Abstract: An injection molding apparatus comprising a clamp plate, a heated manifold, an actuator, a mold and a cooling device, wherein the cooling device comprises: a heat transmitter comprising a distal arm or member and a proximal base or member, the distal arm or member being mounted by a spring loadable interconnection or engagement to or with the proximal base or member, the clamp plate, the mold, the manifold, the actuator and the heat transmitter being assemblable together in an arrangement wherein the spring loadable interconnection is loaded urging the distal end surface of the distal arm or member into compressed engagement with the clamp plate.

Abstract: An apparatus and method for adjusting the axial position of a valve pin in an injection molding system, the apparatus comprising: an actuator comprising a housing having a chamber enclosing a drive member for driving a valve pin along an axial path of travel, the actuator housing slidably mounted and adapted for controlled upstream and downstream movement of the drive member along a path complementary to the axial path of travel of the valve pin, a mounting plate and an axial position adjustment screw screwably mounted within the mounting plate upstream of the housing of the actuator for controllably moving the valve pin to selectable starting or ending injection cycle axial positions.

Abstract: An apparatus for controlling the rate of flow of fluid mold material comprising: a manifold, a valve pin having a pin axis, a pin connector and a stem, the valve pin being drivable into and out of open and closed positions relative to the gate, an electric actuator comprising an electric motor comprised of a motor housing that houses a drive shaft having a drive gear and a drive axis, a transmission comprised of a transmission gear having a gear axis, the drive gear, the transmission gear and the valve pin being drivably interconnected and arranged such that the drive axis and the gear axis are non-coaxially mounted or disposed relative to each other and the valve pin is drivable linearly along the pin axis, wherein one or the other of the motor housing or the transmission housing are removably attached to a top clamping or mounting plate that is mounted upstream of the manifold and fixedly interconnected to a mold.

Abstract: Apparatus and methods for storage and transmission of recipe data (process parameters) for the molding of articles in an injection molding apparatus. A controller includes a flow control microcontroller (MCU) that receives recipe data from a recipe storage microcontroller (MCU) mounted to a mold of an injection molding machine, the recipe storage MCU storing the recipe data defining process parameters for the molding of articles in the mold. The flow control MCU executes instructions for controlling valve pin motions according to the recipe data. In one embodiment, a human operator interface is provided for transmitting data to and/or from at least one of the recipe storage and flow control MCU's, allowing the operator to monitor, modify and/or control the process parameters during a molding cycle and/or to create a modified or new recipe for subsequent storage on the recipe storage MCU.

Abstract: A method and apparatus for performing an injection molding cycle comprising drivably interconnecting a valve pin to an electric motor actuator and controllably operating the electric motor to drive the valve pin at one or more reduced rates of upstream or downstream travel based on either detection of the position of the pin or actuator or on a preselected length of time at which to drive the valve pin.

Abstract: Apparatus and method for performing an injection molding cycle in an injection molding apparatus where the apparatus comprises: a manifold, an actuator associated with a respective gate, each gate having a downstream sensor generating a response signal upon sensing a selected condition of the injection fluid material, each gate having an upstream sensor generating a response signal upon sensing the selected condition of the injection fluid material, the upstream and downstream sensors sending response signals to a controller on performance of each successive injection cycle by the apparatus, the controller comparing a standard amount of elapsed time with a calculated amount of elapsed time and adjusting the velocity or position of each of the actuators such that the amount of time elapsed approaches or matches the standard amount of elapsed time.

Abstract: An injection molding apparatus comprising an injection molding machine, a manifold, a closure valve pin, a first actuator having a linear or axial driver, a second actuator comprising a rotor interconnected to either the closure valve pin or to a second valve pin such that either the closure valve pin or the second valve pin is rotatably driven in unison with the rotor around the rotation axis, the closure pin or second pin being disposed and rotatable within the flow of injection fluid flowing through a flow channel leading to a mold cavity.

Abstract: An injection molding apparatus including: a valve pin driven by an actuator, the valve pin extending axially through at least a portion of the channel length of the fluid flow channel, the fluid flow channel including a throat, downstream flow of the injection fluid being restricted by a bulb portion of the pin, the valve pin having an intermediate position where downstream flow of injection fluid is unrestricted and a fully downstream position where downstream flow of injection fluid is stopped at both the gate and at the throat, wherein the actuator is driven by a valve assembly comprised of a spool mechanically driven by first and second actuators or solenoids that each separately engage the spool at opposing axial ends to effect movement of the spool back and forth between the drive fluid flow positions.

Abstract: An injection molding apparatus comprising: a pneumatically driven actuator having a piston mounted within a fluid sealed chamber for slidable axial movement along or against an interior surface of the fluid sealed chamber via a non-elastomeric engagement or with a non-elastomeric material disposed between the piston and the interior surface of the fluid sealed chamber, the piston forming first and second drive chambers within the fluid sealed chamber, each drive chamber having respective fluid flow ports, a source of pressurized gas that generates gas flow at a selected maximum pressure or flow rate, a gas metering mechanism, a controller interconnected to the gas metering mechanism, the controller controllably moving the gas metering mechanism to selectable positions that correspond to reduced pressures or reduced flow rates during the course of pin travel from the fully downstream gate closed position to the fully upstream gate open position.

Abstract: Apparatus and method for performing an injection molding cycle using the apparatus where the apparatus comprises: a manifold, a pneumatic actuator driven by a pneumatic valve assembly, the actuator driving a valve pin between a gate closed position and a maximum injection fluid flow position, the pneumatic valve assembly having a spool supported within a cylinder driven by a drive device that is supported solely by and translates together with the spool, a controller that instructs the pneumatic valve assembly to cause the actuator to drive the valve pin either upstream or downstream to selected positions or at selected velocities during the course of a single injection cycle based on a feedback signal indicative of position of the pin or actuator or pressure of an injection fluid material.

Abstract: An apparatus for controlling the rate of flow of fluid mold material from an injection molding machine to a mold cavity, the apparatus comprising: a manifold having a delivery channel that delivers fluid material to a first gate; an actuator interconnected to a valve pin having a tip end drivable along a drive path, the actuator and the valve pin being translationally driven at a controllable rate of travel by a valve system comprised of a source of valve drive fluid that pumps the drive fluid at a maximum drive rate, a first valve interconnected to the source that is selectively adjustable to adjust rate of flow of the drive fluid from the source to a selected less than maximum drive rate and a second valve controllably movable between a first position and a second position.

Abstract: An injection molding apparatus comprising a heated manifold, an actuator comprised of an actuator housing containing a drive member interconnected to a valve pin having a drive axis, one or more heat convectors each heat convector comprised of a heat conductive leg disposed within a gap disposed between the manifold and a downstream end of the actuator housing and a heat conductive arm extending distally upstream and away from the gap such that heat is conducted from the leg to the arm upstream and away from the downstream end of the actuator housing.

Abstract: An injection molding apparatus comprising: a pneumatically driven actuator having a piston mounted within a fluid sealed chamber for slidable axial movement along or against an interior surface of the fluid sealed chamber via a non-elastomeric engagement or with a non-elastomeric material disposed between the piston and the interior surface of the fluid sealed chamber, the piston forming first and second drive chambers within the fluid sealed chamber, each drive chamber having respective fluid flow ports, a source of pressurized gas that generates gas flow at a selected maximum pressure or flow rate, a gas metering mechanism, a controller interconnected to the gas metering mechanism, the controller controllably moving the gas metering mechanism to selectable positions that correspond to reduced pressures or reduced flow rates during the course of pin travel from the fully downstream gate closed position to the fully upstream gate open position.

Abstract: An apparatus for controlling the rate of flow to a mold cavity including a controller instructing a valve system to drive an actuator and a valve pin and including instructions that instruct the valve system to drive an actuator and a valve pin and including instructions that instruct the valve system to move from a start position to one or more intermediate drive rate positions and subsequently from the one or more intermediate drive rate positions to a high drive rate position on receipt by the controller of a signal from a position sensor that is indicative of the valve pin having reached a second position.

Abstract: An apparatus for controlling the rate of flow of mold material to a mold cavity, the apparatus comprising: an injection molding machine and a manifold; an actuator interconnected to a valve pin having a tip end; a valve system in fluid communication with the actuator to drive the actuator at one or more rates of travel, the valve system having a start position, one or more intermediate drive rate positions and a high drive rate position, the start position holding the valve pin in a gate closed position; a controller that instructs the valve system to move from the start position to the one or more intermediate drive rate positions and to remain in the one or more intermediate drive rate positions for one or more corresponding predetermined amounts of time and further drives the valve system to move from the one or more intermediate drive rate positions to the high drive rate position on expiration of the one or more predetermined amounts of time.

Abstract: An apparatus for controlling the rate of flow of fluid mold material from an injection molding machine to a mold cavity, the apparatus comprising: a manifold having a fluid delivery channel, an actuator interconnected to a valve pin having a tip end drivable between a first position, a second position upstream and a third position upstream of the second position, the actuator and the valve pin being translationally driven by a valve system adjustable between a start position, a plurality of intermediate drive rate positions and a high drive rate position, a pressure sensor and a controller, the pressure sensor sensing a metered pressure of a drive fluid, the controller instructing the valve system to drive valve pin continuously upstream and including instructions that instruct the valve system to move according to a predetermined profile of metered pressures from the start position to selected intermediate drive rate positions and subsequently to the high drive rate position.

Abstract: A method and apparatus for performing an injection molding cycle comprising drivably interconnecting a valve pin to an electric motor actuator and controllably operating the electric motor to drive the valve pin at one or more reduced rates of upstream or downstream travel based on either detection of the position of the pin or actuator or on a preselected length of time at which to drive the valve pin.

Abstract: An apparatus for controlling the rate of flow of fluid mold material comprising: a manifold, a valve pin having a pin axis, a pin connector and a stem, the valve pin being drivable into and out of open and closed positions relative to the gate, an electric actuator comprising an electric motor comprised of a motor housing that houses a drive shaft having a drive gear and a drive axis, a transmission comprised of a gear shaft, the drive gear and the transmission gear being drivably interconnected and arranged such that the drive axis and the gear axis are non-coaxially mounted or disposed relative to each other, wherein one or the other of the motor housing or the transmission housing are removably attached to a top clamping or mounting plate that is mounted upstream of the manifold and fixedly interconnected to a mold.

Abstract: Apparatus for performing an injection molding cycle, comprising: a manifold routing injection fluid to two or more gates, an actuator associated with each gate, each gate having a downstream sensor that senses a selected condition of the injection fluid material, a controller, the downstream sensors establishing a standard elapsed time, the controller including instructions that compares the standard elapsed time with a calculated amount of elapsed time associated with each of the gates and that adjust the velocity or position of each of the actuators.

Abstract: Apparatus and method for detecting a position of an actuator piston driving a valve pin in an injection molding system. The apparatus includes an actuator housing having a body portion, surrounding an axial bore, of a substantially non-magnetic and/or magnetically permeable material, a piston, movable within the axial bore for driving a valve pin, the piston including a magnetic member generating a magnetic field such that axial movement of the piston in the bore modifies the magnetic field according to the position of the piston relative to a detection position, and a magnetic field detector attached to an exterior surface of the body portion at the detection position for detecting the magnetic field associated with the position of the piston and generating an output signal determined by the piston position.