Injection molding flow control apparatus and method

A method for controlling the rate of flow of a fluid material from an injection molding machine to a gate of a mold cavity during an injection molding process, the method comprising:

• driving, via an actuator interconnected to a valve pin having a tip end, the valve pin upstream along a path of travel between a downstream gate closed position and one or more intermediate upstream gate open positions, the downstream gate closed position being a position wherein the tip end of the valve pin obstructs the gate to prevent fluid material from flowing into the mold cavity, the one or more intermediate upstream gate open positions being predetermined positions between the downstream gate closed position and an end of stroke position upstream of the intermediate upstream gate open positions, wherein the gate is partially open when the valve pin is in the one or more intermediate upstream gate open positions and the gate is more fully open when the valve pin is in the end of stroke position;
• sensing, via a position sensor, the position of the valve pin or the actuator at one or more points along the path of travel,
• controlling, via a controller interconnected to the actuator and to the position sensor, movement of the actuator at least in part according to instructions that instruct the actuator to drive the valve pin:
• upstream at one or more selected intermediate velocities over the course of travel of the valve pin through the one or more intermediate upstream gate open positions in response to receipt by the controller of a signal from the position sensor that the valve pin is disposed in the one or more intermediate upstream gate open positions,
• upstream at a higher upstream velocity than the one or more selected intermediate velocities between the one or more intermediate upstream gate open positions and the end of stroke position in response to receipt by the controller of a signal from the position sensor that the valve pin is disposed in a selected one of the one or more intermediate upstream gate open positions.

An apparatus for controlling the rate of flow of a fluid material from an injection molding machine to a gate of a mold cavity during an injection molding process, the apparatus comprising:

• an actuator interconnected to a valve pin having a tip end, the actuator moving the valve pin upstream along a path of travel between a downstream gate closed position and one or more intermediate upstream gate open positions, the downstream gate closed position being a position wherein a tip end surface of the tip end of the valve pin comprises a cylindrical or tapered configuration and the gate has a complementary cylindrical or tapered surface that mates with the cylindrical or tapered configuration of the tip end surface to close the gate,
• the one or more intermediate upstream gate open positions being predetermined positions between the downstream gate closed position and an end of stroke position upstream of the intermediate upstream gate open positions, wherein the gate is partially open when the valve pin is in the one or more intermediate upstream gate open positions and the gate is more fully open when the valve pin is in the end of stroke position;
• a position sensor that senses position of the valve pin or the actuator,
• a controller interconnected to the actuator and to the position sensor that controls movement of the actuator at least in part according to instructions that instruct the actuator to drive the valve pin:
• upstream at one or more selected intermediate velocities over the course of travel of the valve pin through the one or more intermediate upstream gate open positions in response to receipt by the controller of a signal from the position sensor that the valve pin is disposed in the one or more intermediate upstream gate open positions, and
• upstream at a higher upstream velocity than the one or more selected intermediate velocities between the one or more intermediate upstream gate open positions and the end of stroke position in response to receipt by the controller of a signal from the position sensor that the valve pin is disposed in a selected one of the one or more intermediate upstream gate open positions.

An apparatus (10) for controlling the rate of flow of a fluid material (18, NM) from an injection molding machine to a cavity (30) of a mold, the apparatus comprising:

• a manifold (40) receiving the injected fluid material (18, NM, 100b), the manifold having a delivery channel (19) that delivers the fluid material to first and second gates (32, 34) to the mold cavity;
• first and second actuators (940, 941) interconnected to first and second valve pins respectively (1040, 1041) having a tip end (1142, 155), the second actuator (941) moving the second valve pin (1041) upstream along a path of travel (RP, RP2) between a downstream gate closed position (GC), one or more intermediate upstream gate open positions (COP, COP2) and an end of stroke position at which the fluid material (18, NM, 100b) flows at a selected maximum rate through the gate, the downstream gate closed position being a position wherein the tip end of the valve pin obstructs the gate (32, 34) to prevent fluid material from flowing into the mold cavity, the one or more intermediate upstream gate open positions (COP, COP2) being predetermined positions between the downstream gate closed position (GC) and the end of stroke position (EOS),
• a position sensor (951) that senses position of the second valve pin (1041) or the second actuator (941),
• a controller (16) interconnected to the second actuator (941) and to the position sensor (951) that controls movement of the second actuator at least in part according to instructions that instruct the second actuator (941) to open the second gate (34) after fluid material (100p) injected through the first gate (32) has flowed downstream through the cavity (30) and to drive the second valve pin (1041) upstream at one or more selected intermediate velocities over the course of travel of the second valve pin (1041) through the one or more intermediate upstream gate open positions (COP, COP2) in response to a signal from the position sensor (951) that the second valve pin (1041) is disposed in the one or more intermediate upstream gate open positions and to drive the second valve pin (1041) at a higher velocity than the one or more selected intermediate velocities in response to a signal from the position sensor (951) that the second valve pin is disposed in a predetermined intermediate upstream gate open position (COP, COP2).

An apparatus (10) for controlling the rate of flow of a fluid material (18, NM) from an injection molding machine to a cavity (30) of a mold, the apparatus comprising:

• a manifold (40) receiving the injected fluid material (18, NM, 100b), the manifold having a delivery channel (19) that delivers the fluid material to a gate (32, 34, 36) to the mold cavity (30);
• an actuator (940, 941, 942) interconnected to a valve pin (1040, 1041) having a tip end (1142, 155), the actuator (940, 941, 942) moving the valve pin (1040, 1041, 1042) upstream along a path of travel (RP, RP2) between a downstream gate closed position (GC), one or more intermediate upstream gate open positions (COP, COP2), and an end of stroke position upstream of the intermediate upstream gate open position at which the fluid (18, NM, 100b) flows at a selected maximum rate through the gate, the downstream gate closed position being a position wherein the tip end of the valve pin obstructs the gate (32, 34) to prevent fluid material from flowing into the mold cavity, the one or more intermediate upstream gate open positions (COP, COP2) being predetermined positions between the downstream gate closed position (GC) and the end of stroke position (EOS) wherein the gate (34) is partially open when the valve pin is in the one or more intermediate upstream gate open positions (COP, COP2);
• a position sensor (951) that senses position of the valve pin (1041) or the actuator (941),
• a controller (16) interconnected to the actuator (940, 941) and to the position sensor (941, 942) that controls movement of the actuator at least in part according to instructions that instruct the actuator (940, 941, 942) to drive the valve pin (1041) upstream at one or more selected intermediate velocities over the course of travel of the valve pin (1041) through the one or more intermediate upstream gate open positions (COP, COP2) in response to receipt of a signal from the position sensor (951) that the valve pin (1041) is disposed in the one or more intermediate upstream gate open positions,
• wherein the length of travel between the gate closed position (GC) and one or more selected intermediate upstream gate open positions (COP, COP2) is between about 1 and about 5 mm,
• the valve pin being drivable at a maximum upstream velocity, the one or more selected intermediate velocities being less than the maximum velocity.

An apparatus (10) for controlling the rate of flow of an injection fluid (18, NM, 100p) from an injection molding machine to a cavity (30) of a mold, the apparatus comprising:

• a manifold (40) receiving the injected fluid (18, NM, 100b), the manifold having a delivery channel (19) that delivers the injection fluid to a gate (32, 34, 36) to the mold cavity (30);
• first and second actuators (940, 941) interconnected to first and second valve pins respectively (1040, 1041) having a tip end (1142, 1155) that control delivery of the injection fluid sequentially through first and second gates (32, 34) respectively,
• the second actuator (941) moving the second valve pin (1041) upstream along a path of travel (RP, RP2) between a downstream gate closed position (GC), one or more intermediate upstream gate open positions (COP, COP2) and an end of stroke position at which the injection fluid (18, NM, 100b) flows at a selected maximum rate through the second gate (34), the downstream gate closed position being a position wherein the tip end of the second valve pin (1041) obstructs the second gate (34) to prevent injection fluid from flowing into the mold cavity, the one or more intermediate upstream gate open positions (COP, COP2) being predetermined positions between the downstream gate closed position (GC) and the end of stroke position (EOS) where the second gate (34) is partially open;
• a position sensor (951) that senses position of the second valve pin (1041) or the second actuator (941),
• a controller (16) interconnected to the second actuator (941) and to the position sensor (951) that controls movement of the second actuator (941) at least in part according to instructions that instruct the second actuator (941) to open the second gate (34) after the injection fluid (100p) injected through the first gate (32) has flowed downstream through the cavity (30) and to drive the second valve pin (1041) upstream at one or more selected intermediate velocities over the course of travel of the second valve pin (1041) through the one or more intermediate upstream gate open positions (COP, COP2) in response to receipt by the controller (16) of a signal from the position sensor (951) that the second valve pin (1041) is disposed in the one or more intermediate upstream gate open positions and to drive the second valve pin (1041) at a higher velocity than the one or more selected intermediate velocities in response to receipt of a signal from the position sensor (951) that the second valve pin is disposed in a predetermined intermediate upstream gate open position (COP, COP2),
• the valve pin being drivable at a maximum upstream velocity, the one or more selected intermediate velocities being less than the maximum velocity.

An apparatus for controlling the rate of flow of a fluid material from an injection molding machine to a gate of a mold cavity during an injection molding process, the apparatus comprising:

• an actuator interconnected to a valve pin having a tip end, the actuator moving the valve pin upstream along a path of travel between a downstream gate closed position and one or more intermediate upstream gate open positions, the downstream gate closed position being a position wherein the tip end of the valve pin obstructs the gate to prevent fluid material from flowing into the mold cavity, the one or more intermediate upstream gate open positions being predetermined positions between the downstream gate closed position and an end of stroke position upstream of the intermediate upstream gate open positions, wherein the gate is partially open when the valve pin is in the one or more intermediate upstream gate open positions and the gate is fully open when the valve pin is in the end of stroke position;
• a position sensor that senses position of the valve pin or the actuator,
• a controller interconnected to the actuator and to the position sensor that controls movement of the actuator at least in part according to instructions that instruct the actuator to drive the valve pin:
• upstream at one or more selected intermediate velocities over the course of travel of the valve pin through the one or more intermediate upstream gate open positions in response to receipt by the controller of a signal from the position sensor that the valve pin is disposed in the one or more intermediate upstream gate open positions,
• upstream at a higher upstream velocity than the one or more selected intermediate velocities between the one or more intermediate upstream gate open positions and the end of stroke position,
• wherein the tip end of the valve pin and the gate are adapted to cooperate with each other to restrict rate of flow of the fluid material through the gate over the course of the path of travel of the valve pin from the downstream gate closed position to the one or more intermediate upstream gate open positions, and
• wherein the valve pin is withdrawn at a reduced velocity over more than about 50% of the path of travel of the valve pin from the downstream gate closed position to the one or more intermediate upstream gate open positions.

An apparatus for controlling the rate of flow of a fluid material from an injection molding machine to a gate of a mold cavity during an injection molding process, the apparatus comprising:

• an actuator interconnected to a valve pin having a tip end, the actuator moving the valve pin upstream along a path of travel between a downstream gate closed position and one or more intermediate upstream gate open positions, the downstream gate closed position being a position wherein the tip end of the valve pin obstructs the gate to prevent fluid material from flowing into the mold cavity, the one or more intermediate upstream gate open positions being predetermined positions between the downstream gate closed position and an end of stroke position upstream of the intermediate upstream gate open positions, wherein the gate is partially open when the valve pin is in the one or more intermediate upstream gate open positions and the gate is fully open when the valve pin is in the end of stroke position;
• a position sensor that senses position of the valve pin or the actuator,
• a controller interconnected to the actuator and to the position sensor that controls movement of the actuator at least in part according to instructions that instruct the actuator to drive the valve pin:
• upstream at one or more selected intermediate velocities over the course of travel of the valve pin through the one or more intermediate upstream gate open positions in response to receipt by the controller of a signal from the position sensor that the valve pin is disposed in the one or more intermediate upstream gate open positions,
• upstream at a higher upstream velocity than the one or more selected intermediate velocities between the one or more intermediate upstream gate open positions and the end of stroke position,
• wherein the path of travel of the valve pin from the downstream gate closed position to the one or more intermediate upstream gate open positions is between about 1 and about 8 mm.

An apparatus for controlling the rate of flow of a fluid material from an injection molding machine downstream through a nozzle leading to a gate of a mold cavity during an injection molding process, the apparatus comprising:

• an actuator interconnected to a valve pin having a tip end, the actuator moving the valve pin upstream along a path of travel between a downstream gate closed position and one or more intermediate upstream gate open positions, the downstream gate closed position being a position wherein a tip end surface of the tip end of the valve pin comprises a cylindrical or tapered configuration and the gate has a complementary cylindrical or tapered surface that mates with the cylindrical or tapered configuration of the tip end surface to close the gate into a gate closed position,
• the one or more intermediate upstream gate open positions being predetermined positions between the downstream gate closed position and an end of stroke position upstream of the intermediate upstream gate open positions, wherein a flow restriction gap is formed between outer surfaces of the valve pin and inner surfaces of the nozzle such that flow of fluid material is restricted when the valve pin is in the one or more intermediate upstream gate open positions;
• a position sensor that senses position of the valve pin or the actuator,
• a controller interconnected to the actuator and to the position sensor that controls movement of the actuator at least in part according to instructions that instruct the actuator to drive the valve pin:
• upstream at one or more selected intermediate velocities over the course of travel of the valve pin through the one or more intermediate upstream gate open positions in response to receipt by the controller of a signal from the position sensor that the valve pin is disposed in the one or more intermediate upstream gate open positions, and
• upstream at a higher upstream velocity than the one or more selected intermediate velocities between the one or more intermediate upstream gate open positions and the end of stroke position in response to receipt by the controller of a signal from the position sensor that the valve pin is disposed in a selected one of the one or more intermediate upstream gate open positions.