer edge 77 that are substantially perpendicular to the
`interior surface 70 of the vial cap 14. An end surface 79
`of the seal 74 interconnects the inner edge 75 with the
`outer edge 77, and intersects the edges with an angle of 60
`about 45°. A radius 76 of about 0.003" is provided at the
`intersection of the end surface 79 and the inner edge 75.
`A gap 81 having a width of about 0.032" is provided
`between the annular seal 74 and tee cap rim.
`The seal 74, the gap 81 and the cap rim combine to 65
`form an annular region for -interlocking with the inter(cid:173)
`locking annular region on the vial. The annular seal 74
`is adapted to at least partially fit within the recess
`
`6
`formed at the top of the vial wall 60 by the radius 58 of
`. the first core 48. The end surface 79 is angled so as to
`guide the upper edge 62 of the vial wall into the annular
`gap 81 formed between the seal 74 and the outer cap
`rim. The radius 76 forms a smooth transition surface to
`further guide the seal 74 around the vial wall.
`With continued reference to FIG. 4, at the base 68 of
`the second core 64 is a cylindrical section 78 that ex(cid:173)
`tends from the base end for about 0.025", at which
`point, the core wall tapers inward at an angle of about
`21°. At the intersection 80 of the cylindrical section 78
`and the tapered section 82, a smooth radius of about
`0.005" is formed.
`Turning attention now to FIG. 5, the cap 14 has a
`15 surface 85 formed by the cylindrical section 78 of the
`core 64, and a conically tapered wall section 87 formed
`by the tapered section 82 of the core 64. The radius at
`intersection 80 of the core 64 forms a like radius 84
`intersecting the surface 85 and the wall section 87. The
`gap 81 is thus bounded by the outer wall 77 of the seal
`74 and the wall surfaces 85,87 of the cap rim.
`The annular ridge 63 of the vial 12 is designed to fit
`within the gap 81, with the 21 ° tapered surface 67 of the
`ridge 63 nesting with the 21 ° tapered surface 87 of the
`cap rim.
`With reference now to FIG. 1, the central portion 26
`of the mold 10 fits within a recess in the frame 24. The
`central portion 26 has a substantially cylindrical recess,
`the wall of which provides a surface for forming the
`outer wall of the vial 12. Annular water channels 116
`extend around an outer periphery thereof through
`which channels 116 water is circulated to facilitate
`cooling during the molding process. O-rings 120 are
`provided adjacent the channels 116 to maintain a seal
`around them.
`.
`The end plate 18 has a water channel 104 extending
`therethrough. The water channel 104 interconnects
`with water channels 106,108 extending longitudinally
`through the first and second cores 48,64, respectively.
`O-rings 110,112 are positioned adjacent the intercon-
`nection of the water channels 106,108 of the cores 48,64
`and the water channel 104 of the end plate 18 in order
`to enhance the seal therebetween. The water channels
`104,106,108 facilitate cooling during the molding pro(cid:173)
`cess.
`With reference now to FIGS. 1, 6 and 7, a flipper arm
`28 is arranged adjacent the stripper plate 22, the base 68
`of the second core 64, the central portion 26 of the mold
`10, and the frame 24 of the mold 10. The flipper arm 28
`has pivot pins 86 on opposite sides thereof to permit
`pivoting of the flipper arm 28 within the frame 24 of the
`mold 10 when the plates 18,20,22 are separated there(cid:173)
`from. A surface 88 of the flipper arm 28 forms the out(cid:173)
`side surface 90 of the vial cap 14 during the molding
`process.
`With specific reference to FIGS. 6 and 7, shallow air
`vents 89 are provided in the flipper arm 28. The vents 89
`interconnect the mold surface 88 to outside of the flip(cid:173)
`per arm 28 in order to allow gases trapped within the
`molten plastic to escape from the mold during the injec-
`tion process. The vents 89 are preferably shallow, e.g.,
`about 0.038" deep.
`Without the vents 89 to release the gases, the trapped
`gases would form bubbles in the vial 12 and cap 14. This
`is particularly problematic if bubbles form in the seal 74
`or other areas functionally related to the sealing of the
`cap 14 onto the vial 12.
`
`CLARIANTX 1016 Page 7
`
`

`
`4,783,056
`
`7
`With reference to FIGS. 6 and 7, a slot 92 is provided
`in at least one of the pivot pins 86, and a rectangular
`plate 94 is mounted within the slot such that at least one
`end of the plate 94 extends beyond the pin 86. Con(cid:173)
`trolled air jets (not shown) are provided with the mold 5
`10 to act on the surfaces of the plate 94 projecting from
`the pin 86 so as to pivot the flipper arm 28. The jets can
`be arranged so as to selectively act on either side of the
`plate 94.
`Located within the frame 24 of the mold 10 adjacent 10
`the base of the first core 48 is a sprue gate 96 through
`which molten plastic is injected into the mold 10. The
`diameter of the sprue gate 96 is preferably about 0.060",
`and is chosen to allow the plastic to be injected into the
`mold 10 at as rapid a rate as reasonably possible. The air 15
`vents 89 facilitate the rapid injection of plastic by allow(cid:173)
`ing air present in the mold 10 to escape while the plastic
`is being injected.
`With reference to FIGS. 1 and 8, also located within
`the frame 24 of the mold 10 adjacent the base of the first 20
`core 48 is an air poppet 98 that is used to eject the
`cooled and sealed vial 12 from the mold 10. The air
`poppet 98 has an air channel 100 extending longitudi(cid:173)
`nally therethrough. Within the air poppet 98, at the end 25
`positioned near the first core 48, is a second air channel
`102 extending perpendicularly to the air channel 100.
`The second air channel 102 is arranged so as to receive
`a current of air from the channel 100 and direct it
`against the vial 12 in order to eject the vial 12 from the 30
`mold 10.
`On the exterior surface of the air poppet 98 are two
`O-ring grooves 99, with O-rings 101 provided therein.
`The O-rings 101 provide barnes which coact with com(cid:173)
`pressed air delivered through channel 104 to longitudi- 35
`nally move the poppet 98 within its chamber 103 pro(cid:173)
`vided in the frame 24 of the mold 10.
`When the vial 12 is ready to be ejected from the
`mold, a jet of air from the air channel 104 drives the air
`poppet 98 through its housing until it contacts the vial 40
`12 and pushes it from the mold 10. When the air poppet
`98 is projected into the mold cavity, air currents from
`the air channel 102 then further help to eject the vial 12.
`The air poppet 98 is provided with angled surface 105
`that will contact the vial 12 in a flat manner so as not to 45
`mark the vial 12.
`In operation of the mold 10, the end, intermediate and
`stripper plates 18,20,22 are held against the frame 24 of
`the mold 10 with about fifteen tons of pressure by a
`press means (not shown).
`With the plates 18,20,22 in position against the frame
`24, a cavity 114 is formed with the third plate 22 and the
`first and second cores 48,64 defining one side thereof
`and the flipper arm 28, the central portion 26 and the
`frame 24 derming the other side. Into this cavity 114, 55
`molten plastic is injected through the sprue gate 96 with
`about fifteen tons of pressure so as to form the vial 12
`and cap 14. In an illustrative, preferred embodiment, the
`injected vial 12 and cap 14 are allowed to cool for about
`six seconds while the temperature thereof drops from 60
`about 550° F. to about 100°_120° F. The specific tem(cid:173)
`perature to which the vial 12 is reduced may vary with
`the size and type of vial but should be cool enough so
`that the plastic is actually set, and hot enough to main-
`tain sterility.
`Water is circulated through the water channels
`104,106, 108,116 of the mold 10 in order to accelerate
`the cooling of the vial 12 and the cap 14.
`
`50
`
`8
`When the vial 12 and the cap 14 are sufficiently
`cooled, the end plate 18 and the intermediate plate 20
`are withdrawn from the frame 24 of the mold 10. As
`described above, as the end and intermediate plates
`18,20 initially move away from the frame 24, the spring
`40 acts between the stripper plate 22 and the end plate
`18 to hold the stripper plate 22 against the frame 24.
`After the end and intermediate plates 18,20 have sepa(cid:173)
`rated from the stripper plate 22 by about one inch, the
`head 32 of the bolt 30 engages with the shoulder 36 of
`the chamber 34 within the end and intermediate plates
`18,20 and pulls the stripper plate 22 away from the
`frame 24. The rods 42 are guided within their respective
`openings 44 and bores 46 to maintain the three plates
`18,20,22 in alignment with the frame 24 during the sepa(cid:173)
`ration of the plates 18,20,22 from the frame 24.
`The first and second cores 48,64 being attached to the
`intermediate plate 20, move away from the frame 24
`together with the plates 18,20,22.
`When the base of the first core 48 is about three
`inches from the frame 24, the flipper arm 28 is pivoted
`so as to bend the flange 16 interconnecting the vial 12
`and the cap 14 and to seat the cap 14 onto the vial 12
`while the vial 12 remains within the central portion 26
`of the mold 10. After the cap 14 has been properly
`seated on the vial 12, the flipper arm 28 is then returned
`to its original position in the mold 10.
`When the cap 14 is being seated on the vial 12, the
`radius 76 formed on the end of the annular seal 74,
`together with the end surface 79 of the seal 74 facilitates
`the guiding of the cap 14 onto the vial 12. Also facilitat(cid:173)
`ing the seating of the cap 14 is the smooth transition
`surface at the end of the vial wall formed by radius 58
`on the core 48.
`After the seal 74 has been guided within the vial 12,
`the annular ridge 63 fits within the gap 81, adjacent the
`wall section 85. The angled surface 87 nests against the
`angled surface 67 of the annular ridge 63 and helps
`prevent the cap 14 from inadvertently becoming un(cid:173)
`seated from the vial 12.
`As explained above, the air poppet 98 together with a
`burst of air injected through channels 100,102 in the air
`poppet 98 pushes the vial 12 and cap 14 out of the mold
`10. When the vial 12 and cap 14 have been ejected, the
`plates 18,20,22 are returned to the mold by the press
`means, and additional plastic is injected into the mold to
`repeat the cycle.
`Although the dimensions of the mold 10 and vial 12
`may be varied according to need and the principles of
`the present invention, in the first preferred embodiment,
`the vial 12 is about 3.272" in height with an internal
`diameter ranging from 1.160" at the top to 1.081" at the
`base. The stripper and intermediate plates 22,20 are
`each about 1.375" thick and have outside rectangular
`dimensions of 6.5"X9.875", while the end plate 18 is
`about 1.375" thick and has outside dimensions of
`8"X9.875". The frame 24 is about 5.75" thick with
`approximate outside
`rectangular dimensions of
`8"X9.875".
`With reference to FIG. 9, a second preferred embodi(cid:173)
`ment of the present invention is provided with an end
`plate 118, an intermediate plate 120, and a stripper plate
`122, which are arranged adjacent one another in a man(cid:173)
`ner similar to the arrangement of the plates 18,20,22 of
`the first preferred embodiment. The plates 118,120,122
`do not have a spring arranged between them. Instead,
`through-bores 124,126 extend through the end and in(cid:173)
`termediate plates 118,120. When the press means 150
`
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`CLARIANTX 1016 Page 8
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`4,783,056
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`20
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`9
`engages the end plate 118 with arms 152 and is retract(cid:173)
`ing it from the frame of the mold, retractable projec(cid:173)
`tions 128,130 associated with the press means extend
`through the through-bores 124,126 and press the strip(cid:173)
`per plate 122 against the mold frame for a predeter- 5
`mined period until an arrangement, such as bolt 30 dis(cid:173)
`closed in the first preferred embodiment, engages the
`stripper plate 122 and retracts it away from the frame
`together with the end and intermediate plates 118,120.
`With reference to FIG. 10, in the second preferred 10
`embodiment, a rack and pinion arrangement is provided
`to selectively rotate a flipper arm 128 about pivot pins
`186. The pins 186 of the flipper arm 128 extend through
`openings in the mold frame and are mounted in bearings
`132 attached to the exterior of the mold. On one pin 186 15
`is fixed a pinion 134. A rack 136 is engaged with the
`pinion 134 and mounted on the mold frame so as to be
`driven in an oscillatory manner. Movement of the rack
`136 against the pinion 134 causes the flipper arm 128 to
`pivot about the pins 186.
`On the other pin 186 is fixed an eccentric cam 138. A
`micros witch 140 is mounted on the mold frame with a
`pin 142 adjacent the cam 138. The cam 138 and pin 142
`are oriented such that when the flipper arm 128 is reset
`to its original configuration, i.e., out of the way of the 25
`plates 118,120,122, the microswitch 140 emits a signal
`that enables activation of the press means. Until the cam
`138 initiates such a signal, the press means will not re(cid:173)
`turn the plates 118,120,122 to the mold. Accordingly,
`the positive drive ofthe rack and pinion 134,136 and the 30
`cam 138 and microswitch 140 act to prevent the plates
`118,120,122 from closing and thus inadvertently striking
`the flipper arm 128 before the flipper arm 128 is com(cid:173)
`pletely reset.
`In all other respects, the second preferred embodi- 35
`ment operates in the same manner, and is constructed in
`accordance with the first preferred embodiment. Fur(cid:173)
`thermore, it should be readily apparent to one of ordi(cid:173)
`nary skill in the art that any of the