Abstract: A method for predicting pressures in an injection molding system for molding plastic parts requires providing a mold that has at least one channel with each additional channel having a constant cross-sectional shape along its length and each channel having different thicknesses with a constant cross-sectional shape along its length. At least one first sensor configured to collect pressure data from each channel is provided. At least three second sensors configured to detect the presence of plastic located at known distances downstream of the at least one first sensor. Molten plastic is injected in each of the channels and sensor data is collected for the molten plastic flowing through each channel. A curve is fitted to progressive measured occurrences of pressure at the first sensor when plastic is first detected at each of the second sensors for each channel. Pressure can be predicted for a given flow rate, temperature, and channel thickness at, between, or beyond the measured occurrences.

Abstract: A material characterization system and method for quantifying the characteristics of a flowing thermoplastic material is presented. The system comprises a tool comprising first and second tool halves, a plurality of flowing material characterization channels, and a feed runner. The tool is at a temperature that causes phase changes from fluid to solid in at least a portion of the characterized material and enables solidification of the material in the flowing material characterization channels. The feed runner is connectable to a single flowing material characterization channel. The tool is adjustable to disconnect the feed runner from one flowing material characterization channel and connect it to different flowing material characterization channels. A sensor quantifies the characteristics of the material under different flow conditions.

Abstract: A material characterization system and method for quantifying the characteristics of a flowing thermoplastic material is presented. The system comprises a tool comprising first and second tool halves, a plurality of flowing material characterization channels, and a feed runner. The tool is at a temperature that causes phase changes from fluid to solid in at least a portion of the characterized material and enables solidification of the material in the flowing material characterization channels. The feed runner is connectable to a single flowing material characterization channel. The tool is adjustable to disconnect the feed runner from one flowing material characterization channel and connect it to different flowing material characterization channels. A sensor quantifies the characteristics of the material under different flow conditions.

Abstract: Methods and apparatus adjustably control the repositioning of non-homogeneous fluid conditions across the stream of a laminar flowing fluid to a desirable circumferential position. The invention is particularly applicable to controlling non-homogeneous melt conditions at about the intersection of two flow channels in systems having hot or cold flow channels. Various mechanisms are provided that enable simple adjustments of a flow diverter within a fluid rotation device, making either static or dynamic adjustments, so that the degree of fluid flow repositioning in a runner system can be changed without the need for mold disassembly or retooling. Various forms of actuators effect adjustment and may be manually manipulated or manipulated through various powered devices.

Abstract: Methods and apparatus adjustably control the repositioning of non-homogeneous fluid conditions across the stream of a laminar flowing fluid to a desirable circumferential position. The invention is particularly applicable to controlling non-homogeneous melt conditions in hot or cold runner systems. Various mechanisms are provided that enable simple adjustments of a flow diverter within a fluid rotation device, making either static or dynamic adjustments, so that the degree of fluid flow repositioning in a runner system can be changed without the need for mold disassembly or retooling. Various forms of actuators effect adjustment and may be manually manipulated or manipulated through various powered devices.

Abstract: Methods and apparatus control the direction and/or magnitude of warpage in formed plastic parts through strategic repositioning of the non-homogeneous melt conditions across the stream of a laminar flowing fluid flowing through a flow channel to a desirable state. This may be used in combination with more conventional process variables, such as control of material temperature, pack pressure, and pack time. The invention is particularly useful in any solidifying or non-solidifying runner, or flow channel used to make products from laminar flowing fluids. The runner may be a cold-runner or hot-runner system that flow a stream of laminar flowing material, such as thermosetting or thermoplastic plastic (melt) through at least one runner flowing a non-homogeneous melt, and extruded or packed into a single or multiple-cavity mold.

Abstract: Methods and apparatus control the direction and/or magnitude of warpage in formed plastic parts through strategic repositioning of the non-homogeneous melt conditions across the stream of a laminar flowing fluid flowing through a flow channel to a desirable state. This may be used in combination with more conventional process variables, such as control of material temperature, pack pressure, and pack time. The invention is particularly useful in any solidifying or non-solidifying runner, or flow channel used to make products from laminar flowing fluids. The runner may be a cold-runner or hot-runner system that flow a stream of laminar flowing material, such as thermosetting or thermoplastic plastic (melt) through at least one runner flowing a non-homogeneous melt, and extruded or packed into a single or multiple-cavity mold.