Blow-molding and degating hollow shapes

Claim 1

A method for making a hollow thermoplastic shape, such as a Christmas tree ornament ball, said method comprising forming a tubular thermoplastic parison at plasticized temperature, closing a blow molding die on the parison so as to flatten it and form the parison into two layers, said die having a cavity defining said shape and enclosing a portion of said flattened parison, while closing said die pinching the parison's said two layers together at the periphery of said cavity so as to weld the two layers together while extruding their thermoplastic away from said periphery into a space providing relief accommodating consequent thickening of the two layers and so as to form a gate having a solid pinch which tapers conically with an angularity of from about 40° to about 60° from said layers towards said cavity and has a junction with said portion in the cavity at the cavity's said periphery, blow molding said portion into said cavity to form said shape, opening said die so as to free said parison with the shape connected thereto by said gate, and applying ultrasonic vibration to said gate for transmission through the pinch to said junction so as to heat and melt the latter and free said shape from said parison, said die having a spine cavity and a plurality of said cavities for molding the shapes, said spine cavity being separated from said cavities, and a spine being blow molded from said parison in said spine cavity separately and independently with respect to said blow molding, said die being opened and said parison being allowed to fall and said junction being made with a thickness of from about 0.002" to about 0.012" so as to hold said shape to said parison when the fall of the latter is abruptly stopped, but so as to permit melting of the junction by said ultrasonic vibration, flattening of said parison forming folds joining said two layers, said die being closed on each parison so that said portion of each parison includes one of said folds, and a needle blow pin being pierced through said one of said folds in each instance to effect said blow molding.

Claim 2

A method for making a hollow thermoplastic shape, such as a Christmas tree ornament ball, said method comprising forming a tubular thermoplastic parison at plasticized temperature, closing a blow molding die on the parison so as to flatten it and form the parison into two layers, said die having a cavity defining said shape and enclosing a portion of said flattened parison, while closing said die pinching the parison's said two layers together at the periphery of said cavity so as to weld the two layers together while extruding their thermoplastic away from said periphery into a space providing relief accommodating consequent thickening of the two layers and so as to form a gate having a solid pinch which tapers conically with an angularity of from about 40° to about 60° from said layers towards said cavity and has a junction with said portion in the cavity at the cavity's said periphery, blow molding said portion into said cavity to form said shape, opening said die so as to free said parison with the shape connected thereto by said gate, and applying ultrasonic vibration to said gate for transmission through the pinch to said junction so as to heat and melt the latter and free said shape from said parison, said die having a spine cavity and a plurality of said cavities for molding the shapes, said spine cavity being separated from said cavities, and a spine being blow molded from said parison in said spine cavity separately and independently with respect to said blow molding, said die being opened and said parison being allowed to fall and said junction being made with a thickness of from about 0.002" to about 0.012" so as to hold said shape to said parison when the fall of the latter is abruptly stopped, but so as to permit melting of the junction by said ultrasonic vibration, flattening of said parison forming folds joining said two layers, said die being closed on each parison so that said portion of each parison includes one of said folds, and a needle blow pin being pierced through said one of said folds in each instance to effect said blow molding.