Abstract: Injection machine and fluid distribution system having a valve pin reciprocally movable along its longitudinal axis between upstream and downstream (axial) positions, including a valve pin rotation limiter for resisting or preventing rotation of the valve pin around its axis. The limiter includes an elongated rail having a rail axis, stationarily mounted relative to an actuator that drives the valve pin upstream-downstream along its longitudinal axis wherein the rail axis is radially spaced from the valve pin axis. A finger projects between the rail and the valve pin, having a first end mounted on or to one of the rail and the valve pin, and a second end slidably engaged against a receiving surface of the other of the rail or valve pin, wherein such engagement is adapted to resist or prevent rotation of the valve pin.

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: 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.

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, including a valve system in fluid communication with an 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: 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: A system for mounting an injection molding system actuator to a manifold and a clamp plate comprising: a mount comprised of a thermally conductive material having first and second thermally conductive surfaces, the actuator being mounted to the first thermally conductive surface in thermal communication with the second thermally conductive surface, the clamp plate being mounted in thermal communication with the second thermally conductive surface, the actuator being mounted in thermal communication with the heated manifold; wherein the clamp plate, manifold and mold are assembled together with the actuator and the mount in an assembled operating arrangement such that the second thermally conductive surface is in compressed contact with the clamp plate under a spring force.

Abstract: A system for mounting an injection molding system actuator to a manifold and a clamp plate comprising: a mount comprised of a thermally conductive material having first and second thermally conductive surfaces, the actuator being mounted to the first thermally conductive surface in thermal communication with the second thermally conductive surface, the clamp plate being mounted in thermal communication with the second thermally conductive surface, the actuator being mounted in thermal communication with the heated manifold; wherein the clamp plate, manifold and mold are assembled together with the actuator and the mount in an assembled operating arrangement such that the second thermally conductive surface is in compressed contact with the clamp plate under a spring force.

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 system for mounting an injection molding system actuator to a manifold and a clamp plate comprising: a mount comprised of a thermally conductive material having first and second thermally conductive surfaces, the actuator being mounted to the first thermally conductive surface in thermal communication with the second thermally conductive surface, the clamp plate being mounted in thermal communication with the second thermally conductive surface, the actuator being mounted in thermal communication with the heated manifold; wherein the clamp plate, manifold and mold are assembled together with the actuator and the mount in an assembled operating arrangement such that the second thermally conductive surface is in compressed contact with the clamp plate under a spring force.

Abstract: In an injection molding apparatus comprising a clamp plate, a heated manifold and a mold, a system for mounting an actuator to the manifold and the clamp plate, the system comprising: a mount comprised of a thermally conductive material having first and second heat conductive surfaces; the first conductive surface being in heat conductive communication with the actuator, the second conductive surface being in heat conductive communication with the clamp plate; the actuator being mounted in thermal communication with the manifold; the mount being adjustably mounted to the actuator such that the second conductive surface can be adjusted in position toward and away from the actuator.

Abstract: Apparatus for heating a fluid being injected in an injection molding system, the apparatus comprising a mold having a cavity, a fluid flow distribution manifold, a fluid flow channel body, a coiled heater tube comprised of a thermally conductive wall, a heater device disposed within the coiled tube; the coiled tube having an upstream, downstream and intermediate coiled portions, the upstream and downstream coiled portions of the coiled tube being selectively movable away from each other along the coil axis to cause the intermediate coiled portion of the coiled tube to stretch or extend in coil axial length.

Abstract: Apparatus for measuring the temperature of a nozzle having fluid material injected from an injection molding machine through a flow channel in a heated manifold that is coupled to a nozzle that is coupled to the cavity of a mold, the apparatus comprising: a heating device comprising a controllably heatable thermally conductive heating element; the heating element of the heating device being mounted on or around the outer surface of the tube of the nozzle at an end point; a temperature monitor comprising a temperature sensor mounted on or around the nozzle at a selected position along the axis of the bore of the nozzle; and, a thermal insulator disposed along the axis of the nozzle separating the end point of the heating element and the temperature sensor.

Abstract: An injection molding system comprising an actuator, a mounting plate, a mold and a manifold mounted between the mounting plate and the mold, the mounting plate being removably coupled to the mold, a valve pin comprising a pin stem and a pin connector; the actuator housing being mounted on or within the mounting plate for radial movement upon decoupling of the actuator housing from the mounting plate.

Abstract: An apparatus for controlling the rate of flow of mold material to a mold cavity, including a valve system in fluid communication with an 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 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: A system for mounting an injection molding system actuator to a manifold and a clamp plate comprising: a mount comprised of a thermally conductive material having first and second thermally conductive surfaces, the actuator being mounted to the first thermally conductive surface in thermal communication with the second thermally conductive surface, the clamp plate being mounted in thermal communication with the second thermally conductive surface, the actuator being mounted in thermal communication with the heated manifold; wherein the clamp plate, manifold and mold are assembled together with the actuator and the mount in an assembled operating arrangement such that the second thermally conductive surface is in compressed contact with the clamp plate under a spring force.

Abstract: An injection molding system comprising an actuator, a mounting plate, a mold and a manifold mounted between the mounting plate and the mold, the mounting plate being removably coupled to the mold, the actuator comprising an actuating member reciprocally drivable along an axial path of travel and a housing removably coupled to the mounting plate; a valve pin coupled to the shaft of the actuator for movement of the valve pin together with movement of the actuating member, the valve pin comprising a pin stem and a pin connector; the actuator having an actuator coupling adapted to reversibly couple to and decouple from the pin connector in a radial direction relative to the axial path of travel, the pin stem extending from the actuator into the manifold when the housing of the actuator is coupled to the mounting plate and the pin connector is received within the actuator coupling; the actuator housing being mounted on or within the mounting plate for radial movement upon decoupling of the actuator housing from th

Abstract: Apparatus for heating a fluid being injected in an injection molding system, the apparatus comprising a mold having a cavity, a fluid flow distribution manifold, a fluid flow channel body, a coiled heater tube comprised of a thermally conductive wall, a heater device disposed within the coiled tube; the coiled tube having an upstream, downstream and intermediate coiled portions, the upstream and downstream coiled portions of the coiled tube being selectively movable away from each other along the coil axis to cause the intermediate coiled portion of the coiled tube to stretch or extend in coil axial length.

Abstract: Apparatus for controlling the rate of flow of fluid material through an injection molding flow channel leading to a gate of a mold cavity, the apparatus comprising: a pin having a longitudinal length being adapted for back and forth axial movement through the flow channel; the pin having a protrusion having a maximum diameter circumferential surface; the channel having an interior surface complementary to the maximum diameter circumferential surface of the protrusion; the pin being slidable to a position within the channel such that the maximum diameter circumferential surface of the protrusion forms a seal with the complementary interior surface portion of the channel to stop flow of the fluid material, an electrically powered actuator interconnected to and controllably driving the pin through the channel.