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WO2024118692A1 - Contrôle universel de processus pour moulage par injection - Google Patents

Contrôle universel de processus pour moulage par injection Download PDF

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Publication number
WO2024118692A1
WO2024118692A1 PCT/US2023/081492 US2023081492W WO2024118692A1 WO 2024118692 A1 WO2024118692 A1 WO 2024118692A1 US 2023081492 W US2023081492 W US 2023081492W WO 2024118692 A1 WO2024118692 A1 WO 2024118692A1
Authority
WO
WIPO (PCT)
Prior art keywords
injection molding
process condition
pressure
expected
cushion
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.)
Ceased
Application number
PCT/US2023/081492
Other languages
English (en)
Inventor
Brandon Michael Birchmeier
Lexington Marie PETERSON
Gene Michael Altonen
Robert Paul Cassoni
William Raymond MYERS
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Imflux Inc
Original Assignee
Imflux Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Imflux Inc filed Critical Imflux Inc
Publication of WO2024118692A1 publication Critical patent/WO2024118692A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • 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
    • B29C45/17—Component parts, details or accessories; Auxiliary operations
    • B29C45/76—Measuring, controlling or regulating
    • B29C45/7646—Measuring, controlling or regulating viscosity
    • 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
    • B29C2945/76003—Measured parameter
    • B29C2945/76006—Pressure
    • 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
    • B29C2945/76003—Measured parameter
    • B29C2945/7605—Viscosity
    • 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
    • B29C2945/76177—Location of measurement
    • B29C2945/7618—Injection unit
    • B29C2945/76187—Injection unit screw
    • 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
    • B29C2945/76177—Location of measurement
    • B29C2945/7618—Injection unit
    • B29C2945/762—Injection unit injection piston
    • 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
    • B29C45/72—Heating or cooling
    • B29C45/73—Heating or cooling of the mould

Definitions

  • the present disclosure generally relates to injection molding and, more particularly, to a universal process control for injection molding.
  • iMFLUX Auto-Viscosity Adjust (AV A) technology has made transferring a mold between IMMs easier with their low, constant pressure injection molding process. This technology enables the injection molding process the ability to independently adjust parameters in real time.
  • This disclosure provided herein focuses on developing part process with iMFLUX and its features that are independent of resin and machine. As the present disclosure provides, iMFLUX was able to develop a part process for two molds that were independent of IMM.
  • FIG. 1 is an exemplary flow chart illustrating conventional methods for validating the same mold in two different machines with two different resins
  • FIG. 2 is an exemplary flow chart illustrating a universal process control method for validating the same mold in two different machines with two different resins;
  • FIG. 3 illustrates an MIV transfer verification process, from a conceptual test plan for the VMP;
  • FIG. 4 illustrates a Haitian Zahafir injection molding machine
  • FIG. 5 illustrates a JSW injection molding machine
  • FIG. 6 illustrates a Mitutoyo Crysta-Apex S 500 series coordinate-measuring machine
  • FIG. 7 illustrates a Dynisco LMI5500 melt indexer
  • FIG. 8 illustrates a melt indexer sample collection process
  • FIG. 9 illustrates a process capability report for inner barrel part height by material
  • FIG. 10 illustrates a process capability report for inner barrel part perimeter by material.
  • this method optimizes in response of the “plastic’s point of view.” Since scientific molding process parameters are derived from plastic variables, not IMM variables, an injection mold has the capability to be moved between different IMMs despite them having different tonnages, intensification ratios, screw sizes, etc.
  • IMFLUX AVA technology allows for highly variable resins like sustainable resins to be processed without user adjustments. These alternative resins have varying pellet sizes and molecular weights making them difficult to process conventionally.
  • Post-consumer regrind (PCR), ocean bottle grade plastic, bio-filled plastics and scrap are examples of sustainable resins that have this history of being challenging to process. However, they are competitive alternatives to virgin resin being that they are abundant, more affordable, and craved by consumers.
  • AVA is the component that allows for resin to be independent of mold qualification when using cavity pressure sensors. This technology allows the IMM to behave like a giant rheometer to regulate and maintain stable flow rates into the mold. As most processors know, if the flow rate varies, viscosity varies; if viscosity varies, parts will vary. It allows the screw velocity to be variable to shear the resin as needed to achieve an input cavity pressure at an input fill time. This quality assists with repeatable part weights and dimensions.
  • the Medical Device OEMs’ independent variables mentioned before were fill time, actual melt temperature, volumetric shot size, hold pressure.
  • iMFLUX independent variables, derived from its built-in intelligence, are fill time, process factor A (PFA), and PFA time.
  • AVA technology solves for Melt Pressure as an output. In real-time, this feature analyzes the delta between the target fill time and the actual time being achieved and accommodates for variation in the resin. This feature achieves a stable process when Target Time, or fill time, is equivalent to Actual Time.
  • AVA communicates with our melt pressure transducer (MPT) to solve for the Melt Pressure it needs to keep making the same part dimensionally. For the first time, processors are seeing IMMs solve for the parameters it needs to make the same part regardless of the material or IMM type.
  • FIG. 1 is an exemplary flow chart illustrating conventional methods for validating the same mold in two different machines with two different resins
  • FIG. 2 is an exemplary flow chart illustrating a universal process control method for validating the same mold in two different machines with two different resins, as provided herein.
  • FIG. 2 illustrates an example method for two machines and two resins, the universal process control method can be applied for more than two machines and/or more than two resins.
  • PP post-consumer resins PCRs
  • PIR PP post-industrial regrind
  • virgin PP virgin PP
  • IMMs injection molding machines
  • Each of these molds were designed to produce parts for the assembly of a deodorant container.
  • the parts are referred to as Inner Barrels and Outer Barrels in this paper.
  • the cavitation for each mold was four, and they both had two end of fill cavity pressure sensors to record the response of each leg of the Design of Experiments (DOEs) and validations.
  • This study begins with a range-finding method referred to as LECR.
  • the process range is determined by the fastest and slowest fill time at the shortest and longest Step Times.
  • Step Time is equivalent to injection time and hold times combined.
  • PFA is a factor multiplied by cavity pressure and added/subtracted from melt pressure to achieve a response after the part achieves 95-99% fill.
  • Minitab® is the statistical software used to generate this research’s response surface DOE.
  • a DOE is a standard, statistical method used to study and justify variation within plastic parts under conditions that are assumed to be the source of that variation. This method outputs a combination of parameters to test in several trials and measure how this affects plastics parts’ dimensions. Through a DOE matrix continuous factors and categorical factors can be isolated.
  • Continuous factors are derived IMM inputs which can also be considered machine learned inputs. Examples are PFA Time, PFA, and AVA Target Time, also referred to as fill time. PFA Time is Step Time minus Fill Time. In conventional terms, it can be interpreted as hold time. Categorical factors have a countable number of categories or distinct groups. Examples are the use of several IMMs or various materials which were hypothesized to not be crucial in this study.
  • This study had 65 randomized trials on each IMM tested with five differing resins. On each IMM, sixty-five randomized DOE legs were collected per mold. For each leg, five kilograms of material were used and a resin sample was collected for MFI analysis. Three shots were collected at the beginning, middle, and end of each DOE leg to be weighed and dimensionally measured.
  • This DOE trial data is then analyzed in a Response Optimizer to determine the most ideal settings across IMMs and tested resins.
  • the Response Optimizer provides a single set of validation inputs to be tested for all IMM and Material combinations.
  • a coordinate-measuring machine is a device that measures the geometry of physical samples by sensing discrete points on the surface of the parts with a probe.
  • a Mitutoyo Crysta-Apex S 500 series CMM was used to measure the dimensions for the inner and outer barrel parts.
  • a Gage R&R is developed to ensure that any variation in dimensional measurements comes from the parts and not the process and measurement method.
  • a melt indexer measures a polymer’s resistance to flow, also known as viscosity, at a set temperature, under a force, for a duration of time.
  • Dynisco’s LMI5500 melt indexer was used.
  • a stopper was placed at the bottom capillary to ensure no pellets escaped the heated barrel. Approximately six grams of resin was maneuvered into the barrel. A piston was used to pack the pellets down. A 2.06-kg weight was placed on top of the piston and left to set for seven minutes. The stopper was then removed, and excess resin was trimmed before sample collection began.
  • FIG. 8 provides a depiction of this process.
  • a sample is then extruded for a set amount of time before being trimmed and weighted on a scale.
  • the weight was input into the melt indexer to generate an MFI value in g/1 Omin. This test was done using a sample from each DOE.
  • the validation capability report shown at FIG. 10 is for the perimeter of the inner barrel parts by material based on both IMMs.
  • These charts are showing the capability of each resin with the data from both IMMs. There is a bi-modal distribution in FT200WV, KAL10, and KAL40. Aside from this trend the data between the IMMs was indistinguishable. Each material displays a Cpk value over 1 .33, meaning there would be no defects with these validated parameters. There is a slight mean shift between the resins that iMFLUX plans to address with 2nd level intelligence.
  • iMFLUX Universal Process allows for the IMM type to be independent of the mold qualification process when using the following three independent factors: AVA Fill Time, PFA, and PFA Time. This technology’s feedback loop in its autonomous system

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)

Abstract

Des procédés pour remplir une cavité de moule d'un appareil de moulage par injection avec un matériau thermoplastique fondu pendant un processus de moulage par injection peuvent comprendre : l'identification de paramètres pour le processus, associés à la cavité de moule, au matériau thermoplastique fondu, ou au type d'appareil de moulage par injection ; la fourniture d'une condition de processus attendue à un moment prédéterminé pendant le processus sur la base des paramètres ; la mesure d'une condition de processus réelle de l'appareil au moment prédéterminé ; sur la base d'une différence entre les conditions de processus attendues et réelles, la fourniture d'une courbe prédéterminée d'une condition de processus cible au cours du temps pour un reste du processus ; la mesure d'une condition de processus expérimentée de l'appareil dans le temps pour le reste du processus ; la comparaison de manière itérative de la condition de processus expérimentée à la condition de processus cible à un moment donné sur la courbe prédéterminée pour détecter une variance ; et le réglage automatique du processus de telle sorte que la variance reste dans un seuil.
PCT/US2023/081492 2022-11-30 2023-11-29 Contrôle universel de processus pour moulage par injection Ceased WO2024118692A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US202263429067P 2022-11-30 2022-11-30
US63/429,067 2022-11-30

Publications (1)

Publication Number Publication Date
WO2024118692A1 true WO2024118692A1 (fr) 2024-06-06

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN120962996A (zh) * 2025-10-17 2025-11-18 杭州雷盟机械有限公司 一种注拉吹成型机多工序协同管理的智能控制方法

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3666141A (en) * 1970-05-25 1972-05-30 Cincinnati Milacron Inc Method and apparatus for iterative control of shot size and cushion size
US4060362A (en) * 1975-05-12 1977-11-29 International Business Machines Corporation Injection molding same cycle control
US5792483A (en) * 1993-04-05 1998-08-11 Vickers, Inc. Injection molding machine with an electric drive
US20200078998A1 (en) * 2018-09-07 2020-03-12 iMFLUX Inc. Closed Loop Control for Injection Molding Processes
TW202025005A (zh) * 2018-12-21 2020-07-01 財團法人工業技術研究院 基於模型之機器學習系統

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3666141A (en) * 1970-05-25 1972-05-30 Cincinnati Milacron Inc Method and apparatus for iterative control of shot size and cushion size
US4060362A (en) * 1975-05-12 1977-11-29 International Business Machines Corporation Injection molding same cycle control
US5792483A (en) * 1993-04-05 1998-08-11 Vickers, Inc. Injection molding machine with an electric drive
US20200078998A1 (en) * 2018-09-07 2020-03-12 iMFLUX Inc. Closed Loop Control for Injection Molding Processes
TW202025005A (zh) * 2018-12-21 2020-07-01 財團法人工業技術研究院 基於模型之機器學習系統

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN120962996A (zh) * 2025-10-17 2025-11-18 杭州雷盟机械有限公司 一种注拉吹成型机多工序协同管理的智能控制方法

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