Imflux Inc.

The Procter Gamble Company

Brandon Michael Birchmeier

Gene Michael Altonen

Brian Matthew Burns

Bryler Collins

Chow-Chi Huang

Ethan David Stiefel

William Francis Lawless, Iii

Matthew Craver

Jes Tougaard Gram

William Francis Iii Lawless

Herbert Kenneth Iii Hanson

Iii Hanson Herbert Kenneth

In order to improve the consistency of molded products as viscosity shifts throughout a run, a controller of an injection molding machine executes a calibration cycle in accordance with a mold cycle. The controller analyzes a plurality of sensed melt pressure values during the calibration cycle to determine one or more calibration metrics. The controller then uses the calibration metrics when executing each mold cycle of the run. More particularly, during each mold cycle of the run, the controller detects a plurality of sensed melt pressures prior to and during a fill phase of the mold cycle and compares the plurality of sensed melt pressures to the one or more calibration metrics to predict cavity pressure for a pack and hold phase of the mold cycle. The controller then adjusts a set point pressure for the pack and hold phase based on the predicted cavity pressure.

Systems and methods for controlling injection molding using predicted cavity pressure

A method of detecting and compensating for a non-operational mold cavity in an injection molding apparatus having a plurality of mold cavities and an injection molding screw or ram includes injecting, via the injection molding screw or ram, a molten thermoplastic material into the plurality of mold cavities. The method includes measuring a first process parameter of the injection molding apparatus at a pre-determined time during or after the injecting. The method also includes determining, based on the first process parameter, whether one or more mold cavities of the plurality of mold cavities are non-operational. Then, when it is determined that one or more mold cavities are non-operational, the method includes automatically adjusting the first process parameter or a second process parameter of the injection molding apparatus.

Method of injection molding with down cavity detection

Systems and approaches for determining design of experiment parameters using largest empty area rectangle optimization for an injection molding system. The systems and methods include obtaining pressure versus time data sets indicative of fill step pressures and corresponding fill step times for a plurality of mold cycles and defining a low and high pressure versus time curves from the data sets, with the low and high pressure versus time curves being two surfaces of a geometric shape. The systems and methods further include identifying a top surface and a bottom surface of the geometric shape; identifying a rectangle having the largest area of all rectangles contained within the first geometric shape; and generating design of experiment parameters from the largest area rectangle.

Largest empty corner rectangle based process development

Systems and approaches for controlling an injection molding machine having a first configuration and a mold forming a mold cavity and being controlled according to an injection cycle include obtaining a pattern for a portion of an injection cycle of an injection molding machine having a second configuration and operating the injection molding machine having the first configuration to inject a molten material into the mold cavity. While operating the injection molding machine having the first configuration, the obtained pattern is used to control a portion of the injection cycle.

Systems and approaches for controlling an injection molding machine

Systems and approaches for controlling an injection molding machine having a mold forming a mold cavity and being controlled according to an injection cycle include obtaining a pattern for the injection cycle, operating the injection molding machine to inject a molten material into the mold cavity, and measuring a cavity pressure value of the mold cavity during the mold cycle. Upon measuring a nominal cavity pressure value, a pattern recognition portion of the injection cycle that is at least partially dependent on the obtained pattern commences where a driving force being exerted on the molten material is adjusted such that the measured cavity pressure matches the obtained pattern for the injection cycle.

A method of determining melt flow front travel in a molding apparatus includes setting a sensor threshold, receiving a sensor amount as an output from a sensor monitoring a nozzle of the molding apparatus, and determining that the sensor amount exceeds the sensor threshold. The method further includes receiving a screw location, calculating a travel distance of the screw from the screw location, and calculating melt flow front travel based on the travel distance of the screw. The method further includes receiving, via an interface, an operator generated value for the desired melt flow front travel to be reached, and sending, via an interface, an analog or digital output after the operator generated value has been reached. A method of detecting a leaking condition of a check valve is also included.

Method of determining melt flow front travel using injection melt pressure and screw position to generate an output and continuously monitor check ring repeatability

A method of monitoring and controlling a sequential valve gate molding apparatus in an injection molding or other molding process is disclosed. The method includes creating a target strain profile, receiving a deviation limit, receiving a change in strain relating to a first valve gate from a first strain gauge, identifying whether a deviation exists from a first portion of the target strain profile based on the output from the first strain gauge, determining whether any existing deviation exceeds the deviation limit, and adjusting the position of a first valve gate pin in the first valve gate if it does. The method may further include control of subsequent valve gates. Multiple strain gauges may be used to control a single valve gate, and/or each strain gauge may control more than one valve gate.

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Morrow, OH, United States of America

Brandon Michael Birchmeier