Manifold system having flow control

In an injection molding system having a manifold for injecting material through first and second gates into one or more mold cavities, and a controller for controlling the flow rate of material injected through the first and second gates during an injection cycle according to first and second target profiles, respectively, wherein the first and second target profiles represent a desired value of first and second sensed conditions related to the flow rate of material injected through the first and second gates during an injection cycle, respectively, a method for creating at least the first target profile, the method comprising the steps of:

• (A) selecting a test first target profile to be executed by the controller;
• (B) injecting material through the first gate into a cavity according to the test first target profile executed by the controller;
• and
• (C) determining whether the material injected in step (B) produces an acceptable molded part in the cavity.

In an injection molding system having a manifold for injecting material through a first gate into a first mold cavity, and a controller for controlling the flow rate of material injected through the first gate during an injection cycle according to a first target pressure profile by comparing a target pressure to an actual pressure during the injection cycle, wherein the first target pressure profile represents a target value of the pressure exerted by the material injected through the first gate during the injection cycle, a method for creating the first target pressure profile comprising the steps of:

• (A) selecting a value of a variable corresponding to target injection pressure of the injected material;
• (B) selecting a value of a variable corresponding to target pack pressure of the injected material;
• and
• (C) selecting a value of a variable corresponding to a duration of the injection cycle.

An injection molding apparatus comprising:

• a manifold for directing material through first and second gates into one or more mold cavities;
• a controller to independently control a flow rate of material injected into through the first and second gates during an injection cycle according to a first target profile associated with the material injected through the first gate and a second target profile associated with material injected through the second gate, wherein the first target profile represents target values of a first sensed condition related to the flow rate of material injected through the first gate during the injection cycle and the second target profile represents target values of a second sensed condition related to the flow rate of material injected through the second gate during the injection cycle;
• and
• a graphical user interface for displaying at least the first target profile.

An injection molding apparatus comprising:

• a manifold to direct material to first and second gates into one or more mold cavities, the manifold including first and second wells associated with each gate;
• a first ram to force material from the first well through the first gate;
• a second ram to force material from the second well through the second gate;
• and
• a controller to independently control first and second rates at which the first and second rams force material through the first and second gates and into the one or more mold cavities during an injection cycle.

An injection molding apparatus comprising:

• a manifold to direct material into a mold cavity;
• a valve pin adapted to reciprocate through the manifold toward and away from the mold cavity, wherein valve pin contacts material injected into the mold cavity;
• and
• a controller to control a flow rate of material injected into the first cavity during an injection cycle based on a force exerted on the valve pin by the material.

In an injection molding system apparatus having 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 having a first end coupled to the actuator, and a second end that closes the gate, a method having the steps of:

• (A) prior to the beginning of an injection cycle, placing the valve pin in a rearward position;
• (B) moving the valve pin forward from the rearward position at the beginning of the injection cycle toward the gate to an intermediate position in which material flow is permitted;
• and
• (C) moving the valve pin further toward the gate from the intermediate position to close the gate at the end of the injection cycle.

In an injection molding system having a manifold to direct material to first and second gates which lead to one or more mold cavities, the first and second gates having first and second valve pins associated therewith, the method comprising the steps of:

• (A) injecting material into the manifold;
• (B) determining a first force exerted by the material on the first valve pin, and a second force exerted by the material on the second valve pin, respectively;
• and
• (C) independently controlling the rate at which the material is injected through each of the first and second gates into the one or more mold cavities based on the first and second forces, respectively.

In an injection molding system having a manifold to direct material to first and second gates which lead to one or more mold cavities, the method comprising the steps of:

• (A) injecting material into the manifold;
• (B) controlling in the manifold a first rate at which material is injected through the first gate into the one or more mold cavities based on a first pressure sensed in the one or more cavities;
• and
• (C) controlling in the manifold a second rate at which material is injected through the second gate into the one or more mold cavities based on a second pressure sensed in the one or more cavities.