US 7,108,823 B2
`(10) Patent No.:
`a2) United States Patent
`Kaufman
`(45) Date of Patent:
`Sep. 19, 2006
`
`
`US007108823B2
`
`(54) STAGED COMPRESSION MOLDING
`PROCESS
`
`2/1985 Wilde etal.
`4,497,765 A
`1/1987 Paunov et al. wo... 72/259
`4,635,460 A *
`5/1987 Whitney etal.
`4,664,280 A
`6/1987 Wilde etal.
`4,674,643 A
`(75)
`Inventor: Brett Kaufman, Newburgh, IN (US)
`1/1989 Hughes oe 425/356
`4,797,082 A *
`.
`.
`.
`5/1990 Stewart
`4,921,646 A
`(73) Assignee: perry nastics Corporation.
`
`vansville,IN(US) 5,149,479 A * 9/1992 Nakajima oo... 264/163
`
`(*) Notice:
`Subject to any disclaimer, the term ofthis
`5,642,824 A
`7/1997 Hess et al.
`patent is extended or adjusted under 35
`5,650,113 A
`7/1997 Gregory et al.
`USC. 154(b) by 0 days.
`5,659,518 A
`8/1997 McLaury
`5,807,592 A
`9/1998 Alieri
`6,294,121 BL
`9/2001 Haraetal.
`6,321,923 Bl
`11/2001 Wood
`eee 264/294
`6,471,902 B1* 10/2002 Snyder oo...
`2002/0109267 Al*
`8/2002 Herbst .....0. ee 264/328.7
`2003/0116879 Al
`6/2003 Mueller et al.
`2004/0169307 Al
`9/2004 Muelleret al.
`
`(21) Appl. No.: 10/947,749
`
`(22)
`
`(65)
`
`Filed:
`
`Sep. 23, 2004
`oo,
`.
`Prior Publication Data
`US 2005/0067735 Al
`Mar. 31, 2005
`
`
`
`Related U.S. Application Data
`
`(60) Provisional application No. 60/505,827,filed on Sep.
`* cited by examiner
`25, 2003
`isional
`lication
`No. 60/534,292
`filadon Toe"S3004, appucaron
`ne
`_— Primary Examiner—Jill L. Heitbrink
`y,
`AS
`g
`~
`,
`74) Attorney, Agent, or Firm—Barnes & Thornburg LLP
`
`(51)
`
`Int. Cl.
`(2006.01)
`B29C 43/14
`(52) US. Ch wee 264/294; 264/320; 264/325
`(58) Field of Classification Search ................ 264/245,
`. 264/255, 320, 325, 294, 296, 268, 323
`See application file for complete search history.
`References Cited
`U.S. PATENT DOCUMENTS
`
`(56)
`
`(67)
`
`ABSTRACT
`
`A process of molding a container closure comprises depos-
`iting a gob of thermoplastics material in a mold cavity and
`then moving mold plates in an upper mold portion relative
`to an opposing lower mold portion to form the container
`closure in the mold cavity.
`
`4,343,754 A
`
`8/1982 Wilde etal.
`
`5 Claims, 6 Drawing Sheets
`
`Wy q
`
`Yita v. MacNeil IP, IPR2020-01139, Page 1
`
`MacNeil Exhibit 2175
`
`MacNeil Exhibit 2175
`Yita v. MacNeil IP, IPR2020-01139, Page 1
`
`

`

`U.S. Patent
`
`Sep. 19, 2006
`
`Sheet 1 of 6
`
`LIG 4
`
`“°
`
`
`
`
`US 7,108,823 B2
`
`Yita v. MacNeil IP, IPR2020-01139, Page 2
`
`MacNeil Exhibit 2175
`
`MacNeil Exhibit 2175
`Yita v. MacNeil IP, IPR2020-01139, Page 2
`
`

`

`U.S. Patent
`
`Sep. 19, 2006
`
`Sheet 2 of6
`
`US 7,108,823 B2
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`Yita v. MacNeil IP, IPR2020-01139, Page 3
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`MacNeil Exhibit 2175
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`MacNeil Exhibit 2175
`Yita v. MacNeil IP, IPR2020-01139, Page 3
`
`

`

`U.S. Patent
`
`Sep. 19, 2006
`
`Sheet 3 of 6
`
`So
`
`US 7,108,823 B2
`
`Yita v. MacNeil IP, IPR2020-01139, Page 4
`
`MacNeil Exhibit 2175
`
`MacNeil Exhibit 2175
`Yita v. MacNeil IP, IPR2020-01139, Page 4
`
`

`

`U.S. Patent
`
`Sep. 19, 2006
`
`Sheet 4 of6
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`Yita v. MacNeil IP, IPR2020-01139, Page 5
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`MacNeil Exhibit 2175
`
`MacNeil Exhibit 2175
`Yita v. MacNeil IP, IPR2020-01139, Page 5
`
`

`

`U.S. Patent
`
`Sep. 19, 2006
`
`Sheet 5 of 6
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`MacNeil Exhibit 2175
`
`MacNeil Exhibit 2175
`Yita v. MacNeil IP, IPR2020-01139, Page 6
`
`

`

`U.S. Patent
`
`Sep. 19, 2006
`
`Sheet 6 of 6
`
`US 7,108,823 B2
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`Yita v. MacNeil IP, IPR2020-01139, Page 7
`
`MacNeil Exhibit 2175
`
`MacNeil Exhibit 2175
`Yita v. MacNeil IP, IPR2020-01139, Page 7
`
`

`

`US 7,108,823 B2
`
`1
`STAGED COMPRESSION MOLDING
`PROCESS
`
`This application claimspriority under 35 U.S.C. § 119(e)
`to U.S. Provisional Application Ser. No. 60/505,827, filed
`Sep. 25, 2003 and U.S. Provisional Application Ser. No.
`60/534,292, filed Jan. 5, 2004, which are expressly incor-
`porated by reference herein.
`
`BACKGROUND
`
`The present disclosure relates to compression molding
`processes. Moreparticularly, the present disclosure relates to
`compression molding of plastics materials to produce con-
`tainer closures.
`
`Compression molding of plastics materials typically
`entails forming a portion of raw material into a molded
`end-product such as a household item, for example. Com-
`pression molding methods are used to form thermosetting
`and thermoplastic resins to producearticles such as closures
`for containers.
`
`SUMMARY
`
`In accordance with the present disclosure, a process of
`molding a container closure comprises depositing a gob of
`thermoplastics material in a mold cavity defined between
`upper and lower mold portions and then moving moldplates
`included in the upper mold portion in stages relative to the
`lower mold portion to form a monolithic container closure in
`the mold cavity. In illustrative embodiments, three separate
`mold plates are moved in sequence to apply a low-pressure
`force to the gob in the mold cavity and then the three mold
`plates are moved in unison to apply a relatively higher
`high-pressure force to the gob in the mold cavity. This
`process produces a monolithic container closure comprising
`a base adapted to mount on a container, a cap configured to
`mount on and close a discharge opening formed in the base,
`and a living hinge interconnecting the cap to the base in an
`illustrative embodiment.
`
`Features of the process will become apparent to those
`skilled in the art upon consideration of the following
`detailed description exemplifying the best mode of the
`disclosure as presently perceived.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`The detailed description particularly refers to the accom-
`panying Figures in which:
`FIG. 1 is perspective view, with portions broken away, of
`a container carrying a monolithic container closure of the
`type made ofa plastics material and formed by the staged
`compression molding process disclosed herein;
`FIG. 2 is a sectional view of the closure of FIG. 1 taken
`generally along line 2—2 in FIG. 1 showing (from left to
`right) a lid, hinge, and cap included in the monolithic
`container closure;
`FIG. 3 is a diagrammatic, sectional view of a mold
`comprising a three-section upper mold portion separated
`from and arranged to confront an underlying lower mold
`portion prior to deposit of a “gob”of thermoplastic material
`into an interior region located between the upper and lower
`mold portions:
`FIGS. 4-8 illustrate a molding sequence in accordance
`with the present disclosure;
`
`25
`
`30
`
`35
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`2
`FIG. 4 is a sectional view of the mold of FIG. 3 after
`deposit of an elongated gob of thermoplastics material into
`an interior region of the mold;
`FIG.5 is a sectional view of the mold of FIG. 3 showing
`a first stage of the molding process as low pressure is applied
`by a first-stage mold plate included in the upper mold
`portion to a portion of the underlying thermoplastics mate-
`rial to cause the material to begin flowing across the face of
`the lower mold portion from a first region of a mold cavity
`provided in the mold into other regions of the mold cavity;
`FIG.6 is a sectional view of the mold of FIG. 3 showing
`a second stage of the molding process as low pressure is
`applied byfirst- and second-stage mold plates included in
`the upper mold portion to the underlying thermoplastics
`material to further distribute the material across the face of
`the lower mold portion and within the mold cavity formed
`in the mold;
`FIG.7 is a sectional view of the mold of FIG. 3 showing
`a third stage of the molding process as lowpressure is
`applied simultaneously by first-, second-, and third-stage
`mold plates included in the upper mold portion to distribute
`the thermoplastic material fully across the face of the lower
`mold portion and within the mold cavity;
`FIG. 8 is a sectional view of the mold of FIG. 3 showing
`a fourth andfinal stage of the molding process wherein high
`pressure is applied simultaneously bythefirst-, second-, and
`third-stage mold plates included in the upper mold portion to
`enhance physical properties of the monolithic container
`closure formed in the mold;
`FIG. 9 is a perspective view, with portions broken away,
`of the elongated gob of FIG. 4 after the gob has been
`extruded from an extruding device and separated from an
`extrude discharged from the extruding device;
`FIGS. 10-12 illustrate another molding sequence in
`accordance with the present disclosure;
`FIG. 10 is a sectional view of the mold of FIG. 3 after
`
`deposit of another gob of thermoplastics material into a first
`region of the mold cavity in accordance with another aspect
`of this disclosure;
`FIG.11is a sectional view of the mold of FIG. 3 showing
`a first stage of the molding process as low pressure is applied
`by a first-stage mold plate to the thermoplastics material to
`cause the material to begin flowing across the face of the
`lower mold portion from the first region of the mold cavity
`into other regions of the mold cavity;
`FIG. 12 is a sectional view of the mold of FIG. 3 showing
`a second stage of the molding process as low pressure is
`applied by first- and second-stage mold plates to the ther-
`moplastics material to further distribute the material across
`the face of the lower mold portion and within the mold
`cavity;
`FIG. 13 is a sectional view similar to FIG. 10 showing
`initial deposit of a gob of thermoplastics material into a
`second region of the mold cavity in accordance with yet
`another aspect of the disclosure;
`FIGS. 14-16 illustrate another molding sequence in
`accordance with the present disclosure wherein one gob
`having a first characteristic (e.g., a first color) is associated
`with onefirst-stage mold plate, another gob having a second
`characteristic (e.g., a second color)
`is associated with
`anotherfirst-stage mold plate, and the two gobs are merged
`and molded to create a monolithic container closure;
`FIG. 14 is a sectional view of the mold of FIG. 3 after
`
`deposit of a first gob of thermoplastics material into a first
`region of the mold cavity and deposit of a second gob of
`thermoplastics material into a second region of the mold
`cavity in accordance with another aspect of this disclosure;
`
`Yita v. MacNeil IP, IPR2020-01139, Page 8
`
`MacNeil Exhibit 2175
`
`MacNeil Exhibit 2175
`Yita v. MacNeil IP, IPR2020-01139, Page 8
`
`

`

`US 7,108,823 B2
`
`3
`FIG.15 is a sectional view of the mold of FIG. 3 showing
`a first stage of the molding process as (1) low pressure is
`applied by one moldplate to the first gob to cause material
`in the first gob to begin flowing across the face of the lower
`mold portion from the first region of the mold cavity into
`other regions of the mold cavity and (2) low pressureis also
`applied by another mold plate to the second gob to cause
`material in the second gob to begin flowing across the face
`of the lower mold portion from the second region of the
`mold cavity into other regions of the mold cavity; and
`FIG.16 is a sectional view of the mold of FIG. 3 showing
`a second stage of the molding process as low pressure is
`applied by yet another mold plate to the thermoplastics
`materials extant in the mold cavity to further distribute the
`materials across the face of the lower mold portion and
`within the mold cavity.
`
`DETAILED DESCRIPTION
`
`Methods of compression molding a gob 62 or 162 of a
`thermoplastics material in stages to produce a monolithic
`article such as a container closure are described in this
`disclosure. A “staged” compression mold 110 shownin FIG.
`3 is used to mold a first gob 62 of a thermoplastics material
`made in a manner suggested in FIG. 9 in an illustrative
`sequence shown, for example, in FIGS. 4-8. Mold 110 is
`also used to mold a second gob 162 of a thermoplastics
`material placed in a first region of a mold cavity provided in
`mold 110 in an illustrative sequence shown partly in FIGS.
`10-12. Mold 110 is also available to be used to mold second
`
`gob 162 when that second gob 162 is placed in a second
`region of the mold cavity provided in mold 110 in an initial
`position shown, for example, in FIG. 13. Mold 110 is also
`available to be used to mold two separate gobs 262, 362 of
`material placed in separate regions of the mold cavity
`provided in mold 110 in an illustrative sequence shown
`partly in FIGS. 14-16.
`A container closure 10 includes a base 12 adapted to
`mount on a container 30, a hinge 18, and a cap 20 as shown,
`for example, in FIGS. 1 and 2. Base 12 is formed to include
`a discharge aperture 14 in a top wall 16. Cap 20 is formed
`to include a sealing dome 22 depending from a top wall 28,
`as shown, for example, in FIGS. 1 and 2. Base 12 includes
`an annular side wall 24 adapted to be coupled to an annular
`rim (not shown) of container 30. Cap 20 is adapted to be
`coupled to base 12 so that discharge aperture 14 is closed
`and sealed by sealing dome 22 when cap 20 is moved to a
`closed position (not shown) nesting on and mating with base
`12. It is within the scope ofthis disclosure to vary the shape
`and geometry of the components which cooperate to effect
`the seal established at discharge aperture 14.
`Closure 10 is monolithic and thus is formed as a single
`piece of compression-molded material, in three sections, to
`include base 12, cap 20, and a hinge 18 therebetween, as
`shown best
`in FIG. 1. Other shapes and geometries of
`closure 10 are within the scope of this disclosure. In embodi-
`ments in accordance with the molding process illustrated in
`FIGS. 14-16, a monolithic closure is made using two
`separate gobs wherein each gob has a selected material
`and/or color characteristic.
`
`Hinge 18 is coupled to side wall 24 of base 12 and side
`wall 26 of cap 20 to provide a “living” hinge. Hinge 18 is
`flexible, allowing tethered movement of cap 20 relative to
`base 12. Upon completion of the staged compression mold-
`ing process, base 12 can be of a greater mass than cap 20,
`which is of a greater mass than hinge 18.
`
`20
`
`30
`
`40
`
`45
`
`50
`
`55
`
`60
`
`65
`
`4
`In one embodiment of the staged compression molding
`process, a thermoplastics material
`is extruded from an
`extruder 72 to provide an extrude 73 and the extrude 73 is
`cut into a predetermined mass by a cutting instrument 74 to
`form an elongated gob 62 as suggested in FIG. 9. Gob 62is
`then deposited into and arranged to lie in a mold cavity 70
`provided in mold 110, as shown, for example, in FIG. 4. A
`first gob molding sequence is illustrated in FIGS. 4-8
`showing various stages of manipulating gob 62 to form
`container closure 10. Although in the illustrated embodi-
`ments, each gob is placed on a “core side” of the mold rather
`than in the opposing “cavity side” of the mold, it is within
`the scope of this disclosure to orient the mold so that gobs
`are placed in the cavity side of the mold before the molding
`process is initiated.
`Mold 110 includes an upper mold portion 37 comprising
`a first-stage mold plate 31, a second-stage mold plate 32, and
`a third-stage mold plate 33. Mold 110 also includes a lower
`mold portion 38 which cooperates with upper mold portion
`37 to define an interior region or mold cavity 70 therebe-
`tween, as shown, for example, in FIG. 3. Moldplates 31, 32,
`and 33 are supported to move downwardly in direction 11
`and relative to one another to within a predetermined
`distance of lower mold portion 38 as suggested in FIG.8 to
`compress thermoplastics material associated with gob 62 in
`a mold cavity 70 located between upper and lower mold
`portions 37, 38 to produce a container closure 10 having a
`desired shape and thickness.
`First-stage mold plate 31 is associated with cap 20 and
`includesa top wall 50, a dome-forming cavity 48, and a side
`wall-forming cavity 46. First-stage mold plate 31 is arranged
`to mate with lower mold portion 38 generally to form cap 20
`in the compression molding process by pressing a predeter-
`mined thickness of thermoplastics material against lower
`mold portion 38, as shown, for example, in FIGS. 4 through
`8.
`
`Second-stage mold plate 32 is associated with hinge 18
`and includes a top wall 52. Second-stage mold plate 32 is
`arranged to form hinge 18 in the molding process by
`pressing a predetermined thickness of thermoplastics mate-
`rial against lower mold portion 38, as shown in FIGS. 6-8.
`Second-stage mold plate 32 is arrangedto lie adjacent to and
`betweenfirst- and third-stage mold plates 31, 33, but is able
`to move independently of plates 31 and 33. In the illustrated
`embodiment, second-stage mold plate 32 is contiguous with
`mold plates 31 and 33.
`Third-stage mold plate 33 is associated with base 12 and
`includes an annular side wall 42, a top wall 40, and a
`discharge aperture-forming cavity 44 providing an opening
`in top wall 40. Third-stage moldplate 33 is arranged to mate
`with lower mold portion 38 to form base 12 in the molding
`process by pressing a predetermined thickness of thermo-
`plastics material against lower mold portion 38, as illus-
`trated in FIG. 8. Aperture-forming cavity 44 cooperates with
`plug 54 to form discharge aperture 14 in top wall 16 of base
`12.
`
`Based on the geometry of gob 62, a mold in accordance
`with the present disclosure can be made to work in one stage
`to distribute the plastics material in the interior region 70 of
`mold 110,or as in the illustrated process, molding of closure
`10 is carried out, for example, in four sequential stages. A
`cylindrically shaped gob 62 of thermoplastics material is
`distributed about in interior region 70 of mold 110 during
`stages one, two, and three of the molding process to fill a
`mold cavity formed in mold 110 as suggested in FIGS. 4-7.
`Later, that distributed material is “set” during stage four of
`the molding process as suggested in FIG. 8.
`
`Yita v. MacNeil IP, IPR2020-01139, Page 9
`
`MacNeil Exhibit 2175
`
`MacNeil Exhibit 2175
`Yita v. MacNeil IP, IPR2020-01139, Page 9
`
`

`

`US 7,108,823 B2
`
`5
`As shown, for example, in FIG. 4, an elongated gob 62 is
`deposited into mold cavity 70 located between spaced-apart
`upper and lower portions 37, 38 before the staged molding
`process in accordance with this disclosure is begun. As
`shown in FIG. 4, a portion (621, 622) of gob 62 is placed
`under first-stage and second-stage mold plates 31, 32 and
`another portion (623) of gob 62 is placed under third-stage
`mold plate 33 before first-stage mold plate 31 is moved
`towardfirst mold bottom face 56 duringthe first stage of the
`molding process. In the illustrated embodiment, a first end
`621 of gob 62 lies under plate 31, another end 623 of gob 62
`lies under plate 33, and a middle portion 622 of gob 62
`interconnects ends 621, 623 and lies under plate 32. In the
`illustrated embodiment, each end 621, 623 of gob 62 has the
`same shape.
`In stage one of the compression molding process, first-
`stage mold plate 31 is moved in direction 11 to apply a
`low-pressure force 64, at time (T,), to gob 62 as suggested
`in FIG. 5. Low-pressure force 64 causesa first portion of gob
`62 to be compressed. Compression of gob 62 causes the
`thermoplastics material to begin flowing across a first mold
`bottom face 56, a second mold bottom face 58, and a third
`mold bottom face 60, as can be seen, for example, in FIG.
`5.
`
`6
`An illustrative compression molding process is illustrated
`in FIGS. 4-8. As suggested in FIG. 4, elongated gob 62 of
`thermoplastics material
`is arranged initially in interior
`region or mold cavity 70 of mold 110 to cause one end 621
`of gob 62 to lie underfirst-stage mold plate 31, an opposite
`end 623 of gob 62to lie underthird-stage moldplate 33, and
`a middle portion 622 of gob 62 to lie under second-stage
`mold plate 32. During the compression molding process, end
`621 of gob 62 is compressed (at low pressure) during the
`first stage of compression as shown in FIG. 5; end 621 and
`middle portion 622 of gob 62 are compressed (at
`low
`pressure) during a second stage of compression as shown in
`FIG.6; and end 621, middle portion 622, and end 623 of gob
`62 are compressed (at low pressure) during a third stage of
`compression as shown in FIG.7. Finally, all portions 621,
`622, 623 of gob 62 are compressed (at high pressure)
`simultaneously during a fourth stage of compression as
`shown in FIG. 8.
`
`20
`
`25
`
`30
`
`35
`
`In the illustrated embodiment, a monolithic container
`closure 10 is formed in mold cavity upon movementoffirst-,
`second-, and third-stage mold plates 31, 32, and 33 of upper
`mold portion 37 to predeterminedpositions relative to lower
`mold portion 38. A first portion of gob 62 is compressed in
`a cap-forming region of mold cavity 70 betweenfirst-stage
`mold plate 31 and opposing first mold bottom force 56 to
`define a cap 20 included in container closure 10. A third
`portion of gob 62 is compressed in a base-forming region of
`mold cavity 70 between third-stage mold plate 33 and
`opposing third mold bottom face 60 to define a base 12
`included in container closure 10 and adapted to mount on a
`container 30. A second portion of gob 62 is compressed in
`a living hinge-forming region of mold cavity 70 between
`second-stage mold plate 32 and opposing second mold
`bottom face to define a living hinge 18 arranged to inter-
`connect base 12 and cap 18 to provide monolithic container
`closure 10.
`
`Stage two of the compression molding process begins at
`a later time (T,) and begins with an additional low-pressure
`force 66 being applied to second-stage mold plate 32 as
`suggested in FIG. 6 to cause plate 32 to move downwardin
`direction 11 relative to and toward lower mold portion 38.
`Low-pressure force 66 is applied concurrently with low-
`pressure force 64 to cause a second portion of gob 62 to be
`compressed so that gob 62 further expands and flows across
`all of third mold bottom face 60 and lower mold portion 38.
`Mold 110 is configured as needed to manage flow of gob 62
`during movement of plates 31, 32, and 33 toward mold
`bottom 38 so that plastics material does not “flash over” the
`top of plug 54 to cover the opening into discharge aperture
`14 formed in top wall 16 of closure 10.
`Ata still later time (T3), stage three of the compression
`molding process begins with an additional
`low-pressure
`force 67 being applied to third-stage mold plate 33 as
`suggested in FIG. 7 to cause downward movement of
`third-stage mold plate 33 in direction 11 relative to mold
`bottom 38. This causes a third portion of gob 62 to be
`compressed. First-, second-, and third-stage moldplates 31,
`32, and 33 are now positioned to lie in confronting spaced-
`apart relation to, for example, first, second, and third mold
`bottom faces 56, 58, and 60 of lower mold portion 38 to
`compress gob 62 therebetween as suggested in FIG.7.
`In an illustrative embodiment, the force applied to gob 62
`by each of plates 31, 32, and 33 is relatively low and
`substantially the same. It is within the scope of this disclo-
`sure to vary the magnitude of that force and the relative
`timing of stages one, two, and three to regulate distribution
`and flow of gob 62 in mold cavity 70 provided between
`It is also within the scope of this disclosure to mold gob
`upper and lower mold portions 37, 38 during the molding
`process.
`62 in stages in compression mold 110 after gob 62 is placed
`initially to lie substantially under mold plate 33. In this
`Atlater time (T.,), the simultaneous application of low-
`embodiment, the sequence of movementofplates 31, 32, 33
`pressure forces 64, 66, and 67 to distribute material
`is
`in direction 11 toward lower mold portion 38 is “reversed”
`increased to a high-pressure force 68 applied to plates 31,
`as compared to the sequence disclosed in FIGS. 10-12. In
`32, and 33 to “set” thermoplastics material 62, as illustrated
`connection with the discussion of this embodiment, refer-
`in FIGS. 7 and 8. High-pressure force 68 is greater than
`ence to “stages” associated with plates 31, 32, 33 has been
`low-pressure forces 64, 66, and 67 and causes further
`
`compression of the thermoplastics material in mold cavity omitted. Thus, plate 33 is movedin direction 11 duringafirst
`65
`70 of mold 110 so that thermoplastics material 62 attains the
`stage, plate 32 is moved in direction 11 during a second
`desired shape of the end-product, as for example, container
`stage, and plate 31 is moved in direction 11 during a third
`closure 10 in the illustrative embodiment.
`stage. Further molding of gob 62 during a fourth stage of the
`
`Anotherillustrative staged compression molding process
`is illustrated in FIGS. 10-13. As suggested in FIG. 10, a gob
`162 of thermoplastics material is arranged in interior region
`or mold cavity 70 of mold 110 substantially to lie under
`first-stage mold plate 31. During the compression molding
`process, someportions of gob 62 are compressed (at low
`pressure) by first-stage mold plate 31 and other portions flow
`away from first-stage mold plate 31 to lie under second-
`stage mold plate 32 and perhaps a portion of third-stage
`mold plate 33 as shown in FIG. 11. Then, someportions of
`gob 62 are compressed(at low pressure) by first-stage mold
`plate 31 and second-stage mold plate 32 (at low pressure)
`and other portions flow away from plates 31 and 32 to lie
`undera greater portionofthird-stage mold plate 33 as shown
`in FIG. 12. Further molding of gob 62 to produce container
`closure 10 is carried out in third and fourth stages in a
`mannersimilar to the molding stages illustrated in FIGS. 7
`and 8.
`
`40
`
`45
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`50
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`55
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`60
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`MacNeil Exhibit 2175
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`US 7,108,823 B2
`
`7
`molding process to produce container closure 10 is carried
`out in the manner suggested in FIGS. 7 and 8.
`Some embodiments contemplated by this disclosure may
`have only two mold plates in upper mold portion 37 which
`moverelative to lower mold portion 38. In other embodi-
`ments, there may be four or more mold plates in upper mold
`portion 37 which moverelative to lower mold portion 38.
`Yet anotherillustrative staged compression molding pro-
`cess is illustrated in FIGS. 14-16. As suggested in FIG. 14,
`a first gob 262 of thermoplastics material is arranged in one
`region of mold 110 substantially to lie under mold plate 31
`while a second gob 362 of thermoplastics material
`is
`arranged in another region of mold 110 substantially to lie
`under mold plate 33. In one embodiment, first gob 262 has
`a first color(e.g., red) and second gob 362 has a second color
`(e.g., blue) different from thefirst color. In another embodi-
`ment, first gob 262 comprises a first thermoplastic material
`and second gob 362 comprises a second thermoplastic
`material different from the first thermoplastic material. It is
`within the scope of this disclosure to use a first gob 262
`having selected material, color, or other property of interest
`and to use a second gob 362 having different selected
`materials, colors, or other properties of interest as long as the
`first and second gobs 262, 362 can be “merged” during the
`molding process to produce a monolithic container closure
`
`As suggested in FIG. 15, during the compression molding
`process, first gob 202 is compressed (at low pressure) by
`mold plate 31 while second gob 362 is compressed (at low
`pressure) by mold plate 33. Such compression causes gob
`262, 362 to move toward and contact one another in a region
`in mold cavity 70 located, for example, under mold plate 32.
`As suggested in FIG. 16, mold plate 32 is then moved to
`compress adjacent portions of gobs 262, 362 (at low pres-
`sure) to begin or continue merger of those gob portions in
`the mold region defining, for example,
`living hinge 18.
`Further molding of the material comprising gobs 262, 362 to
`produce container closure 10 is carried out in a third stage
`similar to the molding stage illustrated in FIG. 8 by com-
`pressing that material at high pressure using plates 31, 32,
`and 33.
`The invention claimed is:
`
`1. A process of molding a container closure in stages, the
`process comprising
`
`8
`depositing a gob of thermoplastics material into a mold
`cavity located between spaced-apart upper and lower
`mold portions,
`moving at least a first-stage mold plate and a separate
`second-stage mold plate in sequence relative to the
`lower mold portion to compress the gob during two
`sequential stages of a molding process, the first-stage
`mold plate being movedrelative to the lower mold
`portion to apply a low-pressure force to the gob during
`a first stage of the molding process, the second-stage
`mold plate being movedrelative to the lower mold
`portion to apply a substantially similar low-pressure
`force to the gob during a subsequent secondstage of the
`molding process, and
`moving the first- and second-stage mold plates in unison
`relative to the lower mold portion to apply a high-
`pressure force greater than the low-pressure force to the
`gob during a later stage of the molding process to form
`a monolithic container closure in the mold cavity
`between the upper and lower mold portions.
`2. The process of claim 1, whereinall of the gob is placed
`under the first-stage mold plate before the first-stage mold
`plate is movedrelative to the lower mold portion to begin to
`compress the gob.
`3. The process of claim 2, wherein first, second, and third
`mold plates are moved toward the lower mold portion in
`sequence at different times to compress the gob therebe-
`tween during a first stage of the molding process associated
`with movementofthe first-stage mold plate, a subsequent
`second stage of the molding process associated with move-
`ment of the second-stage mold plate, and a still later third
`stage of the molding process associated with movement of
`a third-stage mold plate.
`4. The process of claim 3, wherein a substantially similar
`low-pressure force is applied to the gob during each of the
`first, second, and third stages of the molding process.
`5. The process of claim 3, wherein thefirst, second, and
`third mold plates are moved toward the lower mold portion
`in unison further to compress the gob therebetween during
`a fourth stage of the molding process after completion of the
`first, second, and third stages of the molding process.
`
`5
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`15
`
`20
`
`25
`
`30
`
`35
`
`40
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`Yita v. MacNeil IP, IPR2020-01139, Page 11
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`MacNeil Exhibit 2175
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`MacNeil Exhibit 2175
`Yita v. MacNeil IP, IPR2020-01139, Page 11
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