Imflux Inc.

The Procter Gamble Company

University of Illinois

The Procter & Gamble

Corium International, Inc.

Chow-Chi Huang

Gene Michael Altonen

Rick Alan Pollard

Ralph Edwin Neufarth

William Francis Lawless, Iii

Charles John Berg, Jr

Michael Thomas Dodd

Chinto Benjamin Gaw

Todd Mitchell Day

Naomi Ruth Nelson

Eric Richard Bartsch

Kimberly Nichole McConnell

Su-Yon McConville

Ayub Ibrahim Khan

Robert J Peterson

H Kenneth Hanson, Iii

Richard Darren Satterfield

Brandon Michael Birchmeier

Jason Craig Campbell

Scott Edward Smith

Stacy Alycia Thomas

Richard M Girardot

Brian David Andres

Peter Charles Mason, Jr

Dragan Danilo Nebrigic

Brian Matthew Burns

Matthew Lloyd Newman

Miguel Alberto Herrera

Michael Hung-Tai Luh

Faiz Feisal Sherman

Christopher Lawrence Smith

Vladimir Gartstein

William Michael Cannon

Ricky Ah-man Woo

Mark John Steinhardt

Vincent Sean Breidenbach

Douglas Scott Miller

Christopher Eugene Bates

Ricky Ah-Man Woo

Christopher Miles Miller

Grover David Owens

Robert E Stahley

Daniel William Volpenhein

Jeffrey Keith Leppla

Danny David Lumpkin

Lia Marie Braaten

William Kater LaSala

Frederick James Rohman

Jes Tougaard Gram

Alfredo Pagan

Widalys Luz Desoto-Burt

Coy Del Ward

Milko Gergov

Matthew John Martin

Bryler Collins

Jennifer Claire Jarvis

Cristian Alexis Viola-Prioli

Aaron Timothy Neate

Nicole Lockett Turner

Steve Andrew Burns

Frank Gustaaf Debruin

Richard Lewis Montague, Ii

Bryan Keith Allen

Eric Jason Wallace

Charles John Berg

Stephen H Iding

Milan Marcel Jevtitch

Michael Bernard Dugas

John Philip Beaumont

Francisco Arias

Daniel David Lumpkin

Miguel Alberto Herrea

Nicholas Mulkern Unkovic

Brandy Renae McGurran Hebert

Ivan Andrew Mc Cracken

Laura Jean Taylor

Edward L Schmidt

Terence McCarthy

Leonard Clyde Graham

Kendall William Kerr

Phillip Cordell Myles

Daniel William Volpenheim

Ivan Andrew McCracken

Milko Georgiev Gergov

Richard Michael Girardot

Robert Edward Stahley

Kimberly Nichole Mcconnell

Stephen Henry Iding

William Francis Iii Lawless

Steven Andrew Burns

Richard Lewis Ii Montague

Herbert Kenneth Iii Hanson

Frederick James Rohrman

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

Embodiments within the scope of the present disclosure are directed to external sensor kits that may be included in new injection molds or retrofitted into existing injection molds in order to approximate conditions within a mold, such as pressure or the location of a melt flow front. Such kits are designed to amplify meaningful measurements obtained by the external sensor kit so that noise measurements do not prevent the approximation of conditions within a mold. In some embodiments within the scope of the present disclosure, an external sensor kit includes a strain gauge sensor, a coupon, a support bracket, and a hammer. The strain gauge sensor is placed on a surface of the coupon and measures the strain in the coupon.

External sensor kit for injection molding apparatus and methods of use

A controller for an injection molding system is in communication with a melt flow control unit, a gas assist control unit, and a gas counter pressure control unit. The controller can effect real-time adjustments to gas assist pressure and/or gas counter pressure as a function of melt pressure or flow front position.

Method for simultaneous closed loop control of gas assist and gas counter pressure in an injection molding process relative to plastic melt pressure and plastic melt flow position

Non-time dependent calculated variables based on measured strain are used to effectively determine an optimal hold profile for an expanding crosslinking polymer part in a mold cavity. A system and/or approach may first inject molten expanding crosslinking polymer into a mold cavity, then measure strain at the mold cavity or at another location within the injection molding system, and then calculate at least one non-time dependent variable during an injection molding cycle. Next, the system and/or method commences a hold profile for the part, and upon completing the hold profile, the part is ejected from the mold cavity, whereupon a cure profile is commenced.

Expanding crosslinking polymer injection molding system

A system includes a cavity, an injection nozzle configured to inject material into the cavity, and a plurality of sensors at sensor locations. Each of the plurality of sensors is configured to measure parameters at one of the sensor locations. The system lacks a strain gauge. The system further includes a controller configured to control a flow rate of the injection of material into the cavity. The controller is configured to receive the measured parameters and compare the received information to predetermined curves. The controller is configured to control the flow rate when the measured parameters deviate from the predetermined curves.

Real time material and velocity control in a molding system

A method of monitoring and controlling a molding clamping 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 mold while it is closing from a first strain gauge, identifying a deviation from a target strain profile based on the output from the first strain gauge, determining that the deviation exceeds the deviation limit, and adjusting the rate or force of clamp movement. The target strain profile may have a first portion relating to a clamp closing process, a second portion relating to a filling process, and a third portion relating to a clamp opening process. The first portion relating to the clamp closing process may include an intermediate portion relating to a coining process having an intermediate clamp force setpoint.

Method for controlling a rate or force of a clamp in a molding system using one or more strain gauges

Non-time dependent measured variables are used to effectively determine an optimal hold profile for an expanding crosslinking polymer part in a mold cavity. A system and/or approach may first inject molten expanding crosslinking polymer into a mold cavity, then measure at least one non-time dependent variable during an injection molding cycle. Next, the system and/or method commences a hold profile for the part, and upon completing the hold profile, the part is ejected from the mold cavity.

Injection molding of crosslinking polymers

Non-time dependent measured variables are used to effectively determine an optimal ejection time of a part from a mold cavity. A system and/or approach may first measure at least one non-time dependent variable during an injection molding cycle. The part is ready to be ejected from the mold upon the measured variable reaching a threshold value indicative of, for example, a part temperature dropping below an activation temperature.

In-mold non-time dependent determination of injection molded part ejection readiness

Injection molding of crosslinking polymers using strain data

Non-time dependent measured variables are used to effectively determine an optimal hold profile for an expanding crosslinking polymer part in a mold cavity. A system and/or approach may first inject molten expanding crosslinking polymer into a mold cavity, then measure at least one non-time dependent variable during an injection molding cycle. Next, the system and/or method commences a hold profile for the part, and upon completing the hold profile, the part is ejected from the mold cavity, whereupon a cure profile is commenced.

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West Chester, OH, United States of America

Chow-Chi Huang