Sequential Injection to Multiple Mold Cavities

A method to perform an injection cycle, comprising:

• clamping a mold system together under a selected clamp force with a clamp device, the mold system having a plurality of mold cavities;
• routing injection fluid via a common distribution channel to one or more first downstream channels, the one or more first downstream channels having respective associated first downstream valves and first gates that deliver injection fluid to a first cavity of the mold system;
• routing injection fluid to one or more second downstream channels having respective associated second downstream valves and second gates that deliver injection fluid to a second cavity of the mold system;
• enabling and disabling flow of injection fluid to the one or more associated first gates via a first upstream valve, wherein enabling flow of injection fluid to the one or more associated first gates includes instructing the first upstream valve to enable flow of injection fluid to the one or more associated first gates at a first selected time;
• enabling and disabling flow of injection fluid to the one or more associated second gates via a second upstream valve wherein enabling flow of injection fluid to the one or more associated second gates includes instructing the second upstream valve to enable flow of injection fluid to the one or more associated second gates at a second selected time that is delayed, subsequent, or sequential in time relative to the first selected time during the injection cycle;
• and
• at least one of the valves having an actuator and a valve pin interconnected to the actuator, wherein the valve pin has a control surface with a selected configuration adapted to cooperate with a selected complementary surface of the respective channel, controlling at least one rate of flow of injection fluid in the respective channel by controlling axial positioning of the control surface of the valve pin relative to the selected complementary surface of the downstream channel.

An injection molding system, comprising:

• a clamp device arranged to clamp a plurality of mold cavities together under a selected clamp force;
• a distribution channel integrated in a distribution manifold and arranged to route injection fluid downstream;
• a plurality of downstream channels fluidly coupled to the distribution channel, the plurality of downstream channels including at least one first downstream channel and at least one second downstream channel;
• first and second gates associated, respectively, with each first and second downstream channel and arranged to pass injection fluid, respectively, to first and second cavities of the plurality of mold cavities;
• first and second downstream valves associated with each of the first and second downstream channels, the first and second downstream valves arranged to control delivery of injection fluid through the respective first and second downstream channels and associated first and second gates;
• first and second upstream valves controllably arranged, respectively, to pass first and second flows of injection fluid, respectively, from the distribution channel to each first and second gate, wherein at least one of the valves has an actuator and a valve pin interconnected to the actuator, wherein the valve pin has a control surface with a selected configuration adapted to cooperate with a selected complementary surface of a respective channel, and wherein at least one rate of flow of injection fluid is controllable by controlling axial positioning of the control surface of the valve pin relative to the selected complementary surface of the respective channel;
• and
• a control system adapted to instruct the first upstream valve to enable the first flow of injection fluid at a first selected time and instruct the second upstream valve to enable the second flow of injection fluid at a second selected time that is delayed, subsequent, or sequential in time relative to the first selected time during an injection cycle.