Abstract: In an injection molding machine having upstream and downstream channels communicating with each other for delivering fluid material to one or more mold cavities, apparatus for controlling delivery of the melt material from the channels to the one or more mold cavities, each channel having an axis, the downstream channel having an axis intersecting a gate of a cavity of a mold, the upstream channel having an axis not intersecting the gate and being associated with an upstream actuator interconnected to an upstream melt flow controller disposed at a selected location within the upstream channel, the apparatus comprising a sensor for sensing a selected condition of the melt material at a position downstream of the upstream melt flow controller; an actuator controller interconnected to the upstream actuator, the actuator controller comprising a computer interconnected to a sensor for receiving a signal representative of the selected condition sensed by the sensor, the computer including an algorithm utilizing a v

Abstract: A system for generating a simulation of fluid flow in an injection molding process carried out by an injection molding machine having an injection unit for injecting the fluid into a manifold delivering the fluid to at least two injection ports leading to one or more cavities of one or more molds. The system comprises one or more programs containing a set of instructions that generate a calculated property, state, position or image of the fluid flowing into or through each cavity, the one or more programs using one or more variable inputs that are representative of one or more selected properties, characteristics or operating parameters of the machine or the fluid. The variable inputs include at least a first value indicative of a first fluid flow rate downstream of the injection unit leading to or through a first injection port and a second value indicative of a second fluid flow rate downstream of the injection unit leading to or through a second injection port.

Abstract: In an injection molding machine having upstream and downstream channels communicating with each other for delivering fluid material to one or more mold cavities, apparatus for controlling delivery of the melt material from the channels to the one or more mold cavities, each channel having an axis, the downstream channel having an axis intersecting a gate of a cavity of a mold, the upstream channel having an axis not intersecting the gate and being associated with an upstream actuator interconnected to an upstream melt flow controller disposed at a selected location within the upstream channel, the apparatus comprising a sensor for sensing a selected condition of the melt material at a position downstream of the upstream melt flow controller; an actuator controller interconnected to the upstream actuator, the actuator controller comprising a computer interconnected to a sensor for receiving a signal representative of the selected condition sensed by the sensor, the computer including an algorithm utilizing a v

Abstract: A system and method are provided in which the rate of material flow to a plurality of gates can be controlled by a single controller. According to one embodiment, material is provided to first and second runners, the first runner comprising a plurality of distribution nozzles, and the flow to the first runner being controllable independently of the flow to the second runner.

Abstract: In an injection molding machine, an apparatus for controlling delivery of a fluid material to mold cavities of selectively variable size, shape, volume or configuration, the apparatus comprising a modular mold mounting mechanism having mounting apertures for receiving first and second molds having first and second mold cavities of different size, shape, volume or configuration, the mounting apertures being adapted for ready insertion and ready removal of the first and second molds; a manifold into which fluid material is injected, the manifold having first and second fluid delivery channels through which the fluid material is injected, one channel having an exit aperture communicating with a gate to the cavity of one mold, the other channel having an exit aperture communicating with a gate to the cavity of the other mold; each channel being associated with a drive mechanism which is interconnected to and controls operation of a fluid flow controller which varies flow of the fluid material through an associate

Abstract: An injection molding apparatus and system are provided in which the rate of material flow during the injection cycle is controlled. According to one preferred embodiment, an injection molding system is provided that includes an injection molding machine including a hydraulic power source, a manifold for distributing material injected from said injection molding machine to a plurality of gates leading to one or more mold cavities, and a controller to individually control respective rates at which material is injected through said gates during an injection cycle. The controller is coupled to the hydraulic power source and the hydraulic power source supplies hydraulic power to both the injection molding machine and to control said respective rates.

Abstract: A valve pin actuator is disclosed that includes a cylinder mounted to the clamping plate, a piston slidably mounted in the cylinder, and a valve pin assembly carried by the piston. A hydraulic or pneumatic circuit is provided for controlling the movement of the piston, and in turn translation of the valve pin between the seated and unseated positions. The valve pin assembly includes a first part removably secured to the piston so as to translate therewith, and a second part for receiving the valve pin and secured to said manifold. The actuator assembly enables removal of the clamping plate without removal of the valve pin assembly, and also adjusting of the valve pin without removal of the clamping plate. The assembly further provides a clearance between the piston and valve pin assembly, to accommodate expansion and movement of the manifold that would otherwise cause a side load to be exerted on the valve pin.

Abstract: A system and method are provided in which the rate of material flow to a plurality of gates can be controlled by a single controller. According to one embodiment, material is provided to first and second runners, the first runner comprising a plurality of distribution nozzles, and the flow to the first runner being controllable independently of the flow to the second runner.

Abstract: In an injection molding machine having first and second nozzles for delivering melt material from a common manifold to one or more mold cavities, apparatus for controlling delivery of the melt material from the nozzles to the one or more mold cavities, each nozzle having an exit aperture communicating with a gate of a cavity of a mold and being associated with an actuator interconnected to a melt flow controller, the apparatus comprising a sensor for sensing a selected condition of the melt material through at least one of the nozzles; an actuator controller interconnected to each actuator, each actuator controller comprising a computer interconnected to a sensor for receiving a signal representative of the selected condition sensed by the sensor, the computer including an algorithm utilizing a value corresponding to a signal received from the sensor as a variable for controlling operation of an actuator for the at least one nozzle; wherein the melt flow controller controls the rate of flow of the melt materi

Abstract: An injection molding apparatus, system and method are provided in which the rate of material flow during the injection cycle is controlled. According to one preferred embodiment, a method of open-mold purging is provided in an injection molding system including a manifold to receive material injected from an injection molding machine. The method includes the steps of selecting a target purge pressure; injecting material from the injection molding machine into the manifold; and controlling the purge pressure to substantially track the target purge pressure, wherein the purge pressure is controllable independently from the injection molding machine pressure.

Abstract: An injection molding apparatus and method are provided in which the rate of material flow during an injection cycle is controlled. According to one preferred embodiment, an injection molding apparatus is provided that includes a manifold, at least one injection nozzle coupled to the manifold, an actuator, and a valve pin adapted to reciprocate through the manifold and the injection nozzle. The valve pin has a first end coupled to the actuator, a second end that closes the gate in a forward position, and a control surface intermediate said first and second ends for adjusting the rate of material flow during an injection cycle. Retracting the valve pin tends to decrease the rate of material flow during the injection cycle and displacing the valve pin toward the gate tends to increase the rate of material flow during the injection cycle.

Abstract: An injection molding apparatus is provided in which the rate of material flow during the injection cycle is controlled. According to one preferred embodiment, a method is provided for use in an injection molding apparatus including a hot runner assembly comprising a manifold and at least first and second injection nozzles, the hot runner assembly to direct material injected into said manifold through said at least first and second injection nozzles through a corresponding at least first and second gates to one or more mold cavities. The method includes the steps of injecting material into the manifold, controlling, in the hot runner away from the first gate, a first rate at which material is injected through the first gate, and controlling, in the hot runner away from the second gate, a second rate at which material is injected through the second gate, independently from the first rate.

Abstract: A valve pin actuator is disclosed that includes a cylinder mounted to the clamping plate, a piston slidably mounted in the cylinder, and a valve pin assembly carried by the piston. A hydraulic or pneumatic circuit is provided for controlling the movement of the piston, and in turn translation of the valve pin between the seated and unseated positions. The valve pin assembly includes a first part removably secured to the piston so as to translate therewith, and a second part for receiving the valve pin and secured to said manifold. The actuator assembly enables removal of the clamping plate without removal of the valve pin assembly, and also adjusting of the valve pin without removal of the clamping plate. The assembly further provides a clearance between the piston and valve pin assembly, to accommodate expansion and movement of the manifold that would otherwise cause a side load to be exerted on the valve pin.

Abstract: An injection molding apparatus is provided for controlling the rate of material flow into a mold cavity or plurality of mold cavities during an injection cycle. The apparatus is, for example, a hot runner system for injecting plastic melt. A valve pin is provided for controlling the flow of material away from the gate. A gap is formed between the surface of the valve pin and the surface of the material flow bore away from the gate. Control of material flow is achieved by displacing the valve pin and thereby adjusting the size of the gap. A control system is provided that compares a sensed condition indicative of the rate of material flow into the mold cavity to a target profile of the sensed condition, and adjusts the valve pin during the injection cycle to mirror the target profile.

Abstract: In an injection molding machine having first and second nozzles for delivering melt material from a common manifold to one or more mold cavities, apparatus for controlling delivery of the melt material from the nozzles to the one or more mold cavities, each nozzle having an exit aperture communicating with a gate of a cavity of a mold and being associated with an actuator interconnected to a melt flow controller, the apparatus comprising: a sensor for sensing a selected condition of the melt material through at least one of the nozzles; and, an actuator controller interconnected to each actuator, at least one actuator controller comprising a computer interconnected to the sensor for receiving a signal representative of the selected condition sensed by the sensor, the computer including an algorithm utilizing a value corresponding to a signal received from the sensor as a variable for controlling operation of an actuator for the at least one nozzle.

Abstract: In an injection molding machine, an apparatus for controlling movement of a pin comprising a plastic melt flow channel having an output end for delivering molten plastic injected into the channel under pressure to a mold cavity, wherein the pin comprises an elongated rod having an axis and an end, the pin being slidably mounted within the channel for movement along its axis within the channel, an electrically driven motor drivably interconnected to an actuating mechanism, wherein the actuating mechanism is drivably interconnected to the end of the pin, the motor being controllably drivable to drive the pin through movement along its axis within the channel

Abstract: In an injection molding machine having first and second nozzles for delivering melt material from a common manifold to one or more mold cavities, apparatus for controlling delivery of the melt material from the nozzles to the one or more mold cavities, each nozzle having an exit aperture communicating with a gate of a cavity of a mold and being associated with an actuator interconnected to a melt flow controller, the apparatus comprising: a sensor for sensing a selected condition of the melt material through at least one of the nozzles; and, an actuator controller interconnected to each actuator, at least one actuator controller comprising a computer interconnected to the sensor for receiving a signal representative of the selected condition sensed by the sensor, the computer including an algorithm utilizing a value corresponding to a signal received from the sensor as a variable for controlling operation of an actuator for the at least one nozzle.

Abstract: A coinjection molding system for injecting skin and core material into a mold cavity. The system includes a three position actuator for moving a valve pin into a closed position in which neither skin nor core flow is permitted, a middle position in which only skin flow is permitted, and an open position in which skin and core flow is permitted. The actuator includes a first piston slidably mounted in an actuator housing, and a second piston, attached to the valve pin, slidably mounted within the first piston. A shut-off is provided in the manifold for preventing skin flow to a particular nozzle during sequential gating.

Abstract: An injection molding apparatus is provided in which the rate of material flow during an injection cycle is controlled. According to one preferred embodiment, an injection molding apparatus is provided that includes a manifold having an inlet for receiving material from an injection molding machine, at least one injection nozzle coupled to the manifold, an actuator, and a valve pin adapted to reciprocate through the manifold and the injection nozzle, the valve pin having a first end coupled to the actuator, a second end that closes the gate in a forward position, and a control surface intermediate said first and second ends for adjusting a rate of material flow during an injection cycle.