U.S. patent application number 14/086356 was filed with the patent office on 2014-05-22 for reduced size runner for an injection mold system.
This patent application is currently assigned to The Procter & Gamble Company. The applicant listed for this patent is The Procter & Gamble Company. Invention is credited to Gene Michael ALTONEN, Charles John BERG, JR., Vincent Sean BREIDENBACH, Chow-chi HUANG, Danny David LUMPKIN, Kimberly Nichole McCONNELL.
Application Number | 20140141117 14/086356 |
Document ID | / |
Family ID | 49759563 |
Filed Date | 2014-05-22 |
United States Patent
Application |
20140141117 |
Kind Code |
A1 |
ALTONEN; Gene Michael ; et
al. |
May 22, 2014 |
Reduced Size Runner for an Injection Mold System
Abstract
A runner system for a multi-cavity injection molding system, the
runner system having runners of reduced size.
Inventors: |
ALTONEN; Gene Michael; (West
Chester, OH) ; BREIDENBACH; Vincent Sean; (Lebanon,
OH) ; McCONNELL; Kimberly Nichole; (Morrow, OH)
; LUMPKIN; Danny David; (Cincinnati, OH) ; HUANG;
Chow-chi; (West Chester, OH) ; BERG, JR.; Charles
John; (Wyoming, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Procter & Gamble Company |
Cincinnati |
OH |
US |
|
|
Assignee: |
The Procter & Gamble
Company
Cincinnati
OH
|
Family ID: |
49759563 |
Appl. No.: |
14/086356 |
Filed: |
November 21, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61729028 |
Nov 21, 2012 |
|
|
|
Current U.S.
Class: |
425/547 ;
425/588 |
Current CPC
Class: |
B29C 2945/7621 20130101;
B29C 2945/76006 20130101; B29C 45/77 20130101; B29C 2045/0086
20130101; B29C 2945/76936 20130101; B29C 45/2701 20130101; B29L
2031/712 20130101; B29C 2045/2722 20130101; B29C 45/2725 20130101;
B29C 45/2704 20130101; B29L 2031/3044 20130101; B29C 2945/76287
20130101; B29C 45/2708 20130101 |
Class at
Publication: |
425/547 ;
425/588 |
International
Class: |
B29C 45/27 20060101
B29C045/27 |
Claims
1. A runner system for a multi-cavity injection molding system, the
runner system comprising a set of runners, each runner of the set
in closest proximity to a mold cavity having a hydraulic diameter
of 0.5-1.5 times a gate thickness for a part to be molded in at
least one cavity of the multi-cavity molding system.
2. The runner system of claim 1, wherein each runner of the set in
closest proximity to a mold cavity has a hydraulic diameter of
0.5-0.9 times a gate thickness of a part to be molded in at least
one cavity of the multi-cavity molding system.
3. A runner system for a multi-cavity injection molding system, the
runner system comprising a set of runners, each runner of the set
in closest proximity to a mold cavity having a hydraulic diameter
less than or equal to 20 times a peak melt pressure at which
polymer is injected by the injection molding system, divided by
(L/T).sup.-1, where L/T is a length-to-thickness ratio of a part to
be molded in at least one cavity of the multi-cavity molding
system.
4. The runner system of claim 3, wherein the hydraulic diameter of
each runner of the set in closest proximity to a mold cavity is at
least sufficiently large so as to permit the flow of molten
polymeric material therethrough and into the respective mold
cavity.
5. The runner system of claim 4, wherein the hydraulic diameter of
each runner of the set in closest proximity to a mold cavity is at
least 0.5 times a gate thickness of a part to be molded in at least
one cavity of the multi-cavity molding system.
6. The runner system of claim 3, wherein the hydraulic diameter is
less than or equal to 8.25 times the peak melt pressure divided by
(L/T).sup.-0.889.
7. A runner system for a multi-cavity injection molding system, the
runner system comprising a set of runners, each runner of the set
in closest proximity to a mold cavity having a cross-sectional area
less than or equal to a quotient of 700 divided by a peak melt
pressure at which polymer is injected by the injection molding
system.
8. The runner system of claim 7, wherein each runner of the set in
closest proximity to a mold cavity having a cross-sectional area
less than or equal to a product of 199.63 times (peak melt
pressure).sup.-0.889.
9. A runner system for a multi-cavity injection molding system, the
runner system comprising a set of runners, each runner of the set
in closest proximity to a mold cavity having a cross-sectional area
less than or equal to 315 times a peak melt pressure at which
polymer is injected by the injection molding system, divided by
(L/T).sup.-2, where L/T is a length-to-thickness ratio of a part to
be molded in at least one cavity of the multi-cavity molding
system.
10. The runner system of claim 9, wherein each runner of the set in
closest proximity to a mold cavity has a cross-sectional area less
than or equal to 53.51 times the peak melt pressure divided by
(L/T).sup.-1.778.
11. A runner system for a multi-cavity injection molding system,
the runner system comprising a set of runners, each runner of the
set in closest proximity to a mold cavity having a cross-sectional
area given by the formula: hydraulic cross-sectional runner
area.ltoreq.360,000/(peak melt pressure).sup.2, where "peak melt
pressure" is the peak melt pressure at which polymer is injected by
the injection molding system.
12. The runner system of claim 11, wherein each runner of the set
in closest proximity to a mold cavity has a hydraulic
cross-sectional runner area given by the formula: hydraulic
cross-sectional runner area.ltoreq.31,313*(peak melt
pressure).sup.-1.778.
13. A runner system for a multi-cavity injection molding system,
the runner system comprising a set of runners, including a first
branch set of runners, each of the runners of the first branch set
of runners being in closest proximity to a respective one of the
mold cavities; a second branch set of runners, each of the runners
of the second branch set of runners being in fluid communication
with at least two of the runners of the first branch set of
runners; and a main runner in fluid communication with each runner
of the second branch set of runners, wherein the main runner has a
hydraulic diameter equal to at least the product of the hydraulic
diameter of each of the runners of the first branch set of runners
times the product of the number of branch sets of runners including
the main runner raised to a power of 1/8.
14. A runner system for a multi-cavity injection molding system,
the runner system comprising a set of runners, including a first
branch set of runners, each of the runners of the first branch set
of runners being in closest proximity to a respective one of the
mold cavities; one or more additional branch sets of runners, each
of the runners of the next-successive branch set of runners being
in fluid communication with at least two of the runners of the
next-lowest branch set of runners, each of said one or more
additional branch sets of runners being identifiable as an integer
value indicative of its level that is one higher than the branch
set of runners in next-closer proximity to the mold cavities; and a
main runner having a branch value of one higher than the highest
value of the one or more additional branch sets of runners, the
main runner being in fluid communication with each runner of that
highest value of the one or more additional branch sets of runners,
wherein the main runner has a hydraulic diameter equal to at least
the product of the minimum diameter of each of the runners of the
first branch set of runners times the branch value of the main
runner raised to a power of 1/8.
15. A runner system for a multi-cavity injection molding system,
the runner system comprising a set of runners, including a first
branch set of runners, each of the runners of the first branch set
of runners being in closest proximity to a respective one of the
mold cavities; one or more additional branch sets of runners, each
of the runners of the next-successive branch set of runners being
in fluid communication with at least two of the runners of the
next-lowest branch set of runners, each of said one or more
additional branch sets of runners being identifiable as an integer
value indicative of its level that is one higher than the branch
set of runners in next-closer proximity to the mold cavities; and a
main runner having a branch value of one higher than the highest
value of the one or more additional branch sets of runners, the
main runner being in fluid communication with each runner of that
highest value of the one or more additional branch sets of runners,
wherein the main runner has a hydraulic diameter equal to a
hydraulic diameter of one of the runners of the first branch set of
runners times a constant (K).
16. A multi-cavity injection molding system having a plurality of
hot runners therein, wherein a hydraulic diameter of at least one
of the runners in closest proximity to one of the mold cavities is
at least sufficiently large so as to permit the flow of molten
polymeric material therethrough and into the respective mold cavity
and is less than 6 mm.
Description
FIELD OF THE INVENTION
[0001] This disclosure relates generally to apparatuses and methods
for injection molding and, more particularly, to apparatuses and
methods for producing injection molded parts at substantially
constant pressure.
BACKGROUND OF THE INVENTION
[0002] Injection molding is a technology commonly used for
high-volume manufacturing of parts made of meltable material, most
commonly of parts made of thermoplastic polymers. During a
repetitive injection molding process, a plastic resin, most often
in the form of small beads or pellets, is introduced to an
injection molding machine that melts the resin beads under heat,
pressure, and shear. The now-molten polymer or resin is forcefully
injected into a mold cavity having a particular cavity shape. The
injected plastic is held under pressure in the mold cavity, cooled,
and then removed as a solidified part having a shape that
essentially duplicates the cavity shape of the mold. The mold
itself may have a single cavity or multiple cavities. Each cavity
may be connected to a flow channel through one or more gates that
direct the flow of the molten resin into the cavity. Thus, a
typical injection molding procedure comprises four basic
operations: (1) heating the plastic in the injection molding
machine to allow it to flow under pressure; (2) injecting the
melted plastic into a mold cavity or cavities defined between two
mold halves that have been closed; (3) allowing the plastic to cool
and harden in the cavity or cavities while under pressure; and (4)
opening the mold halves to cause the part to be ejected from the
mold.
[0003] The molten plastic resin is injected into the mold cavity
and the plastic resin is forcibly pushed through the cavity by the
injection molding machine until the plastic resin reaches the
location in the cavity furthest from the gate. The resulting length
and wall thickness of the part is a result of the shape of the mold
cavity.
[0004] Multi-cavity injection molds require a network of feeder
channels to distribute molten plastic from the machine nozzle to
each individual mold cavity. The feeder channels or runners can be
permitted to cool, or can be actively cooled, such that for each
molding cycle the runners are filled with molten polymer that
solidifies in the runners, and is then removed from the mold as a
solid mass of plastic in the shape of the runner or feeder channel
network. This type of system is referred to in the art as a "cold
runner" system. It is also possible to heat the feeder channel or
runner network, such that for each molding cycle the polymer
remains molten. The molten polymer remains in the feeder channels
or runners after each molding cycle--this molten material is then
injected in to the mold cavity upon initiation of the subsequent
molding cycle. This type of system is referred to as a "hot runner"
system. A "runner system" as used herein, if not preceded by the
adjective "hot" or "cold", refers to either a hot runner system or
a cold runner system, as well as to a hybrid "hot-to-cold" runner
system.
[0005] In the case of a cold runner system, the hydraulic diameter
of the runner or feeder channel in closest proximity to a mold
cavity typically ranges from about 1.5 to about 3 times the nominal
wall thickness of the molded article. See, e.g., Beaumont, Runner
and Gating Design Handbook, second edition, page 152, Hanser
Gardner Publications, 2007. Hydraulic diameter, or D.sub.H, is a
term commonly used in the art to refer not only to the inner
diameter of round tubes, but also to an effective inner diameter of
non-circular tubes or channels, which may be calculated by the
formula=4A/P, where A is the cross-sectional area of the tube or
channel and P is the wetted inner perimeter of the cross-section of
the tube or channel. This hydraulic diameter is intentionally
greater than the article nominal wall thickness (a term defined
hereinafter), so that the runner will remain molten longer than the
molded part, ensuring that molten plastic can continue to be fed
through the feeder network until the mold cavity is completely
filled and packed. If polymeric material within the feeder channel
were to freeze prior to the mold cavity being completely packed,
the molded article would shrink away from the mold cavity
excessively, and the molded article would have poor surface finish
quality and undesirably high dimensional variation.
[0006] In another convention for sizing cold runners, the runners
are designed to have a hydraulic diameter of 1.5 mm greater than
the nominal wall thickness of an article to be molded. See, e.g.,
How to Make Injection Molds, Third Edition, page 153, Carl Hanser,
1993 (Germany).
[0007] In designing runner systems, conventional design parameters
call for the runner to begin near the injection unit machine nozzle
at a larger cross-sectional area, then progressively step down in
cross-sectional area, as the runner is divided to achieve the
desired number of runners to reach each individual mold cavity.
Importantly, conventional wisdom indicates that the flow runner
hydraulic diameter must be increased from a minimum design
hydraulic diameter (as determined above) that feeds the mold
cavity, to a progressively increasing hydraulic diameter at each
branch in the runner along the flow path back to the machine
nozzle. This is particularly the case for cold runner systems, as
in hot runner systems, since there is not the same need to promote
freeze-off and minimize scrap of polymeric material within the
runners by minimizing runner diameter as there is in a cold runner
system, the hydraulic diameters of runners at different branches of
a hot runner system may be more uniform than the
progressively-smaller diameters of a cold runner system with
increasing proximity to the mold cavity.
[0008] In describing a runner system, it is useful to consider the
following terms: The term "main sprue" refers to the first runner
leg that is adjacent to the machine nozzle and receives molten
polymer (also referred to herein as molten polymeric material or
thermoplastic material) from the molding machine. For a
multi-cavity mold, the main sprue is divided into multiple "runner
branches", such that the number of "final runner branches" is equal
to the total number of gate locations (usually one gate per mold
cavity). The term "runner branch" refers to each of the flow
channels in a runner network. The term "final runner branch" refers
to the runner branches that connect directly to the gate, which
then connects to the mold cavity. The term "node" refers to a
location in the runner network where a runner is divided into
smaller runner branches. For example, when the main sprue is
divided into four runner branches extending out to four individual
mold gates, the intersection of the main sprue with the runner
branches is referred to herein as a "node".
[0009] For a conventional molding process, the size of each of the
runner branches is related using the formula
D.sub.m=D.sub.b*N.sup.1/3, where N is the number of runner branches
extending from a feeder branch [D.sub.m]. N is equal to the number
of times a feed runner [D.sub.m] is divided into equal runner
branches [D.sub.b]. D.sub.m and D.sub.b are hydraulic
diameters.
[0010] For example, for a runner system where the main sprue is
divided into four branches to feed four final runners, N would
equal 4. Thus, where D.sub.b is equal to 6 millimeters, D.sub.m is
equal to 6*4.sup.1/3 power, or D.sub.m is equal to about 9.524
millimeters.
[0011] In a second example, a runner system where the main sprue is
divided into four equal branches, and each of the four equal
branches is then divided into four equal final runner branches. The
diameter of the main sprue would be determined by starting with the
diameter of the final runner, then working back through the system
to the main sprue. Thus, where the final runner diameter [D.sub.b]
is equal to 6 millimeters, the feeder runner diameter [D.sub.m] is
equal to 6*4.sup.1/3 power, or is equal to about 9.524 millimeters.
The next feeder runner, which in this case would be the main sprue
diameter, would then be calculated in the same manner starting with
the diameter of about 9.524 millimeters. Thus, the diameter of the
main sprue [D.sub.m] is equal to 9.524*4.sup.1/3, or 15.118
millimeters. An equivalent calculation is Dm=Db*[the total number
of final runners].sup.1/3. For example, the 16 cavity tool
indicated in second example above, if calculated by this formula
provides the same answer of 15.118 millimeters. Specifically 6
mm*16.sup.1/3 equals 15.118 millimeters. This relationship holds
true regardless of the numbers of nodes located between the main
sprue and the final runners. Each interim runner branch step would
be related by the formula D.sub.m=D.sub.b*N.sup.1/3.
[0012] This results in a substantial volume of plastic being
required to distribute the polymer to the injection mold cavities.
In the case of a cold runner system, this large volume can extend
the cycle times for some parts, increase clamp tonnage (because the
larger the volume of the runner system, the higher the volume of
polymer material between the machine nozzle and the mold cavities,
and the more clamp tonnage that may likely be necessary to mold
articles along with the volume of runner material), and this
substantial volume of polymer is typically disposed of for each
"shot" of polymer injected in to the cavity--since the cold runner
is typically discarded as scrap or reground for re-use in
subsequent injection molding cycles. In the case of a hot runner
system, this volume of material is heated during each molding
cycle, thus the higher the volume of the runner, the longer the
polymer residence time, and the longer the polymer is exposed to
heat that degrades the polymer. Furthermore, the more volume of
material contained in the hot runner, the more material that must
be purged from the system when changing the color of a polymer or
changing from one polymer material to another polymer material.
This leads to lost productivity during the material changeover
process. For both hot and cold runners, it is desirable to reduce
the total volume of material contained in the runner.
SUMMARY OF THE INVENTION
[0013] Embodiments of the present invention generally relate to
systems, including runner systems, machines, products, and methods
of producing products by injection molding and more specifically to
systems, including runner systems, products, and methods of
producing products by substantially constant pressure injection
molding.
[0014] The term "low peak pressure" as used herein with respect to
peak melt pressure of a thermoplastic or molten polymeric material
means peak melt pressures in a vicinity of a nozzle of an injection
molding machine of 6000 psi and lower. The peak melt pressure may
be measured at locations in the runner system other than in a
vicinity of the nozzle, such as in the main sprue, any of the
runner branches, or in the vicinity of the gate at the entrance of
the mold cavity.
[0015] The term "intermediate peak pressure" as used herein with
respect to peak melt pressure of a thermoplastic or molten
polymeric material means peak melt pressures in a vicinity of a
nozzle of an injection molding machine of approximately 6,000 psi
to approximately 15,000 psi.
[0016] The term "high peak pressure" as used herein with respect to
peak melt pressure of a thermoplastic or molten polymeric material
means peak melt pressures in a vicinity of a nozzle of an injection
molding machine of greater than 15,000 psi.
[0017] The term "substantially low constant pressure" as used
herein with respect to a melt pressure of a thermoplastic material
means that deviations from a baseline melt pressure do not produce
meaningful changes in physical properties of the thermoplastic
material. For example, "substantially low constant pressure"
includes, but is not limited to, pressure variations for which
viscosity of the melted thermoplastic material does not
meaningfully change. The term "substantially constant" in this
respect includes deviations of approximately 30% from a baseline
melt pressure. For example, the term "a substantially constant
pressure of approximately 4600 psi" includes pressure fluctuations
within the range of about 6000 psi (30% above 4600 psi) to about
3200 psi (30% below 4600 psi). A melt pressure is considered
substantially constant as long as the melt pressure fluctuates no
more than 30% from the recited pressure. The peak melt pressure
could be as high as 6000 psi for a low peak pressure system.
[0018] The term "substantially intermediate constant pressure" as
used herein with respect to a melt pressure of a thermoplastic
material means that deviations from a baseline melt pressure do not
produce meaningful changes in physical properties of the
thermoplastic material. For example, "substantially intermediate
constant pressure" includes, but is not limited to, pressure
variations for which viscosity of the melted thermoplastic material
does not meaningfully change. The term "substantially constant" in
this respect includes deviations of approximately 30% from a
baseline melt pressure. For example, the term "a substantially
constant pressure of approximately 11,000 psi" includes pressure
fluctuations within the range of about 14,300 psi (30% above 11,000
psi) to about 7,700 psi (30% below 11,000 psi). A melt pressure is
considered substantially constant as long as the melt pressure
fluctuates no more than 30% from the recited pressure. The peak
melt pressure could be as high as 14,300 psi. It is found that when
molten polymer is introduced to a mold at substantially constant
pressure with peak melt pressures at approximately 6,000 psi or
below, or between 6,000 psi and 15,000 psi, or between 15,000 and
20,000 psi, as opposed to the conventional mold systems not
maintained at substantially constant pressure because such
conventional systems are controlled by volumetric flow rate, the
size (i.e., volume) of the runners from the nozzle to the mold
cavities, and in particular, the size of the runners in closest
proximity to the mold cavities, may be significantly smaller than
runners in conventional high, variable pressure (sometimes referred
to as spike pressure) injection molding systems. For a given length
runner, the runner size may vary due to changes in the runner
hydraulic cross-sectional area or the runner hydraulic
diameter.
[0019] Decreasing the size of the runners has several benefits. In
the case of cold runners, decreasing the runner size advantageously
increases options regarding the mold cavity spacing because the
cavities may be spaced more closely to one another. Potentially, so
much space between cavities can be saved in an overall mold such
that the number of total cavities that can be provided in a given
mold can be increased. Another advantage to a decreasing runner
size in a cold runner system is that it reduces the energy needed
to introduce molten polymer through the runner system and
ultimately to the mold cavities.
[0020] An additional benefit of smaller feed channels or runners in
a cold runner system as compared to conventional injection molding
systems is that because the cold runner is ejected or otherwise
removed at the end of a molding cycle, and reground for use in
subsequent molding cycles, reducing the size of the runners reduces
the size of those cold runners that need to be ejected or removed
at the end of a molding cycle. By reducing the size of the runners,
and thereby reducing the amount of material that needs to be
reground, the integrity and quality of the resulting molded
articles is increased, because the percentage of regrind in any
given injection molding cycle is reduced.
[0021] For a hot runner system, a benefit of a reduced-sized runner
is that there is less of a pressure drop from branch to branch of
the runners (i.e., from runners closest to the nozzle to the
runners closest to the mold cavities), permitting the injection
molding system to maintain constant pressure and make more
consistent parts. A reduced hot runner size translates to reduced
molten polymer in the runner system, thereby reducing the polymer
residence time, and shortening the duration of exposure to heat
(minimizing polymer degradation). With less polymer material
contained in the hot runner, less material would need to be purged
from the system when changing the color of a polymer or changing
from one polymer material to another polymer material, thereby
reducing changeover time. As with a cold runner system, reduced
runner size could provide benefits in spacing, and even overall
number, of cavities in a given mold.
[0022] The manner in which these and other benefits of an injection
molding system having a reduced runner size is achieved is
explained in the following detailed description of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The embodiments set forth in the drawings are illustrative
and exemplary in nature and not intended to limit the subject
matter defined by the claims. The following detailed description of
the illustrative embodiments can be understood when read in
conjunction with the following drawings, where like structure is
indicated with like reference numerals and in which:
[0024] FIG. 1 illustrates a schematic view of a high productivity
injection molding machine constructed according to the present
disclosure;
[0025] FIG. 2 illustrates a schematic view of a multi-cavity
injection molding system with multiple branches of runners provided
between a nozzle and the mold cavities;
[0026] FIG. 3 illustrates a comparison of the relationship of
hydraulic runner diameter to the quotient of peak melt pressure
over L/T for a part molded at a substantially constant
pressure;
[0027] FIG. 4 illustrates a comparison of the relationship of
hydraulic runner cross-sectional area to the quotient of peak melt
pressure over L/T for a part molded at a substantially constant
pressure;
[0028] FIG. 5 illustrates a comparison of the relationship of
hydraulic runner cross-sectional area to peak melt pressure for a
part molded at a substantially constant pressure;
[0029] FIG. 6 illustrates a comparison of the relationship of
hydraulic runner diameter to peak melt pressure for a part molded
at a substantially constant pressure; and
[0030] FIG. 7 illustrates a top view of an experimental mold and
part used to generate the data from which the comparison charts of
FIGS. 3-6 were formed.
[0031] FIG. 7A illustrates an isometric view of the experimental
mold and part of FIG. 7.
[0032] FIG. 7B illustrates a front view of the experimental mold
and part of FIG. 7.
[0033] FIG. 7C illustrates a cross-sectional view of the
experimental mold and part of FIG. 7.
[0034] FIG. 7D illustrates a side view of the experimental mold and
part of FIG. 7.
DETAILED DESCRIPTION OF THE INVENTION
[0035] Referring to the figures in detail, FIG. 1 illustrates an
exemplary substantially constant pressure (with peak pressures
ranging from about 1,000 to <6000 psi, from about 6,000-about
10,000 psi, about 10,000 to about 15,000 psi, and about 15,000 to
about 20,000 psi) injection molding apparatus 10 for producing
thin-walled parts in high volumes (e.g., a class 101 or 102
injection mold, or an "ultra high productivity mold"). The
injection molding apparatus 10 generally includes an injection
system 12 and a clamping system 14. A thermoplastic material may be
introduced to the injection system 12 in the form of thermoplastic
pellets 16. The thermoplastic pellets 16 may be placed into a
hopper 18, which feeds the thermoplastic pellets 16 into a heated
barrel 20 of the injection system 12. The thermoplastic pellets 16,
after being fed into the heated barrel 20, may be driven to the end
of the heated barrel 20 by a reciprocating screw 22. The heating of
the heated barrel 20 and the compression of the thermoplastic
pellets 16 by the reciprocating screw 22 causes the thermoplastic
pellets 16 to melt, forming a molten thermoplastic material 24. The
molten thermoplastic material is typically processed at a
temperature of about 130.degree. C. to about 410.degree. C.
[0036] The reciprocating screw 22 forces the molten thermoplastic
material 24, toward a nozzle 26 to form a shot of thermoplastic
material, which will be injected into a mold cavity 32 of a mold
28. The molten thermoplastic material 24 may be injected through a
gate 30, which directs the flow of the molten thermoplastic
material 24 to the mold cavity 32. The mold cavity 32 is formed
between first and second mold parts 25, 27 of the mold 28 and the
first and second mold parts 25, 27 are held together under pressure
by a press or clamping unit 34. For instance, the press or clamping
unit 34 applies a clamping force in the range of approximately 1000
psi to approximately 6000 psi during the molding process to hold
the first and second mold parts 25, 27 together while the molten
thermoplastic material 24 is injected into the mold cavity 32. To
support these clamping forces, the clamping system 14 may include a
mold frame and a mold base, the mold frame and the mold base being
formed from a material having a surface hardness of more than about
165 BHN and preferably less than 260 BHN, although materials having
surface hardness BHN values of greater than 260 may be used as long
as the material is easily machinable, as discussed further
below.
[0037] Once the shot of molten thermoplastic material 24 is
injected into the mold cavity 32, the reciprocating screw 22 stops
traveling forward. The molten thermoplastic material 24 takes the
form of the mold cavity 32 and the molten thermoplastic material 24
cools inside the mold 28 until the thermoplastic material 24
solidifies. Once the thermoplastic material 24 has solidified, the
press 34 releases the first and second mold parts 25, 27, the first
and second mold parts 25, 27 are separated from one another, and
the finished part may be ejected from the mold 28. The mold 28 may
include a plurality of mold cavities 32 to increase overall
production rates.
[0038] A controller 50 is communicatively connected with a sensor
52 and a screw control 36. The controller 50 may include a
microprocessor, a memory, and one or more communication links. The
controller 50 may be connected to the sensor 52 and the screw
control 36 via wired connections 54, 56, respectively. In other
embodiments, the controller 50 may be connected to the sensor 52
and screw control 56 via a wireless connection, a mechanical
connection, a hydraulic connection, a pneumatic connection, or any
other type of communication connection known to those having
ordinary skill in the art that will allow the controller 50 to
communicate with both the sensor 52 and the screw control 36.
[0039] In the embodiment of FIG. 1, the sensor 52 is a pressure
sensor that measures (directly or indirectly) melt pressure of the
molten thermoplastic material 24 in the nozzle 26. The sensor 52
generates an electrical signal that is transmitted to the
controller 50. The controller 50 then commands the screw control 36
to advance the screw 22 at a rate that maintains a substantially
constant melt pressure of the molten thermoplastic material 24 in
the nozzle 26. While the sensor 52 may directly measure the melt
pressure, the sensor 52 may measure other characteristics of the
molten thermoplastic material 24, such as temperature, viscosity,
flow rate, etc, that are indicative of melt pressure Likewise, the
sensor 52 need not be located directly in the nozzle 26, but rather
the sensor 52 may be located at any location within the injection
system 12 or mold 28 that is fluidly connected with the nozzle 26.
If the sensor 52 is not located within the nozzle 26, appropriate
correction factors may be applied to the measured characteristic to
calculate the melt pressure in the nozzle 26. In yet other
embodiments, the sensor 52 need not be fluidly connected with the
nozzle. Rather, the sensor could measure clamping force generated
by the clamping system 14 at a mold parting line between the first
and second mold parts 25, 27.
[0040] Although an active, closed loop controller 50 is illustrated
in FIG. 1, other pressure regulating devices may be used instead of
the closed loop controller 50. For example, a pressure regulating
valve (not shown) or a pressure relief valve (not shown) may
replace the controller 50 to regulate the melt pressure of the
molten thermoplastic material 24. More specifically, the pressure
regulating valve and pressure relief valve can prevent
overpressurization of the mold 28. Another alternative mechanism
for preventing overpressurization of the mold 28 is to activate an
alarm when an overpressurization condition is detected.
[0041] Molded parts are generally considered to be thin-walled when
a length of a flow channel L divided by a thickness of the flow
channel T is greater than 100 (i.e., L/T>100), but less than
1000. For mold cavities having a more complicated geometry, the L/T
ratio may be calculated by integrating the T dimension over the
length of the mold cavity 32 from a gate 30 to the end of the mold
cavity 32, and determining the longest length of flow from the gate
30 to the end of the mold cavity 32. The L/T ratio can then be
determined by dividing the longest length of flow by the average
part thickness. In the case where a mold cavity 32 has more than
one gate 30, the L/T ratio is determined by integrating L and T for
the portion of the mold cavity 32 filled by each individual gate
and the overall L/T ratio for a given mold cavity is the highest
L/T ratio that is calculated for any of the gates. In some
injection molding industries, thin-walled parts may be defined as
parts having an L/T>100, or having an L/T>200, but <1000.
The length of the flow channel L is the longest flow length as
measured from the gate 30 to the end 104 of the mold cavity.
Thin-walled parts are especially prevalent in the consumer products
industry.
[0042] High L/T ratio parts are commonly found in molded parts
having average thicknesses less than about 10 mm. In consumer
products, products having high L/T ratios generally have an average
thickness of less than about 5 mm. For example, while automotive
bumper panels having a high L/T ratio generally have an average
thickness of 10 mm or less, tall drinking glasses having a high L/T
ratio generally have an average thickness of about 5 mm or less,
containers (such as tubs or vials) having a high L/T ratio
generally have an average thickness of about 3 mm or less, bottle
cap enclosures having a high L/T ratio generally have an average
thickness of about 2 mm or less, and individual toothbrush bristles
having a high L/T ratio generally have an average thickness of
about 1 mm or less. The high productivity injection molding
processes and devices disclosed herein are particularly
advantageous for parts having a thickness of 5 mm or less and the
disclosed processes and devices are more advantageous for thinner
parts.
[0043] Thin-walled parts with high L/T ratios present certain
obstacles in injection molding. For example, the thinness of the
flow channel tends to cool the molten thermoplastic material before
the material reaches the flow channel end 104. When this happens,
the thermoplastic material freezes off and no longer flows, which
results in an incomplete part. To overcome this problem,
traditional injection molding machines inject the molten
thermoplastic material at high variable pressures, typically
greater than a peak pressure of 15,000 psi, so that the molten
thermoplastic material rapidly fills the mold cavity before having
a chance to cool and freeze off. This is one reason that
manufacturers of the thermoplastic materials teach injecting at
high variable pressures. Another reason traditional injection
molding machines inject at high pressures is the increased shear,
which increases flow characteristics, as discussed above. These
high variable injection pressures require the use of very hard
materials to form the mold 28 and the feed system, among other
things. Moreover, the thin walled parts may include one or more
special features, such as a living hinge, a filament, a closure, a
dispenser, a spout, a bellows, and an actuator, that must be filled
before the material freezes.
[0044] When filling at substantially constant pressure, it was
generally thought that the filling rates would need to be reduced
relative to conventional filling methods. This means the polymer
would be in contact with the cool molding surfaces for longer
periods before the mold would completely fill. Thus, more heat
would need to be removed before filling, and this would be expected
to result in the material freezing off before the mold is filled.
It has been unexpectedly discovered that the thermoplastic material
will flow when subjected to substantially constant pressure
conditions despite a portion of the mold cavity being below the
no-flow temperature of the thermoplastic material. It would be
generally expected by one of ordinary skill in the art that such
conditions would cause the thermoplastic material to freeze and
plug the mold cavity rather than continue to flow and fill the
entire mold cavity. Without intending to be bound by theory, it is
believed that the substantially constant pressure conditions of
embodiments of the disclosed method and device allow for dynamic
flow conditions (i.e., constantly moving melt front) throughout the
entire mold cavity during filling. There is no hesitation in the
flow of the molten thermoplastic material as it flows to fill the
mold cavity and, thus, no opportunity for freeze-off of the flow
despite at least a portion of the mold cavity being below the
no-flow temperature of the thermoplastic material.
[0045] Additionally, it is believed that as a result of the dynamic
flow conditions, the molten thermoplastic material is able to
maintain a temperature higher than the no-flow temperature, despite
being subjected to such temperatures in the mold cavity, as a
result of shear heating. It is further believed that the dynamic
flow conditions interfere with the formation of crystal structures
in the thermoplastic material as it begins the freezing process.
Crystal structure formation increases the viscosity of the
thermoplastic material, which can prevent suitable flow to fill the
cavity. The reduction in crystal structure formation and/or crystal
structure size can allow for a decrease in the thermoplastic
material viscosity as it flows into the cavity and is subjected to
the low temperature of the mold that is below the no-flow
temperature of the material.
[0046] Referring to FIG. 2, which schematically illustrates
portions of a multi-cavity injection molding system, a plurality of
mold cavities 32 are provided, in each of which a distinct article
or part is to be injection molded. A system of feeder channels or
runners 60 is provided between a nozzle 26 and gates 30. The
runners 64 of a first branch set, also referred to herein as the
final runners, are the runners disposed in closest proximity to the
mold cavities 32. Each of the runners 66 of a second branch set of
runners are in fluid communication with at least two of the runners
64 of the first branch set of runners. The runners 66 of the second
branch set of runners are disposed one step, or branch level, more
remote from the gates 30 of the mold cavities 32 (and thus one
step, or branch level, closer to the nozzle 26) than the runners 64
of the first branch set of runners.
[0047] A main runner 68 is in fluid communication with each runner
66 of the second branch of runners, with the main runner 68 being
the runner in closest proximity to the nozzle 26, and thus most
remote from the gates 30 of the mold cavities 32. The main runner
68 may be the main sprue of the system. As used herein, runners and
other structural elements in fluid communication with one another
need not be in direct fluid communication, but merely must have the
capability of molten polymeric material moving from one to the
other, whether directly or indirectly.
[0048] While FIG. 2 illustrates a four-cavity mold with three
runner branches, it is recognized that additional mold cavities 32
and branch sets of runners may be provided intermediate a first
runner branch set of runners 64 in closest proximity to a plurality
of mold cavities and a main runner 68 in closest proximity to a
nozzle 26. In addition, while FIG. 2, for convenience, is
illustrated in two dimensions, it is recognized that runner systems
may be designed and manufactured to split off at each branch in a
number of directions. For instance, while the main runner 68 in
closest proximity to the nozzle 26 is illustrated as a single
runner, the nozzle 26 may alternatively split immediately into a
set of main runners that split into, for example, four directions.
While even numbered cavity distributions are often used for ease
manufacturing and mold layout, alternate configurations including
odd number of splits, leading to any number of total cavities,
whether even or odd. If one were to desire a non-even numbered
cavity distribution, a substantially constant pressure injection
molding process would facilitate that.
[0049] In the design of conventional multi-cavity injection molding
systems, various rules of thumb or industry-accepted benchmarks
have been developed for determining appropriate runner size for a
given part to be molded. As discussed in the Background of the
Invention section, some of these include:
[0050] The hydraulic diameter of the runner or feeder channel in
closest proximity to a mold cavity should range from about 1.5 to
about 3 times the nominal wall thickness of the molded article.
See, e.g., Beaumont, Runner and Gating Design Handbook, second
edition, page 152, Hanser Gardner Publications, 2007.
[0051] The hydraulic diameter of the runner or feeder channel in
closest proximity to a mold cavity should be at least 1.5 mm
greater than the nominal wall thickness of a part to be molded.
See, e.g., How to Make Injection Molds, third edition, page 153,
Carl Hanser, 1993 (Germany).
[0052] The hydraulic diameter of the main runner 68 [d.sub.main]
(which is the runner closest to the machine nozzle) and the
hydraulic diameter of each runner 66, 64 of the subsequent (i.e.,
lower-numbered) runner branches [d.sub.branch], is related by the
formula d.sub.main=d.sub.branch.times.N.sup.1/3, where N is the
number of runner branches needed between the machine nozzle 26 and
a single mold cavity 32.
[0053] As used herein, the term "nominal wall thickness" is defined
as the theoretical thickness of a mold cavity if the mold cavity
were made to have a uniform thickness. The nominal wall thickness
may be approximated by the average wall thickness. The nominal wall
thickness may be calculated by integrating length and width of the
mold cavity that is filled by an individual gate. It is recognized
that articles or parts molded in a mold cavity can vary in
thickness across the length of the part. In some instances, the
thickness of a part in its gate region(s) (i.e., in the portion(s)
of the part positioned in the mold cavity at the location(s) where
molten polymeric material was introduced from a feeder channel or
runner system through gate(s) 30 and into the mold cavity 32) is
significantly thinner than the thickness of the overall part. As it
is found that the hydraulic diameter of a runner can be minimized
when designed based on relationships to the wall thickness of the
part at the gates, as opposed to a nominal wall thickness of an
overall part, this disclosure refers to a "gate thickness" of the
article or part to be molded in a given mold cavity 32. However, it
is recognized that for parts having a substantially constant
thickness throughout, including in the gate location, the formulas
and relationships described herein could likewise refer to the
nominal wall thickness of the mold cavity.
[0054] It is found that by operating a multi-cavity injection
molding system at a substantially constant pressure, at peak
pressures below 20,000 psi, runner size may be reduced relative to
injection molding systems operating at variable pressure. Such an
injection molding system may utilize coated or uncoated molds
manufactured of a high thermal conductivity material, such as
aluminum, aluminum alloy, or beryllium copper. Alternatively, lower
thermal conductivity coated or uncoated molds, such as steel or
steel alloys, in multi-cavity injection molding can be operated at
substantially constant pressure. Adjacent and surrounding mold
plates may also be made of materials including aluminum, aluminum
alloy, beryllium copper, steel, or steel alloy. All of these
substantially constant pressure injection molding systems enable
effective use of reduced-size runners as compared to conventional
injection molding systems operating at variable pressure. Because
the substantially constant pressure injection molding process
requires significantly less force and energy to introduce molten
polymeric material into a runner system, the hydraulic diameters of
individual feed channels or runners throughout that runner system,
including at least those in closest proximity to the mold cavities
32, but in many cases, even the main runner 68 closest to the
nozzle 26, can be significantly smaller than the hydraulic
diameters of runners that would be designed for a conventional
injection molding system in accordance with the aforementioned
industry-accepted runner design calculations.
[0055] For example, it is found that the hydraulic diameter of the
main runner 68 [d.sub.main] and the hydraulic diameter of each
runner 36, 34 of the subsequent runner branches [d.sub.branch], in
a substantially constant injection molding system of the present
disclosure, may be related by the formula
d.sub.main=d.sub.branch.times.N.sup.1/3.1, where N is the number of
runner branches needed between the machine nozzle 26 and a single
mold cavity 32. Alternately, they may be related by the formula
d.sub.main=d.sub.branch.times.N.sup.1/8.
[0056] Furthermore, the hydraulic diameter of the runners 64 of the
first branch set of runners may be less than the gate thickness
(i.e., less than the nominal wall thickness of a mold cavity for a
part having substantially the same thickness throughout, including
at the gate(s)), which is contrary to the conventional teachings of
designing runners such that the hydraulic diameters thereof are
about 1.5 to about 3 times the nominal wall thickness, or 1.5 mm
larger than the nominal wall thickness, of a part molded in the
mold cavity. Not only can the hydraulic diameter of the runners 64
of the first branch set of runners may be less than the gate
thickness, but they can be less than 93% of the gate thickness.
Example 1
[0057] A test was performed to determine how runner sizes could be
designed for use with a substantially constant pressure injection
molding process as compared to a conventional variable pressure
injection molding process. The test was performed using 20MFI
Braskem Polypropelene Homopolymer FT200WV (with no colorant). The
test was performed using an Engel 100TL 100-ton hydraulic
tiebarless injection molding press. The test was performed with a
mold temperature at a constant 65.degree. F. The Melt Temperature
was 420.degree. F. For the conventional variable pressure process,
a mold viscosity test was performed to establish the injection
rate. A set point of 4.5 in/second was used for each run, or
volumetrically, 2.65 in.sup.3/sec (43.43 cm.sup.3/sec).
[0058] For the substantially constant pressure process, or "SCPP",
the pressure and time were controlled to achieve the given part
weight of 2.51 grams without freezing the gate or runner that would
lead to short shots.
[0059] A steel prototyping/experimental mold as depicted in FIG. 7
was used, with cold runner inserts of the following hydraulic
diameters and respective runner L/T ratios: 0.030''(100),
0.040''(75), 0.045''(67), 0.062''(48), 0.078''(38), 0.093''(32),
and 0.125''(24). The runner length was a constant 3'' and the
runner had a full round profile. For this test, the part L/T was 35
with nominal wall thickness 0.043 inch.
[0060] The focus of the test was to determine processing parameters
and pressures required to produce a qualitatively acceptable
injection molded part. A part was determined to be qualitatively
acceptable by measuring its final part weight and inspecting it for
the absence of flash or sink. If the injection molding process
conditions failed to fully pack the part (i.e., there was a short
shot), the part was deemed unacceptable. Data measurements were
taken in the form of peak melt pressure measured at the injection
nozzle, and peak post gate pressure, which were recorded, and the
corresponding pressure loss across the part.
[0061] During the test, parts were held to within 0.5% of the
processes being compared (i.e., substantially constant pressure
processes versus variable pressure or conventional processes). On
average, conventional pressures were approximately 29% higher than
that of the substantially constant pressures, with the percent
difference increasing slightly as runner diameter increased.
[0062] Peak pressures were recorded using a Dynisco Melt Transducer
located in the nozzle. Post gate pressures were recorded using a
Kistler 2.5 mm Kistler Pressure/Temperature sensor running through
a 5073 programmable charge amp, also from Kistler.
TABLE-US-00001 TABLE 1 Experimental Results of: Conventional
Process Control.sup.&& and Substantially Constant Pressure
Process Control.sup.## versus Cold Runner Diameter.sup.%% Peak Melt
Pressure/Part L/T Col A Col B Peak Melt Pressure (psi) (psi per
dimensionless part L/T ratio) Molded Part Quality Actual Calc
Runner Conventional Substantially Conventional Substantially
Conventional Substantially Runner Cross-Sectional Process Control
Constant Process Control Constant Process Control Constant
Diameter.sup.a Area.sup.b (~Constant Pressure (~Constant Pressure
(~Constant Pressure (inches) (inches.sup.2) Volumetric Rate)
Control Volumetric Rate) Control Volumetric Rate) Control 0.03
0.000707 25067 20151 696.3 559.8 Fail Pass 0.04 0.001257 19272
14411 535.3 400.3 Marginal Pass 0.045 0.001590 17576 13243 488.2
367.9 Pass Pass 0.062 0.003019 12401 8270 344.5 229.7 Pass Pass
0.078 0.004778 9904 6644 275.1 184.6 Pass Pass 0.093 0.006793 9114
5385 253.2 149.6 Pass Pass 0.125 0.012271 7486 4332 207.9 120.3
Pass Pass Notes .sup.&&An (approximate) constant volumetric
setting was employed for the Conventional Process Control .sup.##A
transducer sensor in the melt in the vicinity of the nozzle
provided data to a substantially constant pressure process
controller for controlling to a substantially constant pressure.
.sup.%%Diameter of the sprue was held constant and is 0.23 inch.
.sup.aIn this experiment runner cross-section was circular in shape
therefore actual runner diameter = hydraulic runner diameter.
.sup.bIn this experiment runner cross-section was circular in shape
therefore actual runner cross-sectional area = hydraulic runner
cross-sectional area. This column is calculated from Col A via
formula for area of a circle. Molded Part Quality Key: Pass = parts
at that condition met the full part weight target of 2.51 grams and
there was no flashing or sink in the parts. Fail = parts at that
condition resulted in short shots and did not meet the full part
weight target of 2.51 grams. Marginal = parts at that condition met
full the part weight target of 2.51 grams, but there was flashing
and sink in the parts.
[0063] For each runner diameter, ten parts were each made for the
Conventional Process Control and Substantially Constant Pressure
Control conditions. The reported data is the average of the ten
parts produced at each test condition.
[0064] Single cavity mold with cold runner system. Runner length
constant at 3 inches.
[0065] A runner system for a multi-cavity mold for a substantially
constant pressure injection molding system may therefore be
designed with each runner 64 of the branch runner set closest to
the mold cavities 32 having a hydraulic diameter of less than 1.5
times the gate thickness, and preferably in a range of 0.5-1.5
times the gate thickness, and for systems operating at relatively
lower pressures, more preferably in a range of 0.5 to 0.9 times a
gate thickness.
[0066] Based on the above-described comparative test for
conventional injection molding systems as well as for injection
molding systems intended for operation at substantially constant
pressure, various relationships between hydraulic runner diameter
for the runner 64 of the branch runner set closest to the mold
cavities 32 and peak melt pressure, as well as between
cross-sectional area of the runner 64 of the branch runner set
closest to the mold cavities 32 and peak melt pressure, are
definable.
[0067] Turning to FIG. 3, a comparison of the relationship of
hydraulic runner diameter to the quotient of peak melt pressure
over L/T for a part is illustrated. The data from which the
comparison plot was generated is provided in the following
table:
TABLE-US-00002 Curve 74 Peak Melt Runner Pressure/Part (L/T) Runner
Diameter = 20 * Peak SCPP Actual Dia Melt Pressure/L/T.sup.-1
(Curve 72) Conventional Runner Dia 0.02 1000 559.8 696.3 0.03 0.022
909.0909091 400.3 535.3 0.04 0.024 833.3333333 367.9 488.2 0.045
0.026 769.2307692 229.7 344.5 0.062 0.028 714.2857143 184.6 275.1
0.078 0.03 666.6666667 149.6 253.2 0.093 0.032 625 120.3 207.9
0.125 0.034 588.2352941 0.036 555.5555556 0.038 526.3157895 0.04
500 0.042 476.1904762 0.044 454.5454545 0.046 434.7826087 0.048
416.6666667 0.05 400 0.052 384.6153846 0.054 370.3703704 0.056
357.1428571 0.058 344.8275862 0.06 333.3333333 0.062 322.5806452
0.064 312.5 0.066 303.030303 0.068 294.1176471 0.07 285.7142857
0.072 277.7777778 0.074 270.2702703 0.076 263.1578947 0.078
256.4102564 0.08 250 0.082 243.902439 0.084 238.0952381 0.086
232.5581395 0.088 227.2727273 0.09 222.2222222 0.092 217.3913043
0.094 212.7659574 0.096 208.3333333 0.098 204.0816327 0.1 200 0.102
196.0784314 0.104 192.3076923 0.106 188.6792453 0.108 185.1851852
0.11 181.8181818 0.112 178.5714286 0.114 175.4385965 0.116
172.4137931 0.118 169.4915254 0.12 166.6666667 0.122 163.9344262
0.124 161.2903226 0.126 158.7301587 0.128 156.25 0.13
153.8461538
[0068] The curve 70, depicted as the "Conventional" curve farthest
to the upper right, represents the relationship of hydraulic runner
diameter to [peak melt pressure/(part LIT)] for a conventional
injection molding system or process. The curve 72, depicted as the
"SCPP" curve farthest to the lower left, represents the
relationship of hydraulic runner diameter to [peak melt
pressure/(part L/T)] for a substantially constant injection molding
system or process of the present disclosure. The curve 74
intermediate curves 70 and 72 represents an average of the data
points between the data used to generate the Conventional and SCPP
curves 70 and 72. A regression curve was fit to the average data to
derive a power equation used to generate the data at all the runner
diameters in the range of 0.020'' to 0.130''. As this data
supports, a runner system for a multi-cavity mold for a
substantially constant pressure injection molding system may be
designed and manufactured such that the hydraulic runner diameter
(D.sub.H) of the runner closest to a molding cavity is less than or
equal to 20 times a peak melt pressure at which polymer is injected
by the injection molding system, divided by (L/T).sup.-1, where L/T
is a length-to-thickness ratio of a part to be molded in at least
one cavity of the multi-cavity molding system, or
formulaically:
D.sub.H.ltoreq.20*Peak Melt Pressure/(L/T).sup.-1
[0069] The hydraulic diameter of the runner closest to a molding
cavity must be sufficiently large so as to permit the flow of
molten polymeric material therethrough and into the respective mold
cavity. Therefore, there is a practical minimum hydraulic diameter
for the runner. This practical minimum is on the order of 0.5 times
the gate thickness for the part to be molded. Preferably, the
hydraulic runner diameter of the runner closest to a molding cavity
is less than or equal to 8.25 times the peak melt pressure, divided
by (L/T).sup.-0.889 runner diameter, or formulaically:
D.sub.H.ltoreq.8.25*Peak Melt Pressure/(L/T).sup.-0.889
[0070] Turning now to FIG. 4, a comparison of the relationship of
hydraulic runner cross-sectional area to the quotient of peak melt
pressure over L/T for a part is illustrated. The data from which
the comparison plot was generated is provided in the following
table:
TABLE-US-00003 Curve 84 Cross Sectional Runner Actual Area = 315 *
Cross Curve Cross Peak Melt Sectional 82 Sectional Pressure/Part
(L/T) Area SCPP Conventional Area 1000.00 0.000314159 559.76 696.30
0.000706858 909.09 0.000380133 400.31 535.32 0.001256637 833.33
0.000452389 367.86 488.22 0.001590431 769.23 0.000530929 229.72
344.47 0.003019071 714.29 0.000615752 184.56 275.11 0.004778362
666.67 0.000706858 149.58 253.17 0.006792909 625.00 0.000804248
120.33 207.94 0.012271846 588.24 0.00090792 555.56 0.001017876
526.32 0.001134115 500.00 0.001256637 476.19 0.001385442 454.55
0.001520531 434.78 0.001661903 416.67 0.001809557 400.00
0.001963495 384.62 0.002123717 370.37 0.002290221 357.14
0.002463009 344.83 0.002642079 333.33 0.002827433 322.58
0.003019071 312.50 0.003216991 303.03 0.003421194 294.12
0.003631681 285.71 0.003848451 277.78 0.004071504 270.27 0.00430084
263.16 0.00453646 256.41 0.004778362 250.00 0.005026548 243.90
0.005281017 238.10 0.005541769 232.56 0.005808805 227.27
0.006082123 222.22 0.006361725 217.39 0.00664761 212.77 0.006939778
208.33 0.007238229 204.08 0.007542964 200.00 0.007853982 196.08
0.008171282 192.31 0.008494867 188.68 0.008824734 185.19
0.009160884 181.82 0.009503318 178.57 0.009852035 175.44
0.010207035 172.41 0.010568318 169.49 0.010935884 166.67
0.011309734 163.93 0.011689866 161.29 0.012076282 158.73
0.012468981 156.25 0.012867964 153.85 0.013273229
[0071] The curve 80, depicted as the "Conventional" curve farthest
to the upper right, represents the relationship of hydraulic runner
cross-sectional area to [peak melt pressure/(part LIT)] for a
conventional injection molding system or process. The curve 82,
depicted as the "SCPP" curve farthest to the lower left, represents
the relationship of hydraulic runner cross-sectional area to [peak
melt pressure/(part L/T)] for a substantially constant injection
molding system or process of the present disclosure. The curve 84
intermediate curves 80 and 82 represents an average of the data
points between the data used to generate the Conventional and SCPP
curves 80 and 82. As this data supports, a runner system for a
multi-cavity mold for a substantially constant pressure injection
molding system may be designed and manufactured such that the
hydraulic runner cross-sectional area of the runner closest to a
molding cavity is less than or equal to 315 times a peak melt
pressure at which polymer is injected by the injection molding
system, divided by (L/T).sup.-2, where L/T is a length-to-thickness
ratio of a part to be molded in at least one cavity 32 of the
multi-cavity molding system, or formulaically:
Hydraulic Cross-Sectional Runner Area.ltoreq.315*Peak Melt
Pressure/(L/T).sup.-2
[0072] Preferably, the hydraulic runner cross-sectional area of the
runner closest to a molding cavity is less than or equal to 53.51
times the peak melt pressure, divided by (L/T).sup.-1.778, or
formulaically:
Hydraulic Cross-Sectional Runner Area.ltoreq.53.51*Peak Melt
Pressure/(L/T).sup.-1.778
[0073] Turning now to FIG. 5, a comparison of the relationship of
hydraulic cross-sectional runner area to peak melt pressure is
illustrated. The data from which the comparison plot was generated
is provided in the following table:
TABLE-US-00004 Runner Cross Sectional Area vs Peak Melt Pressure
Actual Cross Curve 94 Cross Sectional Sectional Area SCPP Curve
Conventional Area = 360,000 * Peak Runner Cross Tested (in.sup.2)
92 Pressure Melt Pressure.sup.-2 Sectional Area 0.000706858 20151.4
25066.7 33851.37501 0.000314159 0.001256637 14410.9 19590.5
30773.97728 0.000380133 0.001590431 13242.6 17575.9 28209.47918
0.000452389 0.003019071 8269.8 12401 26039.51924 0.000530929
0.004778362 6644.9 9904.2 24179.55358 0.000615752 0.006792909
5385.2 9114.4 22567.58334 0.000706858 0.012271846 4331.8 7486.3
21157.10938 0.000804248 19912.57354 0.00090792 18806.31945
0.001017876 17816.51316 0.001134115 16925.68751 0.001256637
16119.70239 0.001385442 15386.98864 0.001520531 14717.98914
0.001661903 14104.73959 0.001809557 13540.55001 0.001963495
13019.75962 0.002123717 12537.5463 0.002290221 12089.77679
0.002463009 11672.88794 0.002642079 11283.79167 0.002827433
10919.79839 0.003019071 10578.55469 0.003216991 10257.99243
0.003421194 9956.286768 0.003631681 9671.821432 0.003848451
9403.159726 0.004071504 9149.020274 0.00430084 8908.256582
0.00453646 8679.839747 0.004778362 8462.843753 0.005026548
8256.43293 0.005281017 8059.851194 0.005541769 7872.412794
0.005808805 7693.494321 0.006082123 7522.527781 0.006361725
7358.994568 0.00664761 7202.420216 0.006939778 7052.369794
0.007238229 6908.44388 0.007542964 6770.275003 0.007853982
6637.524512 0.008171282 6509.87981 0.008494867 6387.051889
0.008824734 6268.773151 0.009160884 6154.795457 0.009503318
6044.888395 0.009852035 5938.837722 0.010207035 5836.443968
0.010568318 5737.521189 0.010935884 5641.895835 0.011309734
5549.40574 0.011689866 5459.899196 0.012076282 5373.234129
0.012468981 5289.277346 0.012867964 5207.903848 0.013273229
[0074] The curve 90, depicted as the curve farthest to the upper
right, represents the relationship of hydraulic runner
cross-sectional area to peak melt pressure for a conventional
injection molding system or process. The curve 92, depicted as the
curve farthest to the lower left, represents the relationship of
hydraulic runner cross-sectional area to peak melt pressure for a
substantially constant injection molding system or process of the
present disclosure. The curve 94 intermediate curves 90 and 92
represents an average of the data points between the data used to
generate the Conventional and SCPP curves 90 and 92. As this data
supports, a runner system for a multi-cavity mold for a
substantially constant pressure injection molding system may be
designed and manufactured such that the hydraulic runner
cross-sectional area of the runner closest to a molding cavity is
less than or equal to the quotient of 360,000 divided by the square
of the peak melt pressure, or formulaically:
Hydraulic Cross-Sectional Runner Area.ltoreq.360,000/(Peak Melt
Pressure)
[0075] Preferably, the hydraulic runner cross-sectional area of the
runner closest to a molding cavity is less than or equal to 31,313
times (peak melt pressure).sup.-1.778, or formulaically:
Hydraulic Cross-Sectional Runner Area.ltoreq.31,313*(Peak Melt
Pressure).sup.-1.778
[0076] Turning to FIG. 6, a comparison of the relationship of
hydraulic runner diameter to peak melt pressure is illustrated. The
data from which the comparison plot was generated is provided in
the following table:
TABLE-US-00005 Runner Diameter vs. Peak Melt Pressure SCPP Curve
102 Curve 104 Peak Melt Runner Melt Conventional Runner Pressure =
Diameter Pressure Peak Melt Diameter 700 * (Runner (in) (psi)
Pressure (psi) (in) Dia).sup.-1 0.017 35000 -- 0.02 35000 0.03
20151.4 25066.7 0.022 31818.18182 0.04 14411 19271.6 0.024
29166.66667 0.045 13243 17576 0.026 26923.07692 0.062 8270 12401
0.028 25000 0.078 6644 9904 0.03 23333.33333 0.093 5385 9114 0.032
21875 0.125 4332 7486 0.034 20588.23529 0.036 19444.44444 0.038
18421.05263 0.04 17500 0.042 16666.66667 0.044 15909.09091 0.046
15217.3913 0.048 14583.33333 0.05 14000 0.052 13461.53846 0.054
12962.96296 0.056 12500 0.058 12068.96552 0.06 11666.66667 0.062
11290.32258 0.064 10937.5 0.066 10606.06061 0.068 10294.11765 0.07
10000 0.072 9722.222222 0.074 9459.459459 0.076 9210.526316 0.078
8974.358974 0.08 8750 0.082 8536.585366 0.084 8333.333333 0.086
8139.534884 0.088 7954.545455 0.09 7777.777778 0.092 7608.695652
0.094 7446.808511 0.096 7291.666667 0.098 7142.857143 0.1 7000
0.102 6862.745098 0.104 6730.769231 0.106 6603.773585 0.108
6481.481481 0.11 6363.636364 0.112 6250 0.114 6140.350877 0.116
6034.482759 0.118 5932.20339 0.12 5833.333333 0.122 5737.704918
0.124 5645.16129 0.126 5555.555556 0.128 5468.75 0.13
5384.615385
[0077] The curve 100, depicted as the "Conventional" curve farthest
to the upper right, represents the relationship of hydraulic runner
diameter to peak melt pressure for a conventional injection molding
system or process. The curve 102, depicted as the "SCPP" curve
farthest to the lower left, represents the relationship of
hydraulic runner diameter to peak melt pressure for a substantially
constant injection molding system or process of the present
disclosure. The curve 104 intermediate curves 100 and 102
represents an average of the data points between the data used to
generate the Conventional and SCPP curves 100 and 102. As this data
supports, a runner system for a multi-cavity mold for a
substantially constant pressure injection molding system may be
designed and manufactured such that the hydraulic runner diameter
of the runner closest to a molding cavity is less than or equal to
700 divided by the peak melt pressure, or formulaically:
D.sub.H.ltoreq.700*Peak Melt Pressure.sup.-1
[0078] Preferably, the hydraulic runner diameter of the runner
closest to a molding cavity is less than or equal to 199.63 times
the peak melt pressure).sup.-0.889, or formulaically:
D.sub.H.ltoreq.199.63*Peak Melt Pressure.sup.-0.889
[0079] In a multi-branch, multi-cavity injection molding system of
the present disclosure, it is also found that for a hot runner
manifold, even when operating at substantially constant pressure,
there is some pressure drop from the inlet of the feed system to
the outlet of the feed system. As mentioned above, by running at
substantially constant pressures (as opposed to variable peak
pressures), it is found that the runner size may be reduced,
resulting in significant benefits. A particular benefit of reduced
runner size in a hot runner system is that a frequent concern when
operating a hot runner system is the fact that because molten
polymeric material is compressible, there is some lag or hysteresis
after stopping actuation of the reciprocating screw 22 (or plunger)
of the injection molding system, after which the momentum of the
still-molten polymeric material, and release of potential energy
due to compression, cause that material to continue to flow toward
the mold cavities. The larger the volume of the runners, the more
pronounced this continued flow following screw or plunger stoppage
phenomenon. Conversely, by reducing the size of the runners in a
hot runner system, the effects of continued molten polymeric
material flow following stoppage of the reciprocating screw 22 or
plunger are abated.
[0080] When designing a hot runner system according to the formula
D.sub.m=D.sub.b*N.sup.1/3, where N equals the number of branches
extending from a node. Using this formula, the sum of the cross
sectional area of the final runner branches [A.sub.b] is
substantially higher than the cross sectional area at the feed
system inlet or the main sprue [A.sub.m]. The relationship of
D.sub.m to D.sub.b can further be expressed by the formula
D.sub.m=D.sub.b*[the total number of final runners].sup.1/3. This
relationship holds true regardless of the number of final runner
branches, so long as the runner sizes are determined using the
formula D.sub.m=D.sub.b*N.sup.1/3 as discussed above. Based on this
relationship, it can further be determined that the ratio of
A.sub.b to A.sub.m will always follow the proportions shown in the
table below, where D.sub.b is shown for a 6 millimeter system and
for a 3 millimeter system to illustrate that the relationship
always holds. Therefore, a system having a hot runner in closest
proximity to a mold cavity with a minimum hydraulic diameter at
least sufficiently large so as to permit the flow of molten
polymeric material therethrough and into the mold cavity, and less
than 6 millimeters, is achievable with the substantially constant
pressure injection molding process of the present disclosure.
A.sub.m and A.sub.b are hydraulic cross sectional areas. Two tables
are shown below. Table 2 involves the conventional minimum final
hot runner hydraulic diameter of 6 mm for thermoplastic materials.
Table 3 provides one example of a smaller final runner hydraulic
diameter made possible constant pressure processing using
thermoplastic materials.
TABLE-US-00006 TABLE 2 # of Final Ab/Am Runners D.sub.main* A.sub.m
A.sub.b Ratio 4 9.52 71.211 113.040 1.587 8 12.00 113.040 226.080
2.000 16 15.12 179.440 452.160 2.520 32 19.05 284.843 904.320 3.175
64 24.00 452.160 1808.640 4.000 128 30.24 717.759 3617.280 5.040
256 38.10 1139.372 7234.560 6.350 *Assumes a 6 millimeter final
runner diameter.
TABLE-US-00007 TABLE 3 # of Final Ab/Am Runners D.sub.main**
A.sub.m A.sub.b Ratio 4 4.76 17.803 28.260 1.587 8 6.00 28.260
56.520 2.000 16 7.56 44.860 113.040 2.520 32 9.52 71.211 226.080
3.175 64 12.00 113.040 452.160 4.000 128 15.12 179.440 904.320
5.040 256 19.05 284.843 1808.640 6.350 **Assumes a 3 millimeter
final runner diameter.
[0081] The use of constant pressure processing enables this ratio
to be reduced, which in turn reduces the pressure loss that will
occur in the feed system. This is possible, since a mold cavity can
be filled at a substantially lower flow rate, and thus polymer can
be forced through the feed system at much lower pressures according
to Bernoulli's Principle. This ratio can be reduced, such that the
ratio of A.sub.b to A.sub.m is lower than the standard ratio
applied in the table above. For example, if a 3 millimeter final
runner diameter is used, while maintaining the main runner diameter
the same as for a standard 6 millimeter final runner system, then
the resulting A.sub.b to A.sub.m ratio is shown in the table
below.
TABLE-US-00008 TABLE 4 # of Final Runners A.sub.b/A.sub.m Ratio***
4 0.397 8 0.500 16 0.630 32 0.794 64 1.000 128 1.260 256 1.587
***Where A.sub.b is for a 3 millimeter final runner diameter, and
A.sub.m is calcucated for a main runner diameter for a system
having a 6 mm final runner using the formula D.sub.m = D.sub.b *
N.sup.1/3.
[0082] This demonstrates that a runner system can be designed such
that there is considerably less pressure loss across the runner
network when a substantially constant pressure process is used.
Based on the experimental data shared in Table 1, above, the ratio
of A.sub.b/A.sub.m in Table 4 can be reduced to 1:1, or even less.
Thus, a runner system for a substantially constant pressure process
can be designed such that reduced pressure loss contribution occurs
across the runner network as a result of an increase in
cross-sectional flow area. It is understood that some losses may
occur related to the frictional losses in the system, and also that
shear thinning behaviors of the flowing liquid will also affect the
pressure required to flow through the system. However, the
relationship associated with the cross sectional hydraulic flow
diameters shown above will continue to be true regardless of these
other factors.
[0083] For a multi-branch, multi-cavity substantially constant
pressure injection molding system having a system of hot runners
arranged as a system of feeder channels or runners 60 such as
illustrated schematically in FIG. 2, it is found that the hot
runner system may be designed and manufactured such that the
cross-sectional area of the main runner 68 is equal to the
cross-sectional area of each of the runners 64 in the first runner
branch set of runners in closest proximity to a plurality of mold
cavities 32, times a constant K, or formulaically:
A.sub.main=A.sub.final branch*K
Where A.sub.main=.pi.(D.sub.H main/2).sup.2 and
A.sub.final branch=.pi.(D.sub.H final branch/2).sup.2
the formula becomes .pi.(D.sub.H main/2).sup.2=.pi.(D.sub.H final
branch/2).sup.2*K,
which simplifies to: D.sub.H main.sup.2=D.sub.H final
branch.sup.2*K
[0084] As discussed in U.S. patent application Ser. No. 13/476,073,
entitled "Non-Naturally Balanced Feed System for an Injection
Molding Apparatus", the entire disclosure of which is incorporated
herein by reference, it is possible to provide flow channels or
runner systems in an asymmetric pattern between nozzle 26 and gates
30. Another benefit of the reduced-runner sizes contemplated by the
present disclosure is the ability to optimize the distribution of
multiple mold cavities in a single mold by combining the benefits
of a non-naturally balanced feed system with feed channels of
reduced hydraulic diameter or cross-section as compared to
conventional injection molding systems.
[0085] It is noted that the terms "substantially," "about," and
"approximately," unless otherwise specified, may be utilized herein
to represent the inherent degree of uncertainty that may be
attributed to any quantitative comparison, value, measurement, or
other representation. These terms are also utilized herein to
represent the degree by which a quantitative representation may
vary from a stated reference without resulting in a change in the
basic function of the subject matter at issue. Unless otherwise
defined herein, the terms "substantially," "about," and
"approximately" mean the quantitative comparison, value,
measurement, or other representation may fall within 20% of the
stated reference.
[0086] It should now be apparent that the various embodiments of
the products illustrated and described herein may be produced by a
substantially constant pressure molding process. While particular
reference has been made herein to products for containing consumer
goods or consumer goods products themselves, it should be apparent
that the molding method discussed herein may be suitable for use in
conjunction with products for use in the consumer goods industry,
the food service industry, the transportation industry, the medical
industry, the toy industry, and the like. Moreover, one skilled in
the art will recognize the teachings disclosed herein may be used
in the construction of stack molds, multiple material molds
including rotational and core back molds, in combination with
in-mold decoration, insert molding, in mold assembly, and the
like.
[0087] While particular embodiments have been illustrated and
described herein, it should be understood that various other
changes and modifications may be made without departing from the
spirit and scope of the claimed subject matter. Moreover, although
various aspects of the claimed subject matter have been described
herein, such aspects need not be utilized in combination. It is
therefore intended that the appended claims cover all such changes
and modifications that are within the scope of the claimed subject
matter.
[0088] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm."
[0089] Every document cited herein, including any cross referenced
or related patent or application, is hereby incorporated herein by
reference in its entirety unless expressly excluded or otherwise
limited. The citation of any document is not an admission that it
is prior art with respect to any invention disclosed or claimed
herein or that it alone, or in any combination with any other
reference or references, teaches, suggests or discloses any such
invention. Further, to the extent that any meaning or definition of
a term in this document conflicts with any meaning or definition of
the same term in a document incorporated by reference, the meaning
or definition assigned to that term in this document shall
govern.
[0090] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
* * * * *