Abstract: An apparatus suitable for extruding curable polymers for forming elastomer articles using additive manufacturing, and curable fluorine-containing polymer compositions suitable for use in such an apparatus are disclosed along with an additive manufacturing method for forming a fluorine-containing elastomer article including providing a filament formed of a curable fluoropolymer composition; providing an additive manufacturing printer having a drive mechanism and a printer nozzle; feeding the filament into an additive manufacturing printer through the drive mechanism and through a longitudinal passage defined by an interior wall of a support tube, wherein the support tube extends from a first end to a second end, and wherein the second end of the support tube is positioned near an inlet to a printer nozzle; applying heat to the filament; and printing successive layers of the heated filament exiting an outlet of the nozzle onto a substrate using the additive manufacturing printer to form the fluorine-containing

Abstract: A method for use in forming a molded part includes providing a mold having a cavity and a movable pin, injecting a moldable material into the cavity, biasing the movable pin to maintain an end of the movable pin in contact with the moldable material in the cavity during the curing of the moldable material and until the moldable material is cured, and monitoring movement of the biased movable pin during curing of the moldable material in the mold. Also disclosed is a sensor engageable with an end of a movable pin of a mold for monitoring the forming of a moldable part, and systems employing the same.

Abstract: Apparatus and methods for self-alignment and assembly of objects with micron-level and/or nanometer-level alignment accuracy. Mating alignment features spanning multiple length scales are disposed at surfaces of objects to be brought into contact. When the objects are pressed together, the alignment features guide alignment of the objects with respect to each other. The alignment features may provide retaining forces to hold the objects together. Micron-level and nanometer-level alignment accuracies may be achieved over large surface areas.

Abstract: A method for use in forming a molded part includes providing a mold having a cavity and a movable pin, injecting a moldable material into the cavity, biasing the movable pin to maintain an end of the movable pin in contact with the moldable material in the cavity during the curing of the moldable material and until the moldable material is cured, and monitoring movement of the biased movable pin during curing of the moldable material in the mold. Also disclosed is a sensor engageable with an end of a movable pin of a mold for monitoring the forming of a moldable part, and systems employing the same.

Abstract: A computer-implemented decision support system provides a performance-based representation using multi-dimensional clipping and transformation algorithms. Three types of supporting information are presented to the decision maker: a function matrix that describes the performance attributes varying with the decision variables; a decision space that illustrates the feasible decision set that meets performance requirements; and, a performance space that provides the feasible performance region displays the Pareto Optimal set.

Abstract: Methods and devices are provided for controlling melt pressure in an apparatus that processes molten material. In one exemplary embodiment, the methods and devices utilize a self-regulating valve that is effective to regulate a melt pressure through a melt flow channel. In particular, the valve can be adapted to maintain an equilibrium between a control force applied to a control member and a dynamic force applied to the control member by the melt pressure of a melt flowing through a melt flow channel.

Abstract: Injection molding apparati, systems and methods are provided for limiting forward valve pin movement during flow control. According to one embodiment, an injection molding apparatus is provided that includes an actuator, and a valve pin coupled to the actuator. The valve pin is adapted to open and close a gate to a mold, and to control a rate of material flow through the gate during an injection cycle. The actuator is further adapted to control the valve pin in a first range of movement in which the valve pin is adapted to control the rate of material flow and cannot close the gate, and to control the valve pin in a second range of movement which includes the valve pin closing the gate.

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: 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: 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: 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 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 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 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: 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 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: 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: Injection molding apparati, systems and methods are provided for limiting forward valve pin movement during flow control. According to one embodiment, an injection molding apparatus is provided that includes an actuator, and a valve pin coupled to the actuator. The valve pin is adapted to open and close a gate to a mold, and to control a rate of material flow through the gate during an 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.