Patents by Inventor Brian Matthew Burns
Brian Matthew Burns has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
-
Publication number: 20230330906Abstract: A method of detecting and compensating for a non-operational mold cavity in an injection molding apparatus having a plurality of mold cavities and an injection molding screw or ram includes injecting, via the injection molding screw or ram, a molten thermoplastic material into the plurality of mold cavities. The method includes measuring a first process parameter of the injection molding apparatus at a pre-determined time during or after the injecting. The method also includes determining, based on the first process parameter, whether one or more mold cavities of the plurality of mold cavities are non-operational. Then, when it is determined that one or more mold cavities are non-operational, the method includes automatically adjusting the first process parameter or a second process parameter of the injection molding apparatus.Type: ApplicationFiled: June 20, 2023Publication date: October 19, 2023Inventors: Bryler Collins, Brian Matthew Burns, Gene Michael Altonen, Brandon Michael Birchmeier, Matthew Craver
-
Patent number: 11766818Abstract: Systems and approaches for controlling an injection molding machine and a mold forming a mold cavity and being controlled according to an injection cycle. The systems and methods include analyzing a model of at least one of the injection molding machine, the mold, and a molten material to determine initial values for one or more control parameters of the injection molding machine, and executing a run of injection cycles at the injection molding machine; measuring operation of the injection molding machine during a particular injection cycle of the run of injection cycles; determining one or more operational parameters exceed a threshold; and upon determining that the one or more operational parameters exceed the threshold, adjusting the one or more control parameters for subsequent injection cycles of the run of injection cycles.Type: GrantFiled: March 31, 2023Date of Patent: September 26, 2023Assignee: IMFLUX INC.Inventors: Brian Matthew Burns, Gene Michael Altonen
-
Patent number: 11718008Abstract: A method of detecting and compensating for a non-operational mold cavity in an injection molding apparatus having a plurality of mold cavities and an injection molding screw or ram includes injecting, via the injection molding screw or ram, a molten thermoplastic material into the plurality of mold cavities. The method includes measuring a first process parameter of the injection molding apparatus at a pre-determined time during or after the injecting. The method also includes determining, based on the first process parameter, whether one or more mold cavities of the plurality of mold cavities are non-operational. Then, when it is determined that one or more mold cavities are non-operational, the method includes automatically adjusting the first process parameter or a second process parameter of the injection molding apparatus.Type: GrantFiled: May 19, 2021Date of Patent: August 8, 2023Assignee: IMFLUX INC.Inventors: Bryler Collins, Brian Matthew Burns, Gene Michael Altonen, Brandon Michael Birchmeier, Matthew Craver
-
Publication number: 20230234272Abstract: Systems and approaches for controlling an injection molding machine and a mold forming a mold cavity and being controlled according to an injection cycle. The systems and methods include analyzing a model of at least one of the injection molding machine, the mold, and a molten material to determine initial values for one or more control parameters of the injection molding machine, and executing a run of injection cycles at the injection molding machine; measuring operation of the injection molding machine during a particular injection cycle of the run of injection cycles; determining one or more operational parameters exceed a threshold; and upon determining that the one or more operational parameters exceed the threshold, adjusting the one or more control parameters for subsequent injection cycles of the run of injection cycles.Type: ApplicationFiled: March 31, 2023Publication date: July 27, 2023Inventors: Brian Matthew Burns, Gene Michael Altonen
-
Patent number: 11642823Abstract: Systems and approaches for controlling an injection molding machine and a mold forming a mold cavity and being controlled according to an injection cycle. The systems and methods include analyzing a model of at least one of the injection molding machine, the mold, and a molten material to determine initial values for one or more control parameters of the injection molding machine, and executing a run of injection cycles at the injection molding machine; measuring operation of the injection molding machine during a particular injection cycle of the run of injection cycles; determining one or more operational parameters exceed a threshold; and upon determining that the one or more operational parameters exceed the threshold, adjusting the one or more control parameters for subsequent injection cycles of the run of injection cycles.Type: GrantFiled: December 7, 2021Date of Patent: May 9, 2023Assignee: IMFLUX INC.Inventors: Brian Matthew Burns, Gene Michael Altonen
-
Publication number: 20230041317Abstract: Systems and approaches for controlling an injection molding machine having a first configuration and a mold forming a mold cavity and being controlled according to an injection cycle include obtaining a pattern for a portion of an injection cycle of an injection molding machine having a second configuration and operating the injection molding machine having the first configuration to inject a molten material into the mold cavity. While operating the injection molding machine having the first configuration, the obtained pattern is used to control a portion of the injection cycle.Type: ApplicationFiled: October 20, 2022Publication date: February 9, 2023Inventors: Bryler Collins, Ethan David Stiefel, Gene Michael Altonen, Brandon Michael Birchmeier, Brian Matthew Burns
-
Publication number: 20230031650Abstract: Systems and approaches for controlling an injection molding machine having a mold forming a mold cavity and being controlled according to an injection cycle include obtaining a pattern for the injection cycle, operating the injection molding machine to inject a molten material into the mold cavity , and measuring a cavity pressure value of the mold cavity during the mold cycle. Upon measuring a nominal cavity pressure value, a pattern recognition portion of the injection cycle that is at least partially dependent on the obtained pattern commences where a driving force being exerted on the molten material is adjusted such that the measured cavity pressure matches the obtained pattern for the injection cycle.Type: ApplicationFiled: October 5, 2022Publication date: February 2, 2023Inventors: Ethan David Stiefel, Bryler Collins, Gene Michael Altonen, Brian Matthew Burns, Brandon Michael Birchmeier
-
Patent number: 11498253Abstract: Systems and approaches for controlling an injection molding machine having a first configuration and a mold forming a mold cavity and being controlled according to an injection cycle include obtaining a pattern for a portion of an injection cycle of an injection molding machine having a second configuration and operating the injection molding machine having the first configuration to inject a molten material into the mold cavity. While operating the injection molding machine having the first configuration, the obtained pattern is used to control a portion of the injection cycle.Type: GrantFiled: June 11, 2019Date of Patent: November 15, 2022Assignee: IMFLUX INC.Inventors: Bryler Collins, Ethan David Stiefel, Gene Michael Altonen, Brandon Michael Birchmeier, Brian Matthew Burns
-
Patent number: 11491694Abstract: Systems and approaches for controlling an injection molding machine having a mold forming a mold cavity and being controlled according to an injection cycle include obtaining a pattern for the injection cycle, operating the injection molding machine to inject a molten material into the mold cavity, and measuring a cavity pressure value of the mold cavity during the mold cycle. Upon measuring a nominal cavity pressure value, a pattern recognition portion of the injection cycle that is at least partially dependent on the obtained pattern commences where a driving force being exerted on the molten material is adjusted such that the measured cavity pressure matches the obtained pattern for the injection cycle.Type: GrantFiled: June 11, 2019Date of Patent: November 8, 2022Assignee: IMFLUX INC.Inventors: Ethan David Stiefel, Bryler Collins, Gene Michael Altonen, Brian Matthew Burns, Brandon Michael Birchmeier
-
Publication number: 20220332029Abstract: In order to reduce oscillations in process variables of an injection molding process, an injection molding machine may be operatively connected to a model database that stores models of injection molding machines and molds. A tuning controller may set initial gain values of a variable-gain proportional-integral-derivative (PID) controller. To set the initial gains, the tuning controller may be configured to obtain, from the model database, a model for a first and second injection molding machines and a model for a mold. The tuning controller may analyze the models to determine a correlation between injection molding machine parameters and mold cycle performance for the mold. Accordingly, the tuning controller may apply the correlation to determine an initial gain value for a least one of the first, second, and third gains of the PID controller. The tuning controller may then set the initial gain values for the PID controller.Type: ApplicationFiled: July 1, 2022Publication date: October 20, 2022Inventors: Gene Michael Altonen, Brian Matthew Burns
-
Patent number: 11440230Abstract: A method of determining melt flow front travel in a molding apparatus includes setting a sensor threshold, receiving a sensor amount as an output from a sensor monitoring a nozzle of the molding apparatus, and determining that the sensor amount exceeds the sensor threshold. The method further includes receiving a screw location, calculating a travel distance of the screw from the screw location, and calculating melt flow front travel based on the travel distance of the screw. The method further includes receiving, via an interface, an operator generated value for the desired melt flow front travel to be reached, and sending, via an interface, an analog or digital output after the operator generated value has been reached. A method of detecting a leaking condition of a check valve is also included.Type: GrantFiled: March 26, 2019Date of Patent: September 13, 2022Assignee: IMFLUX INC.Inventors: William Francis Lawless, III, Brandon Michael Birchmeier, Brian Matthew Burns, Gene Michael Altonen, Ethan David Stiefel, Bryler Collins
-
Publication number: 20220266493Abstract: In order to improve the consistency of molded products as viscosity shifts throughout a run, a controller of an injection molding machine executes a calibration cycle in accordance with a mold cycle. The controller analyzes a plurality of sensed melt pressure values during the calibration cycle to determine one or more calibration metrics. The controller then uses the calibration metrics when executing each mold cycle of the run. More particularly, during each mold cycle of the run, the controller detects a plurality of sensed melt pressures prior to and during a fill phase of the mold cycle and compares the plurality of sensed melt pressures to the one or more calibration metrics to predict cavity pressure for a pack and hold phase of the mold cycle. The controller then adjusts a set point pressure for the pack and hold phase based on the predicted cavity pressure.Type: ApplicationFiled: May 11, 2022Publication date: August 25, 2022Inventors: Bryler Collins, Gene Michael Altonen, Chow-Chi Huang, Brandon Michael Birchmeier, Brian Matthew Burns
-
Patent number: 11407158Abstract: In order to reduce oscillations in process variables of an injection molding process, an injection molding machine may be operatively connected to a model database that stores models of injection molding machines and molds. A tuning controller may set initial gain values of a variable-gain proportional-integral-derivative (PID) controller. To set the initial gains, the tuning controller may be configured to obtain, from the model database, a model for a first and second injection molding machines and a model for a mold. The tuning controller may analyze the models to determine a correlation between injection molding machine parameters and mold cycle performance for the mold. Accordingly, the tuning controller may apply the correlation to determine an initial gain value for a least one of the first, second, and third gains of the PID controller. The tuning controller may then set the initial gain values for the PID controller.Type: GrantFiled: September 6, 2018Date of Patent: August 9, 2022Assignee: IMFLUX INC.Inventors: Gene Michael Altonen, Brian Matthew Burns
-
Patent number: 11358317Abstract: In order to improve the consistency of molded products as viscosity shifts throughout a run, a controller of an injection molding machine executes a calibration cycle in accordance with a mold cycle. The controller analyzes a plurality of sensed melt pressure values during the calibration cycle to determine one or more calibration metrics. The controller then uses the calibration metrics when executing each mold cycle of the run. More particularly, during each mold cycle of the run, the controller detects a plurality of sensed melt pressures prior to and during a fill phase of the mold cycle and compares the plurality of sensed melt pressures to the one or more calibration metrics to predict cavity pressure for a pack and hold phase of the mold cycle. The controller then adjusts a set point pressure for the pack and hold phase based on the predicted cavity pressure.Type: GrantFiled: May 2, 2019Date of Patent: June 14, 2022Assignee: IMFLUX INC.Inventors: Bryler Collins, Gene Michael Altonen, Chow-Chi Huang, Brandon Michael Birchmeier, Brian Matthew Burns
-
Publication number: 20220097273Abstract: Systems and approaches for controlling an injection molding machine and a mold forming a mold cavity and being controlled according to an injection cycle. The systems and methods include analyzing a model of at least one of the injection molding machine, the mold, and a molten material to determine initial values for one or more control parameters of the injection molding machine, and executing a run of injection cycles at the injection molding machine; measuring operation of the injection molding machine during a particular injection cycle of the run of injection cycles; determining one or more operational parameters exceed a threshold; and upon determining that the one or more operational parameters exceed the threshold, adjusting the one or more control parameters for subsequent injection cycles of the run of injection cycles.Type: ApplicationFiled: December 7, 2021Publication date: March 31, 2022Inventors: Brian Matthew Burns, Gene Michael Altonen
-
Patent number: 11241813Abstract: In order to reduce oscillations in process variables of an injection molding process, a variable-gain proportional-integral-derivative (PID) controller is utilized to control one or more of the process variables. The injection molding system may also include a tuning controller to automatically tune at least one of the proportional, integral, or derivative gains within a mold cycle. The tuning controller may obtain sensor data that monitors the operation of the injection molding machine to determine an adjustment to at least one of the proportional, integral, or derivative gains. The tuning controller may adjust the gains of the variable-gain PID controller in accordance with the determined adjustment to the at least one of the proportional, integral, or derivative gains.Type: GrantFiled: September 6, 2018Date of Patent: February 8, 2022Assignee: IMFLUX INC.Inventors: Gene Michael Altonen, Brian Matthew Burns
-
Patent number: 11225006Abstract: Systems and approaches for controlling an injection molding machine and a mold forming a mold cavity and being controlled according to an injection cycle. The systems and methods include analyzing a model of at least one of the injection molding machine, the mold, and a molten material to determine initial values for one or more control parameters of the injection molding machine, and executing a run of injection cycles at the injection molding machine; measuring operation of the injection molding machine during a particular injection cycle of the run of injection cycles; determining one or more operational parameters exceed a threshold; and upon determining that the one or more operational parameters exceed the threshold, adjusting the one or more control parameters for subsequent injection cycles of the run of injection cycles.Type: GrantFiled: June 5, 2019Date of Patent: January 18, 2022Assignee: IMFLUX INC.Inventors: Brian Matthew Burns, Gene Michael Altonen
-
Publication number: 20210387390Abstract: Systems and approaches for controlling an injection molding machine having a mold forming a mold cavity include feeding a molten polymer into a barrel containing a screw disposed in a first position, advancing the screw a first instance, from the first position to a second position, to inject the molten polymer into the mold cavity to form a molded part, and ejecting a first molded part or a first set of molded parts from the mold cavity. Further, the screw is advanced a second instance, from the second position to a third position, to inject the molten polymer into the mold cavity to form an additional molded part. A second molded part or a second set of molded parts is ejected from the mold cavity. After the second advancing instance, a recovery profile is commenced in which the screw is returned to the first position.Type: ApplicationFiled: May 21, 2021Publication date: December 16, 2021Inventors: Brandon Michael Birchmeier, Brian Matthew Burns, Gene Michael Altonen, William Francis Lawless, III
-
Publication number: 20210387391Abstract: Systems and approaches for controlling an injection molding machine having a mold forming a mold cavity and being controlled according to an injection cycle include injecting a molten polymer into the mold cavity according to a startup profile. A first sensor is used to measure at least one variable during the startup profile. The startup profile is terminated upon the at least one variable exceeding a first threshold. The molten polymer is then injected into the mold cavity according to a primary injection profile.Type: ApplicationFiled: May 21, 2021Publication date: December 16, 2021Inventors: Brandon Michael Birchmeier, Brian Matthew Burns, Gene Michael Altonen
-
Publication number: 20210387393Abstract: A method of detecting and compensating for a non-operational mold cavity in an injection molding apparatus having a plurality of mold cavities and an injection molding screw or ram includes injecting, via the injection molding screw or ram, a molten thermoplastic material into the plurality of mold cavities. The method includes measuring a first process parameter of the injection molding apparatus at a pre-determined time during or after the injecting. The method also includes determining, based on the first process parameter, whether one or more mold cavities of the plurality of mold cavities are non-operational. Then, when it is determined that one or more mold cavities are non-operational, the method includes automatically adjusting the first process parameter or a second process parameter of the injection molding apparatus.Type: ApplicationFiled: May 19, 2021Publication date: December 16, 2021Inventors: Bryler Collins, Brian Matthew Burns, Gene Michael Altonen, Brandon Michael Birchmeier, Matthew Craver