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US20180147762A1 - Injection Molding Apparatus and Method of Use - Google Patents

Injection Molding Apparatus and Method of Use Download PDF

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Publication number
US20180147762A1
US20180147762A1 US15/495,367 US201715495367A US2018147762A1 US 20180147762 A1 US20180147762 A1 US 20180147762A1 US 201715495367 A US201715495367 A US 201715495367A US 2018147762 A1 US2018147762 A1 US 2018147762A1
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United States
Prior art keywords
valve
gate pin
injection molding
injection mold
mold
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US15/495,367
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English (en)
Inventor
Robert Folaron
Scott Sando
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Universal Smart Inc
Original Assignee
Universal Smart Inc
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Filing date
Publication date
Application filed by Universal Smart Inc filed Critical Universal Smart Inc
Priority to US15/495,367 priority Critical patent/US20180147762A1/en
Assigned to SMART NANOS, LLC reassignment SMART NANOS, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SANDO, Scott
Assigned to SMART NANOS, LLC reassignment SMART NANOS, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: FOLARON, ROBERT
Assigned to UNIVERSAL SMART INC. reassignment UNIVERSAL SMART INC. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: SMART NANOS, LLC
Publication of US20180147762A1 publication Critical patent/US20180147762A1/en
Priority to US16/572,967 priority patent/US10843393B2/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/03—Injection moulding apparatus
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14065—Positioning or centering articles in the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/16—Making multilayered or multicoloured articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/1703—Introducing an auxiliary fluid into the mould
    • B29C45/1734—Nozzles therefor
    • B29C45/1735—Nozzles for introducing the fluid through the mould gate, e.g. incorporated in the injection nozzle
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/27—Sprue channels ; Runner channels or runner nozzles
    • B29C45/28—Closure devices therefor
    • B29C45/2806—Closure devices therefor consisting of needle valve systems
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/27—Sprue channels ; Runner channels or runner nozzles
    • B29C45/28—Closure devices therefor
    • B29C45/2896—Closure devices therefor extending in or through the mould cavity, e.g. valves mounted opposite the sprue channel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/40—Removing or ejecting moulded articles
    • B29C45/4005—Ejector constructions; Ejector operating mechanisms
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/76—Measuring, controlling or regulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14065—Positioning or centering articles in the mould
    • B29C2045/14139—Positioning or centering articles in the mould positioning inserts having a part extending into a positioning cavity outside the mould cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/27—Sprue channels ; Runner channels or runner nozzles
    • B29C45/28—Closure devices therefor
    • B29C45/2806—Closure devices therefor consisting of needle valve systems
    • B29C2045/2872—Closure devices therefor consisting of needle valve systems with at least three positions, e.g. two different open positions to control the melt flow
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/40—Removing or ejecting moulded articles
    • B29C2045/4094—Ejectors located on the fixed mould half
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
    • B29C2945/76—Measuring, controlling or regulating
    • B29C2945/76494—Controlled parameter
    • B29C2945/76568—Position
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/26—Moulds
    • B29C45/34—Moulds having venting means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0094—Geometrical properties

Definitions

  • the present invention relates to an apparatus and process to decrease maintenance and increase process efficiency surrounding injection molding.
  • the field of injection molding surrounds a manufacturing process for producing parts by injecting material into a mold having at least two adjoining portions creating a specifically designed cavity resembling the form of the desired part to be made.
  • a mold is manufactured from any suitable material, usually metals, and machined to form the features of the desired part. This mold is usually affixed to an injection molding machine which uses the mold to produce the part as designed.
  • the injection molding process typically fills the cavity with a liquefied material which is then cooled, cured, and solidified to produce the part as designed.
  • An injection mold typically has two or more parts.
  • a first side sometimes referred to as the A-side, is the side from which the material is typically injected through an injector or valve-pin and into the cavity of the mold.
  • the second side sometimes referred to as the B-side, typically retains the part when the mold is open after the material injection process.
  • a typical injection molding process involves a series of steps.
  • a first step of clamping secures the first side to the second side in a manner that aligns the cavity of the A-side with the cavity of the B-side in preparation for the following steps.
  • an injecting step involves the preparation and delivery of material under pressure into the cavity of the mold.
  • the material for injection is initially fed into a heating chamber prior to being forced into the cavity.
  • Material is delivered into the cavity through a flow control system, often through a valve-gate system, such as disclosed by U.S. Pat. No. 5,948,450 to Swenson et al., the entirety of which is herein incorporated by reference.
  • valve-gate systems are configured with a valve-pin that opens/closes flush with the outer boundary of the mold cavity to prevent interference with part molding.
  • a vent is commonly used to allow the equalization of gasses to be purged from the cavity.
  • a dwelling step involves a pause in the injection process. During the dwelling step, maintaining the material motionless under pressure, ensures that all voids of the cavity are filled with the injected material.
  • a cooling step then allows the material to cool and harden to the configuration of the mold cavity.
  • the mold is then opened and the part removed. In many scenarios, an additional step of removing the part from the opened mold is required. Part removal is often performed by a machine attendant or using a mechanism referred to as an ejector pin or knock-out pin.
  • Ejector pins as used in the injection molding industry, provide the functionality of ejecting or removing molded parts from a mold without the direct physical involvement of a machine operator or attendant.
  • Ejector pins have linear or rotational actuation functionality and are typically installed in the second side, or B-side, of the mold.
  • the ejector pins When the mold is opened during the opening step, the ejector pins are actuated to extend the ejector pins outward from behind the molded part. The actuation of the ejector pins pushes the part away from the mold which releases the part and allows it to fall away from the mold.
  • ejector pins decreases the need for mold maintenance and decreases injection molding machine downtime.
  • the elimination of ejector-pins also serves to allow the manufacture of injection molds from alternative materials from traditionally used steel, and eliminates injection mold complexity amongst other advantages.
  • Certain embodiments of the invention provide functionality for the mechanical extraction of a molded part from an injection mold while eliminating the need for ejector pins.
  • the elimination of ejector pins serves to reduce mold preparation cost and decreases mold maintenance frequency.
  • a valve-gate pin is installed on a first side of the mold with a distal portion of the valve-gate pin protruding into the cavity of the mold cavity.
  • the valve-gate pin provides both the functionality of controlling flow of the liquefied material into the cavity of the mold as well as extracting the part from the mold.
  • the part forms and solidifies around the protruding portion of the valve-gate pin, thereby affixing the part to the protruding portion of the valve-gate pin.
  • the part When the mold is opened, the part is pulled away from the second side of the mold by the connection of the part to the valve-gate pin, thus essentially retaining the part in the first side of the mold. Once the connection between the part and the valve-gate pin is broken, the part may be removed. The valve-gate pin may be further actuated to retract or extend, to provide self-release of the part from the valve-gate pin.
  • the apparatus and method of use surrounding the invention may be used for pre-existing injection molding tools that use valve-gate pins to control the flow of liquid material into the mold cavity.
  • Valve-gate pins of existing molds may be replaced with multi-functional valve-gate pins for the delivery of molding material and to extract the molded part from a mold, eliminating the need for ejection pins.
  • the present invention surrounds an apparatus and method for the improvement of the field of injection molding through the elimination of ejection pins by using valve-gate pins.
  • Valve-gate pins as discussed herein provide the functionality of controlling the injection of material into a cavity of a mold through an aperture as well as extracting the part from the mold.
  • Certain embodiments of the invention allow the capability to precisely and repeatedly control the position, speed and flow aperture characteristics of a valve-gate pin.
  • the precise control of the position of a valve-gate pin surrounding extension and retraction allows the finite control and adjustability of the location of the valve-gate pin throughout the injection molding process.
  • the adjustment of flow aperture characteristics of the valve-gate pin allows for optimization of flow characteristics for the parts being made after the injection mold has been manufactured.
  • the valve-gate pin may be used to influence the speed and flow characteristics of the material entering the mold cavity, affecting part formation and effectiveness of the valve-gate pin to develop a desired connection to the molded part.
  • a valve-gate pin as described in the present application further comprise pathway through the length or partial length of the valve-gate pin, typically consistent with a central axis of the valve-gate pin.
  • the pathway provides the ability to inject or push a fluid, or other material, into the cavity within the injection mold.
  • gas-assist injection molding such as disclosed by U.S. Pat. No. 6,019,918 to Guergov, the entirety of which is herein incorporated by reference.
  • Such a pathway may also be used for gas ejection of a part such as disclosed in U.S. Pat. No. 4,653,997 to Sheffield et al., the entirety of which is herein incorporated by reference.
  • a part may still be retained by a first side of an injection mold after the retraction of a valve-gate pin.
  • it may be further desired to extend the valve-gate pin such that it once again protrudes into the injection mold cavity.
  • the extension of the valve-gate pin following retraction serves to push the part away from the first side of the mold and release the part from the mold.
  • the extension of the valve-gate pin following retraction may also serve to re-seal the part if additional fluids are injected through the valve-gate pin.
  • the protruding portion of the valve-gate pin comprise a retention feature.
  • Certain embodiments of a valve-gate pin comprise a retention feature having an undercut around the perimeter of the protruding portion of the valve-gate pin. An undercut in this situation provides increased connection strength between the part and the valve-gate pin following part molding.
  • the retention feature of a valve-gate pin may comprise any form, dimension, depth or profile. In certain embodiments, it may be desired to have a plurality of undercuts in the protruding portion of the valve-gate pin.
  • a retention feature as disclosed herein may comprise any form or feature known to those skilled in the art to provide an increased connection strength between a part and a valve-gate pin, including but not limited to, annular undercut features, helical undercut features, threaded features. Certain embodiments of a valve-gate pin comprise retention features that exceed a diameter of a portion of the valve-gate pin which protrudes into the cavity of an injection mold.
  • the configuration of a retention feature of a valve-gate pin depends upon the part for molding as well as the material used in the injection molding of the part.
  • Mold shrinkage is the phenomenon where the volume of the flowable material filled inside the cavity of a mold shrinks at the same time as being cooled and solidifying.
  • the extent of this shrinkage is commonly referred to as a molding shrinkage factor.
  • the value of the molding shrinkage factor is generally a number in the range of about 0.02% to 2%. It will be appreciated by those skilled in the art that the molding shrinkage associated with a given injection mold and part is affected by type of molding material, internal surface temperature of the injection mold.
  • a retention feature comprises an undercut
  • a retention feature comprises threaded features
  • inventive concept surrounding an injection molding apparatus having a valve-gate pin may be used in injection molding applications as well as known to be applicable by those skilled in the art. Furthermore, it will be appreciated that the inventive concept as disclosed may be used individually in applications, as a plurality of units controlled independently within a system, or a plurality of units controlled in concert within a system. Such control may be performed in an automotive manner such as disclosed by U.S. Pat. No. 5,316,707 to Stanciu et al., herein incorporated by reference in its entirety.
  • a system in which a plurality of valve-gate pins is used may comprise an injection mold having a cavity, an injection mold having a plurality of cavities, or a plurality of injection molds.
  • valve-gate pin as discussed herein, such as retention features, and a pathway, may be used independently in concert while remaining in-line with the inventive concepts as discussed herein.
  • certain valve-gate pins may be used for the purposes of part retention and part extraction, while other valve-gate pins are used to control the flow of material into an injection mold for an injection molding process.
  • FIG. 1A A cross-sectional view of an embodiment of an injection molding apparatus
  • FIG. 1B A cross-sectional detail view of an embodiment of an injection molding apparatus
  • FIG. 2 A perspective view of an embodiment of a valve-gate pin
  • FIG. 3A A cross-sectional detail view of an embodiment of an injection molding apparatus with a valve-gate pin in an open position
  • FIG. 3B A cross-sectional detail view of an embodiment of an injection molding apparatus with a valve-gate pin in a closed position
  • FIG. 4 A cross-sectional view of an embodiment of an injection molding apparatus with a first-side of an injection mold separated from a second side of an injection mold
  • FIG. 5 A cross-sectional view of an embodiment of an injection molding apparatus with a first-side of an injection mold separated from a second side of an injection mold
  • FIG. 6A A detailed view of an embodiment of a valve-gate pin showing an embodiment of a retention feature
  • FIG. 6B A detailed view of an embodiment of a valve-gate pin showing an embodiment of a retention feature
  • FIG. 6C A detailed view of an embodiment of a valve-gate pin showing an embodiment of a retention feature
  • FIG. 6D A detailed view of an embodiment of a valve-gate pin showing an embodiment of a retention feature
  • FIG. 7 A cross-sectional view of an embodiment of an injection molding apparatus with a first-side of an injection mold separated from a second side of an injection mold
  • FIG. 8 A cross-sectional view of an embodiment of an injection molding apparatus
  • FIG. 9 An embodiment of an injection molding method
  • FIG. 10 An embodiment of an injection molding method
  • FIG. 1A and FIG. 1B surrounds an injection molding apparatus 1000 comprising a valve-gate pin 1005 installed on a first side 1010 of an injection mold 1020 .
  • the valve-gate pin 1005 having a shaft 1025 , further comprises a first end 1030 for protruding into a cavity 1040 defined by a first side 1010 and a second side 1050 of the injection mold, with the second side having a vent mechanism 1052 .
  • the first end 1030 of the valve-gate pin comprises a retention feature 1060 .
  • the retention feature 1060 comprises a first dimension 1070 and a second dimension 1080 .
  • the first dimension, proximate to the first end 1030 of the valve-gate pin, is larger than the second dimension 1080 . Due to the retention feature 1060 , when a part 1090 forms in the injection mold 1020 , a connection is formed between the first end 1030 of the valve-gate pin and the part 1090 . Although a retention feature 1060 is typically consistent with the first end 1030 of the valve-gate pin, it will be appreciated that a retention feature 1060 may be offset from the first end 1030 of the valve-gate pin.
  • the valve-gate pin 1005 traverses through a material delivery chamber 1095 , through which material passes for the injection into the cavity 1040 of the injection mold.
  • the valve-gate pin 1005 protrudes into the cavity 1040 through an aperture 1055 extending between the material delivery chamber 1095 and the cavity 1040 .
  • a valve-gate pin 1005 as shown in FIG. 1A and FIG. 1B , and disclosed herein, may comprise a material composition of metal, composite materials such as nano-particle enhanced composites, plastics or other materials appreciated by those skilled in the art.
  • valve-gate pin 1005 for example shown in FIG. 2 , comprise a first end 1030 with a retention feature 1060 .
  • the valve-gate pin 1005 comprises a round profile having a plurality of diameters.
  • the retention feature comprises a first diameter 1100 consistent with the first end 1030 of the valve-gate pin and a second diameter 1110 offset from the first end 1030 .
  • the second diameter 1110 is equal to the minor diameter 1130 of an annular recess 1140 .
  • the second diameter 1110 of the valve-gate pin 1005 is equal with the major diameter 1150 of the annular recess.
  • a retention feature 1060 may comprise a feature providing differing form from the first diameter 1100 or the second diameter 1110 of the valve-gate pin 1005 .
  • Certain embodiments of a valve-gate pin may comprise a form which protrudes from the valve-gate pin.
  • a valve-gate pin 1005 is longitudinally positionable to allow the extension and retraction of the valve-gate pin through an aperture 1055 and in relation to a cavity 1040 of an injection mold 1020 . It will be appreciated that when a valve-gate pin 1005 is in an open position, a second dimension 1080 of a valve gate pin is configured to interface an aperture 1055 such that material for injecting into a cavity 1040 can bypass the valve-gate pin 1005 into the cavity 1040 . In other embodiments of the present invention, for example shown in FIG.
  • a first dimension 1070 is configured to be offset from an aperture 1055 such that material for injecting into a cavity 1040 cannot bypass the valve-gate pin 1005 into the cavity 1040 .
  • an injection molding apparatus 1000 shown in FIG. 4 , are used in conjunction with an injection mold 1020 comprising a first side 1010 and a second side 1050 .
  • the connection of a part 1090 to a valve-gate pin 1005 is accomplished by accounting for material properties such as thermal expansion characteristics, stress/strain considerations and elasticity of the selected material or composition used for manufacturing the part 1090 .
  • the part 1090 solidifies and contracts in volume causing the part 1090 to be affixed to a retention feature 1060 of the valve-gate pin.
  • connection between the part 1090 and valve-gate pin 1005 has a retention force defined by the force required, directed axially away from the valve-gate pin 1005 , to break the connection between the part 1090 and the valve-gate pin 1005 .
  • This retention may be equal to or greater than the force needed to remove the molded part from the second side 1050 of the injection mold.
  • the retention force of the attachment between the part 1090 and the valve-gate pin 1005 pin extracts the part 1090 from the second side 1050 of the injection mold.
  • the part 1090 and the valve-gate pin 1005 If the retention force between the part 1090 and the valve-gate pin 1005 is equal to the retention forces between the part 1090 and the second side 1050 of the injection mold, the part releases from the second side 1050 and the first side 1010 of the injection mold simultaneously. If the retention between the part 1090 and the valve-gate pin 1005 exceeds the retention forces between the part 1090 and the second side 1050 of the injection mold, the part 1090 will be pulled away from the second side 1050 and remain in contact with the valve-gate pin. In certain embodiments, it may be required for a machine operator to manually extract, or a mechanical device to be used to extract, the part 1090 from the first side 1010 of the injection mold 1020 by applying enough force to break the connection between the part 1090 and the valve-gate pin 1005 .
  • an injection molding apparatus 1000 shown in FIG. 5 , comprise a valve-gate pin 1005 configured to retract and extend.
  • linear actuating mechanisms 1065 such as, but not limited to, electro-mechanical actuators, mechanical actuators, hydraulic actuators, pneumatic actuators, piezoelectric actuators or other mechanisms known to those skilled in the art.
  • actuating mechanisms interface with a second end 1035 of the valve-gate pin, but it will be appreciated that the connection between a valve-gate pin 1005 and an actuation mechanism may comprise alternate configurations as appreciated by those skilled in the art.
  • valve-gate pin 1005 may be retracted.
  • the retraction of the valve-gate pin 1005 pulls the valve-gate pin 1005 from the part 1090 with enough force to exceed the retention force between the part 1090 and the valve-gate pin 1005 .
  • the retraction distance of the valve-gate pin 1005 may be of distance less than, equal to, or greater than the distance which the valve-gate pin 1005 protrudes into the cavity 1040 of the injection mold 1020 .
  • valve-gate pin 1005 may be extended into the cavity 1040 of the injection mold, and the first side 1010 of the injection mold mated with the second side 1050 of the injection mold prior to manufacturing another part 1090 .
  • an injection molding apparatus 1000 comprising a valve-gate pin 1005 further comprise a retention feature 1060 .
  • the retention feature 1060 may comprise at least one alternate form configured to provide retention of a part 1090 .
  • Such embodiments may comprise an annular recess having a semi-circular undercut ( FIG. 6A ), a rectangular undercut ( FIG. 6B ), a threaded feature 1200 ( FIG. 6C ), or a projecting feature 1230 ( FIG. 6D ).
  • a retention feature may comprise any form that provides a retention force between a retention feature 1060 and a part 1090 .
  • a valve-gate pin 1005 comprises a retention feature 1060 having a threaded feature 1200 .
  • the retention feature 1060 protrudes into the cavity 1040 of the injection mold 1020 .
  • the part 1090 cools and creates an attachment between the part 1090 and the retention feature 1060 of the valve-gate pin.
  • Such actuation may be performed using rotative actuating mechanism 1065 independently or in conjunction with a linear actuating mechanism 1065 to retract the valve-gate pin 1005 from the cavity 1040 of the injection mold.
  • Rotative actuating mechanisms 1065 include technologies such as but not limited to servo motors, stepper motors, hydraulic actuators, and pneumatic actuators. Typically, such actuating mechanisms interface with a second end 1035 of the valve-gate pin, but it will be appreciated that the connection between a valve-gate pin 1005 and an actuation mechanism may comprise alternate configurations as appreciated by those skilled in the art.
  • an injection molding apparatus 1000 shown in FIG. 8 , comprise a valve-gate pin 1005 having a pathway 1250 longitudinally in the valve-gate pin 1005 such that such a pathway 1250 is exposed to the cavity 1040 of an injection mold 1020 .
  • a pathway 1250 and typically substantially consistent with a central axis 1260 of the valve-gate pin 1005 .
  • Such a pathway 1250 provides capability for processes including gas-assist injection molding, and gas assisted part ejection.
  • a part may be removed from a first side of an injection mold manually, mechanically, through the use of robotics or through the use of automated systems.
  • breaking the connection between the retention feature of the valve-gate pin and the part may not release the part from the first side of the injection mold.
  • an additional step of pushing 1380 a fluid through the pathway may be desired.
  • the pushing step 1380 may occur anywhere throughout the process dependent upon the intended purpose of the pushing step 1380 .
  • a pushing step may follow the injecting step for the introduction of a gas for gas-assist injection molding.
  • a pushing step may occur following the dwelling step 1330 for the purposes of introducing a fluid—including a gas, liquid, powder or flowable solid—to encapsulate the fluid within the part.
  • the pushing step may occur following the retracting 1360 step to provide gas-assisted ejection of a part from the injection mold. It will be appreciated by those skilled in the art that steps including, but not limited to, positioning 1310 the valve-gate pin and, retracting 1360 the valve-gate pin may occur at alternate stages of the process while remaining consistent with the inventive nature of the present invention.
  • first,” “second,” “proximal,” “distal,” etc. are intended for illustrative purposes only and do not limit the embodiments in any way. Additionally, the term “plurality,” as used herein, indicates any number greater than one, either disjunctively or conjunctively, as necessary, up to an infinite number.
  • the benefits, advantages, solutions to problems, and any element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced are not to be construed as a critical, required, or essential features or elements of any or all the claims.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
US15/495,367 2016-04-22 2017-04-24 Injection Molding Apparatus and Method of Use Abandoned US20180147762A1 (en)

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US15/495,367 US20180147762A1 (en) 2016-04-22 2017-04-24 Injection Molding Apparatus and Method of Use
US16/572,967 US10843393B2 (en) 2016-04-22 2019-09-17 Injection molding apparatus and method of use

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US201662326655P 2016-04-22 2016-04-22
US15/495,367 US20180147762A1 (en) 2016-04-22 2017-04-24 Injection Molding Apparatus and Method of Use

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US16/572,967 Expired - Fee Related US10843393B2 (en) 2016-04-22 2019-09-17 Injection molding apparatus and method of use

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KR (1) KR102370897B1 (es)
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CN109070419A (zh) 2018-12-21
MX2018012829A (es) 2019-07-08
WO2017185095A2 (en) 2017-10-26
EP3445557A4 (en) 2020-05-13
WO2017185095A3 (en) 2017-11-23
CA3021715A1 (en) 2017-10-26
BR112018071653A2 (pt) 2019-02-19
US10843393B2 (en) 2020-11-24
EP3445557B1 (en) 2022-07-27
US20200009775A1 (en) 2020-01-09
KR102370897B1 (ko) 2022-03-07
KR20190009305A (ko) 2019-01-28
JP2019514764A (ja) 2019-06-06
WO2017185095A4 (en) 2018-01-18
EP3445557A2 (en) 2019-02-27

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