Patents Assigned to iMFLUX Inc.
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Patent number: 10427341Abstract: An injection molding machine uses a controller to effectively control its operation. The controller may determine and/or receive information regarding the machine's maximum load capacity, and may also determine a current operational load value of the machine. The controller may cause the machine to operate at any number of combinations of settings of operational parameters which result in the machine operating at or below the maximum load value by adjusting any number of machine parameters associated with the injection molding machine based on feedback sensors measuring real-time operating conditions of the machine.Type: GrantFiled: August 31, 2017Date of Patent: October 1, 2019Assignee: IMFLUX INC.Inventors: Gene Michael Altonen, Brian Matthew Burns, H. Kenneth Hanson, III
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Patent number: 10399264Abstract: Embodiments within the scope of the present disclosure are directed to external sensor kits that may be included in new injection molds or retrofitted into existing injection molds in order to approximate conditions within a mold, such as pressure or the location of a melt flow front. Such kits are designed to amplify meaningful measurements obtained by the external sensor kit so that noise measurements do not prevent the approximation of conditions within a mold. In some embodiments within the scope of the present disclosure, an external sensor kit includes a strain gauge sensor, a coupon, a support bracket, and a hammer. The strain gauge sensor is placed on a surface of the coupon and measures the strain in the coupon.Type: GrantFiled: March 3, 2017Date of Patent: September 3, 2019Assignee: IMFLUX, INC.Inventors: Chow-Chi Huang, Rick Alan Pollard, Gene Michael Altonen
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Patent number: 10399262Abstract: A remote controller can be provided on any apparatus that employs feedback control from a native controller to add functionality to the apparatus where the native controller is not capable of providing such functionality independently.Type: GrantFiled: December 14, 2016Date of Patent: September 3, 2019Assignee: IMFLUX INCInventors: Brian Matthew Burns, Gene Michael Altonen
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Patent number: 10300647Abstract: A carousel-like continuous molding system includes an arrangement of inclined feed channels. Each of the feed channels has a controllable valve therein positioned upstream of an inlet to an associated mold cavity. The valve is controllable so that adjustments may be made in real time to achieve or maintain delivery of molten polymeric material to the mold cavity at constant pressure.Type: GrantFiled: December 8, 2015Date of Patent: May 28, 2019Assignee: IMFLUX INC.Inventors: Coy Del Ward, Ralph Edwin Neufarth, Gene Michael Altonen, Chow-chi Huang, Charles John Berg, Jr.
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Patent number: 10279525Abstract: A carousel-like continuous co-injection molding system includes an arrangement of upper and lower inclined feed channels. Each of the feed channels has a valve therein positioned upstream of an inlet to an associated mold cavity. The valve is controllable so that adjustments may be made in real time to achieve or maintain delivery of molten polymeric material to the mold cavity at constant pressure.Type: GrantFiled: February 23, 2018Date of Patent: May 7, 2019Assignee: IMFLUX INC.Inventors: Coy Del Ward, Ralph Edwin Neufarth, Gene Michael Altonen, Chow-Chi Huang, Charles John Berg, Jr.
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Patent number: 10281891Abstract: A remote controller can be provided on any apparatus that employs feedback control from a native controller to add functionality to the apparatus where the native controller is not capable of providing such functionality independently.Type: GrantFiled: December 14, 2016Date of Patent: May 7, 2019Assignee: IMFLUX INC.Inventors: Brian Matthew Burns, Gene Michael Altonen
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Patent number: 10226885Abstract: A nozzle assembly for an injection molding system has a nozzle adapter with one or more vent holes therein. A porous metal insert is provided in fluid communication with at least one of the vent holes. The porous metal insert is also in fluid communication with a flow channel through the nozzle assembly. As molten polymeric material advances through the flow channel from a barrel to a mold assembly, gases entrained in the molten polymeric material are vented through the porous metal insert and escape through the one or more vent holes. Pressurized air may be introduced through the vent holes, such as by one or more blow-back modules, to unclog pores of the one or more porous metal inserts between shots of the injection molding system.Type: GrantFiled: March 2, 2017Date of Patent: March 12, 2019Assignee: IMFLUX, INC.Inventors: Frank Gustaaf Debruin, Chow-Chi Huang, Michael Thomas Dodd
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Patent number: 10226889Abstract: A injection molding method involves measuring, using at least one external sensor, a change in a parameter of a mold side of a mold cavity, approximating a condition within the mold cavity based on the change in the parameter, such as pressure within the mold cavity or flow front position, and comparing the approximated condition to a trigger point. If the approximated condition equals or exceeds the trigger point, activating a virtual cavity sensor having an optimal pre-defined pressure-time curve, and upon activation, the virtual cavity sensor tracks an approximated condition calculated from the change in parameter measurements measured by the at least one external sensor over time. In an embodiment, results of the approximated parameter tracking can be used in conjunction with an optimal pre-defined pressure-time curve.Type: GrantFiled: July 22, 2016Date of Patent: March 12, 2019Assignee: IMFLUX, INC.Inventors: Rick Alan Pollard, Joshua Douglas Raker, Gene Michael Altonen, H. Kenneth Hanson, III
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Patent number: 10169721Abstract: An injection molding machine uses a native controller and a retrofit controller to effectively control its operation. The controllers may determine and/or receive information regarding the machine's maximum load capacity, and may also determine a current operational load value of the machine. The retrofit controller may cause the machine to operate at any number of combinations of settings of operational parameters which result in the machine operating at or below the maximum load value by adjusting any number of machine parameters associated with the injection molding machine based on feedback sensors measuring real-time operating conditions of the machine.Type: GrantFiled: March 21, 2017Date of Patent: January 1, 2019Assignee: IMFLUX, INC.Inventors: Gene Michael Altonen, Brian Matthew Burns, Herbert Kenneth Hanson, III
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Patent number: 10107697Abstract: A strain gauge nozzle adapter that may be placed between a barrel end cap and a nozzle body of an injection molding system, the strain gauge nozzle adapter having a strain gauge pin that measures strain within the strain gauge nozzle adapter for use in approximating conditions within an injection molding system, such as pressure or the location of a melt flow front. The strain gauge nozzle adapter may include a plurality of strain gauge pins. An alternative material insert in the strain gauge nozzle adapter may surround a strain gauge pin to amplify meaningful measurements obtained by the strain gauge pin so that noise measurements do not compromise the accuracy of approximation of conditions within a mold.Type: GrantFiled: June 7, 2017Date of Patent: October 23, 2018Assignee: IMFLUX INC.Inventors: Rick Alan Pollard, Bryan Keith Allen, Chow-Chi Huang, Gene Michael Altonen
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Patent number: 10076861Abstract: A low constant pressure injection molding machine forms molded parts by injecting molten thermoplastic material into a mold cavity at low substantially constant pressures of 6,000 psi and less. As a result, the low constant pressure injection molding machine includes a mold formed of easily machineable material that is less costly and faster to manufacture than typical injection molds.Type: GrantFiled: August 31, 2012Date of Patent: September 18, 2018Assignee: IMFLUX INCInventors: Gene Michael Altonen, Ralph Edwin Neufarth, Gary Francis Schiller
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Patent number: 9937647Abstract: A carousel-like continuous co-injection molding system includes an arrangement of upper and lower inclined feed channels. Each of the feed channels has a valve therein positioned upstream of an inlet to an associated mold cavity. The valve is controllable so that adjustments may be made in real time to achieve or maintain delivery of molten polymeric material to the mold cavity at constant pressure.Type: GrantFiled: December 8, 2015Date of Patent: April 10, 2018Assignee: IMFLUX INC.Inventors: Coy Del Ward, Ralph Edwin Neufarth, Gene Michael Altonen, Chow-chi Huang, Charles John Berg
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Patent number: 9937646Abstract: A low constant pressure injection molding machine forms molded parts by injecting molten thermoplastic material into a mold cavity at low constant pressures of 6,000 psi and lower. As a result, the low constant pressure injection molding machine includes a mold formed of easily machineable material that is less costly and faster to manufacture than typical injection molds.Type: GrantFiled: December 15, 2014Date of Patent: April 10, 2018Assignee: IMFLUX, INC.Inventors: Gene Michael Altonen, Charles John Berg, Jr., Ralph Edwin Neufarth, Gary Francis Schiller
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Patent number: 9855694Abstract: A feed system for an injection molding machine. The feed system includes a first part with a first channel, and a second part with a second channel. The first channel and the second channel together form a molten plastic feed conduit when they are engaged. The first part and the second part are unbonded to one another.Type: GrantFiled: August 27, 2015Date of Patent: January 2, 2018Assignee: IMFLUX INC.Inventors: Gene Michael Altonen, Ralph Edwin Neufarth, Chow-chi Huang, Michael Thomas Dodd, Matthew Lloyd Newman
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Patent number: 9815233Abstract: A substantially constant pressure injection molding method and machine that forms molded parts by injecting molten thermoplastic material into a mold cavity at a substantially constant pressure. As a result, the mold cavity is filled with molten thermoplastic material by advancing a continuous flow front of thermoplastic material from a gate to an end of the mold cavity.Type: GrantFiled: February 26, 2016Date of Patent: November 14, 2017Assignee: IMFLUX, INC.Inventors: Gene Michael Altonen, Michael Thomas Dodd, Natalia Maria Ramon Martinez, Kimberly Nichole McConnell, Danny David Lumpkin, Vincent Sean Breidenbach, John Russell Lawson
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Patent number: 9731443Abstract: An injection molding machine that uses a mold and a native controller to operate according to an original mold cycle to mold plastic objects is retrofitted with a retrofit controller; the retrofitted machine uses the mold and the retrofit controller to operate according to a retrofit mold cycle to mold plastic objects. The retrofit mold cycle has a maximum injection pressure that is less than a maximum injection pressure of the original mold cycle. The retrofit mold cycle can also have more constant injection pressures than the original mold cycle.Type: GrantFiled: September 22, 2015Date of Patent: August 15, 2017Assignee: IMFLUX INCInventors: Gene Michael Altonen, Michael Thomas Dodd
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Patent number: 9718229Abstract: An injection molding machine that uses a mold and a native controller to operate according to an original mold cycle to mold plastic objects is retrofitted with a retrofit controller; the retrofitted machine uses the mold and the retrofit controller to operate according to a retrofit mold cycle to mold plastic objects. When molding according to the retrofit mold cycle, the injection molding machine uses lower temperatures, when compared to molding according to the original mold cycle.Type: GrantFiled: September 22, 2015Date of Patent: August 1, 2017Assignee: IMFLUX INC.Inventors: Gene Michael Altonen, Michael Thomas Dodd
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Patent number: 9707709Abstract: Disclosed herein is a method of injection molding at low, substantially constant melt pressures. Embodiments of the disclosed method now make possible a method of injection molding that is more energy—and cost—effective than conventional high-velocity injection molding processes. Embodiments of the disclosed method surprisingly allow for the filling of a mold cavity at low melt pressure without undesirable premature hardening of the thermoplastic material in the mold cavity and without the need for maintaining a constant temperature or heated mold cavity. Heretofore, it would not have been expected that a constant pressure method could be performed at low pressure without such premature hardening of the thermoplastic material when using an unheated mold cavity or cooled mold cavity.Type: GrantFiled: May 21, 2012Date of Patent: July 18, 2017Assignee: IMFLUX INCInventors: Gene Michael Altonen, Charles John Berg, Jr., Ralph Edwin Neufarth, Gary Francis Schiller, John Moncrief Layman, Rainer Scharrenberg
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Patent number: 9694527Abstract: An injection molding machine that uses a mold and a native controller to operate according to an original mold cycle to mold plastic objects is retrofitted with a retrofit controller; the retrofitted machine uses the mold and the retrofit controller to operate according to a retrofit mold cycle to mold plastic objects. When molding according to the retrofit mold cycle, the injection molding machine can obtain a faster cycle time.Type: GrantFiled: September 22, 2015Date of Patent: July 4, 2017Assignee: IMFLUX INCInventors: Gene Michael Altonen, Michael Thomas Dodd
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Patent number: 9682505Abstract: An injection mold assembly for a high output consumer product injection molding machine, the injection mold assembly having a simplified cooling system that is an evaporative cooling system or a cooling system including a hazardous, dangerous, or expensive cooling fluid. The simplified cooling system has a cooling fluid channel that is confined to a mold support plate.Type: GrantFiled: September 19, 2014Date of Patent: June 20, 2017Assignee: IMFLUX INCInventors: Ralph Edwin Neufarth, Niall D Robinson, Rainer Scharrenberg, Robert Lawrence Prosise, Charles John Berg, Jr.