CN116472160A

CN116472160A - Method and apparatus for controlled injection fluid flow

Info

Publication number: CN116472160A
Application number: CN202180054059.7A
Authority: CN
Inventors: V·加拉蒂; D·汉森; H·莫伊
Original assignee: Synventive Molding Solutions Inc
Current assignee: Synventive Molding Solutions Inc
Priority date: 2020-07-01
Filing date: 2021-01-26
Publication date: 2023-07-21

Abstract

A method of performing an injection molding cycle in an injection molding apparatus (10), the method comprising: controlling the actuator (941, 942) to drive a distal axial portion (1041 d 1) of a valve pin (1041, 1042) interconnected thereto upstream and downstream through a downstream channel (1006), the distal axial portion (1041 d 1) having a selected distal configuration (1041 cs); configuring a selected distal configuration (1041 cs) of the valve pin (1041, 1042) and a selected control surface of the control surface (1008) to interact with each other along a selected upstream travel path (1006 dsl) of the valve pin from a Gate Closed (GC) position; an actuator (941, 942) is controllably driven to drive the distal axial portion (1041 d 1) through a selected upstream travel path (1006 dsl) at a single selected upstream acceleration (900) from the gate-off (GC) zero-velocity position.

Description

Method and apparatus for controlled injection fluid flow

Cross Reference to Related Applications

The disclosures of all of the following applications are incorporated herein by reference in their entirety as if fully set forth herein: U.S. Pat. No. 5,894,025, U.S. Pat. No. 6,062,840, U.S. Pat. No. 6,294,122 (7018), U.S. Pat. No. 6,309,208, U.S. Pat. No. 6,287,107, U.S. Pat. No. 6,343,921, U.S. Pat. No. 6,343,922, U.S. Pat. No. 6,254,377, U.S. Pat. No. 6,261,075, U.S. Pat. No. 6,361,300 (7006), U.S. Pat. No. 6,419,870, U.S. Pat. No. 6,464,909 (7031), U.S. Pat. No. 6062840 (7052), U.S. Pat. No. 6261075 (7052 US 1), U.S. Pat. No. 6,599,116, U.S. Pat. No. 7,234,929 (7075 US 1), U.S. Pat. 7,419,625 (7075 US 2), U.S. Pat. No. 7,569,169 (7075 US 3), U.S. No. 8297836 (7087), U.S. 10/214,118 (7006) filed 8 of 2022, U.S. Pat. No. 7,029,268 (7077 US 1), U.S. 7,270,537 (7077 US 2); U.S. patent No. 7,597,828 (7077 US 3), U.S. patent application serial No. 09/699,856 (7056) filed on 10 months of 2000 and 30 days of 2000, U.S. patent application serial No. 10/269,927 (7031) filed on 10 months of 2002, U.S. patent application serial No. 09/503,832 (7053) filed on 15 months of 2000, U.S. patent application serial No. 09/656,846 (7060) filed on 9 months of 2000, U.S. patent application serial No. 10/006,504 (7068) filed on 12 months of 20001 and 3 days of 2000, U.S. application serial No. 10/101,278 (7070) filed on 19 months of 2000 and PCT application serial No. PCT/US11/062099 (7100 WO 0) and PCT application serial No. PCT/US11/062096 (7100 WO 1), U.S. patent No. 8,562,336, U.S. patent No. 8,091,202 (7097 US 1) and U.S. patent No. 8,282,388 (7097 US 2), U.S. Pat. No. 9,724,861 (7129 US 4), U.S. Pat. No. 9662820 (7129 US 3), published number WO2015006261 (7135 WO 0), published number WO2014209857 (7134 WO 0), published number WO2016153632 (7149 WO 2), international published number WO2016153704 (7149 WO 4), U.S. Pat. No. 9205587 (7117 US 0), U.S. Pat. No. 15/432,175 (7117 US 2) filed on month 14 of 2017, U.S. Pat. No. 9144929 (7118 US 0), U.S. Pat. No. 20170341283 (7118 US 3), international patent application WO2017214387 (7163 WO 0), international application PCT/US17/043029 (7165 WO 0) filed on month 20 of 2017, international application PCT/US17/043100 (7165 WO 1) filed on month 8 of 2017, and International application WO2018129015 (7169 WO 0), international application WO2018148407 (7170), WO 32 (7118 US 0), international patent application No. 5271, WO 48, WO 72 (7172), international patent application WO 48, WO 72 (7172 WO 35, WO 35 (7172 WO 35), international patent application WO 35 (7172 WO 35, WO 35) and International patent application WO 35 (7172).

Background

An injection molding system for use in a sequential gate application comprising: a system having a single tapered configuration of the inner nozzle passage as shown in fig. 1A; and a system capable of withdrawing the valve pin from an upstream gate closed position at multiple or uncontrolled accelerations or even increasing to multiple subsequent intermediate speeds before reaching an end-of-travel position.

Disclosure of Invention

According to the invention there is provided an injection moulding apparatus (10) comprising: an injection molding machine (13) that injects a jet of injection fluid (18) into a heated manifold (40); a heated manifold (40) that distributes injection fluid (18) to distribution channels for delivery of the injection fluid to gates (34, 36, 1000g, 3000 gep) of the mold cavities (30, 3000). The injection molding apparatus (10) includes:

one or more valves, each comprising an actuator (941, 942) interconnected with a valve pin (1041, 1042) having a linear axis of travel (X) in an arrangement in which the actuator (941, 942) controllably drives the valve pin (1040, 1041, 1042) interconnected therewith upstream and downstream through a downstream channel (1006) having a downstream channel portion (1006 ds), the downstream channel portion (1006 ds) having a control surface (1008),

Wherein the control surface (1008) is sloped, or configured as conical, cylindrical, rectilinear or curvilinear, and forms a channel or limiting gap (CG, 1006 rg) of selected size or configuration disposed upstream from the gate (34, 1000g, 3000 gep) to the mold cavity (30, 3000);

the valve pin (1041) having a distal axial portion (1041 d 1) adapted to be controllably driven upstream and downstream through the channel or restriction gap (CG, 1006 rg), the actuator being adapted to drive the distal axial portion (1041 d 1) upstream through the channel or restriction gap (CG, 1006 rg) from a gate closed zero velocity position until a selected reduced upstream velocity (less than the maximum velocity of the drivable valve pin (1041)) is increased;

the control surface (1008) is disposed along an axial length (CT) of about 3mm to about 6mm of the passage or restriction gap (CG, 1006 rg), and a minimum radial diameter (CD) of the control surface (1008) or a minimum radial diameter (CD, 1006 dsd) of the portion (1006 dsp) is about 0.1mm to about 0.8mm longer than a maximum radial diameter (1041 md) of the distal axial portion (1041 d 1).

In the apparatus, the restriction gap (CG, 1006 rg) and the valve pin are adapted to cooperate with each other to restrict flow of injection fluid into the mold cavity (30, 300) through the downstream channel portion (1006 ds) at one or more selected reduced rates when the distal axial portion is withdrawn upstream from the downstream channel portion (1006 ds), the one or more selected reduced rates being less than a maximum rate of injection fluid flow when the valve pin is disposed in the row Cheng Zhongzhi (EOS) position.

In the apparatus, the actuator is adapted to drive the distal axial portion (1041 d 1) upstream through the channel or restriction gap (CG, 1006 rg) at a single selected upstream acceleration rate from the gate-off zero speed position until the acceleration is to a selected reduced upstream speed,

the selected size or configuration of the channel or restriction gap (CG, 1006 rg) and the single selected upstream acceleration are selected in combination with each other so as to control the flow of injection fluid (18) through the channel gap (CG, 1006 rg) at a selected flow rate when the distal axial portion (1041 d 1) is driven at the single selected upstream acceleration from the gate closed zero velocity position.

In the apparatus, the downstream channel portion (1006 DS) preferably includes an inner surface (1010) extending along a distal portion (DS) of the downstream channel (1006); the distal end portion (DS) of the downstream channel (1006) is disposed immediately downstream of the control surface (1008) and is adapted to engage or mate with an outer surface (1041 cs) of a distal axial portion (1041 d 1) of the selected valve pin (1041) such that the selected gate (34, 100G) is closed when the selected valve pin (1041) is disposed at a position where the distal axial portion (1041 d 1) is disposed within the distal end portion (DS) of the downstream channel portion (1006 DS).

In this apparatus, the downstream channel (1006) generally includes an upstream channel portion (1006 us) having a conical or tapered or sloped surface (1009); the tapered or sloped surface (1009) is disposed upstream relative to the downstream channel portion (1006 ds) and is sloped or angled (UAG) at an angle (UAG) relative to the linear axis (a) or the circumferential surface (1041 cs) of the valve pin (1041) and extends along the axial length (UCT) of the downstream channel (1006) such that the stream of injection fluid (18) passes through the upstream channel portion (1006 us) without significantly restricting flow.

The tapered or inclined or configured surface (1008) is typically disposed along or within a distal inner surface of an insert or extension (1003) disposed within the distal end of the nozzle body (1004).

The tapered or sloped surface (1008) may be disposed or formed along or within the distal inner surface of the nozzle body (1004) or within the gate inlet portion (3000 gep) of the mold (3002).

In the apparatus, the flow rate of the injection fluid (18) through the Channel Gap (CG) is controlled to a selected flow rate less than the maximum flow rate by controllably driving a selected valve pin upstream at a single selected upstream acceleration.

In this apparatus, the actuators (1040, 1041, 1042) typically comprise an electric motor having an electrically driven rotor drivingly interconnected with a valve pin in an arrangement that converts rotational movement of the rotor into linear movement of the valve pin (1041).

In the apparatus, a gate (34, 36) of one or more valves is arranged downstream of an upstream gate (32) of an upstream valve, injection fluid being injected into the cavity (30, 300) at a first time through the upstream gate (32) of the upstream valve; the actuator (941, 942) drives the valve pin (1041, 1042) at a second time after the first time to open the gate (34, 36) such that injection fluid injected through the gate (34, 36) is injected into a stream of injection fluid injected through the upstream gate (32) and travels downstream through the cavity (30, 300) past the gate (34, 36).

In the apparatus, the valve pin is preferably adapted to be driven at a single selected upstream acceleration between about 1mm to about 5mm of travel path until it is accelerated to a selected reduced upstream velocity.

In this apparatus, the reduced upstream velocity is preferably selected to be less than about 75% of the maximum velocity.

In another aspect of the present invention, there is provided an injection molding apparatus (10) comprising: an injection molding machine (13) that injects a jet of injection fluid (18) into a heated manifold (40); a heated manifold (40) distributes injection fluid (18) to distribution channels that deliver the injection fluid to gates (32, 34, 36, 1000g, 3000 gep) of the mold cavities (30, 3000). The injection molding apparatus (10) includes:

One or more valves, each comprising an actuator (940, 941, 942) interconnected with a valve pin (1040, 1041, 1042) having a linear axis of travel (X) in an arrangement in which the actuator (940, 941, 942) controllably drives the valve pin (1040, 1041, 1042) interconnected therewith upstream and downstream through a downstream channel (1006) having a downstream channel portion (1006 ds), the downstream channel portion (1006 ds) having a control surface (1008),

wherein the control surface (1008) is sloped, tapered, cylindrical, rectilinear or curvilinear and forms a channel or limiting gap (CG, 1006 rg) of a selected size or configuration disposed upstream from the gate (34, 1000g, 3000 gep) to the mold cavity (30, 3000);

the valve pin (1041) having a distal axial portion (1041 d 1) adapted to be controllably driven upstream and downstream through a passage or restriction gap (CG, 1006 rg), the actuator being adapted to controllably drive the distal axial portion (1041 d 1) at a single selected upstream acceleration from a gate-closed zero velocity position until the speed is increased to a selected reduced upstream velocity (less than the maximum velocity of the drivable valve pin (1041);

wherein the selected size or configuration of the channel or restriction gap (CG, 1006 rg) and the single selected upstream acceleration are selected in combination with each other such that, when driving the distal axial portion (1041 d 1) with the single selected upstream acceleration increasing to a selected upstream velocity greater than zero starting from the gate closed zero velocity position, the flow of injection fluid (18) through the channel gap (CG, 1006 rg) at the selected flow rate is controlled.

The size or volume of the channels or restriction gaps (CG, 1006 rg) is selected according to one or both of the following: the Angle (AG) between the control surface (1008) and the linear axis of travel (X) of the valve pin (1041), and the minimum diameter (CD, 1006 dsd) of the control surface (1008) or portion (1006 dsp) of the control surface (1008), the minimum diameter (CD, 1006 dsd) of the control surface (1008) or portion (1006 dsp) of the control surface (1008) being greater than the maximum diameter (1041 d1 d) of the distal axial portion (1041 d 1) by a selected distance.

The downstream channel (1006) of the apparatus generally includes an upstream channel portion (1006 us) having a tapered or sloped surface (1009), the tapered or sloped surface (1009) being disposed upstream relative to the downstream channel portion (1006 ds) and being sloped or angled (UAG) at an angle (UAG) relative to a linear axis (a) or a circumferential surface (1041 cs) of the valve pin (1041) and extending along an axial length (UCT) of the downstream channel (1006) such that the stream of injection fluid (18) passes through the upstream channel portion (1006 us) without significantly restricting flow.

In the apparatus, wherein the control surface (1008) is tapered or inclined, preferably the control surface is inclined or at an Angle (AG) of about 3 ° to about 6 ° relative to the linear axis (a) or the circumferential surface (1041 cs) of the valve pin (1041).

In the device, wherein the control surface (1008) is tapered or inclined, the angle (UAG) is greater than the Angle (AG).

In the apparatus, wherein the control surface (1008) is tapered or inclined, the control surface is typically disposed along an axial length (CT) of about 3mm to about 6 mm.

In the device, the minimum radial diameter (CD, 1006 dsd) of the control surface (1008) or the portion (1006 dsp) of the control surface (1008) is typically about 0.1mm to about 0.8mm longer than the maximum radial diameter (1041 md) of the distal axial portion (1041 d 1).

In the apparatus, the downstream channel portion (1006 DS) preferably includes an inner surface (1010) extending along a distal portion (DS) of the downstream channel (1006); the distal end portion (DS) of the downstream channel (1006) is disposed immediately downstream of the control surface (1008) and is adapted to engage or mate with an outer surface (1041 cs) of a distal axial portion (1041 d 1) of the selected valve pin (1041) such that the selected valve pin (1041) is closed when axially positioned or driven to a position where the distal axial portion (1041 d 1) is disposed within the distal end portion (DS) of the downstream channel portion (1006 DS).

In the apparatus, a single selected upstream acceleration is selected to reduce the flow rate of injection fluid through the gate (32, 34) to a selected reduced flow rate that is less than the maximum flow rate of injection fluid (18) flowing at the row Cheng Zhongzhi (EOS) location.

In the apparatus, the tapered or inclined surface (1008) is optionally inclined or angled relative to the linear axis (a) at an Angle (AG) selected to limit the flow of injection fluid into the mold cavity (30, 1000) through the passage gap (CG); by controllably positioning or driving the distal axial portion (1041 d 1) of the selected valve pin (1041) from a closed position downstream of the Channel Gap (CG) to a position upstream of the Channel Gap (CG), or from a position upstream of the Channel Gap (CG) to a travel path inside the Channel Gap (CG) downstream of the closed position of the Channel Gap (CG), the mold cavity (30, 1000) is capable of controllably accelerating or decelerating the flow rate of injection fluid (1153) through the gate relative to the acceleration or deceleration occurring at a linear or cylindrical channel surface.

The tapered or inclined or configured surface (1008) can be disposed or formed along or within the distal inner surface of the nozzle body (1004) or within the gate inlet portion (3000 gep) of the mold (3002).

In the apparatus, the flow rate of injection fluid (18) through the Channel Gap (CG) is controlled to a selected flow rate that is less than the maximum flow rate by controllably driving a selected valve pin upstream at a single selected upstream acceleration.

According to the invention there is provided an injection moulding apparatus (10) comprising: an injection molding machine (13) that injects a jet of injection fluid (18) into a heated manifold (40); a heated manifold (40) distributes injection fluid (18) to distribution channels that deliver the injection fluid to gates (32, 34, 36, 1000g, 3000 gep) of the mold cavities (30, 3000).

The injection molding apparatus (10) includes:

one or more valves, each valve comprising an actuator (940, 941, 942) interconnected to a valve pin (1040, 1041, 1042) in an arrangement in which the actuator (940, 941, 942) controllably drives the valve pin (1040, 1041, 1042) interconnected thereto upstream and downstream through a downstream channel (1006) having a downstream channel portion (1006 ds), the downstream channel portion (1006 ds) having a tapered or inclined surface (1008), the surface (1008) being inclined or angled relative to a linear axis (a) along which the selected valve pin (1041) travels;

wherein the tapered or sloped wall surface (1008) forms a Channel Gap (CG) disposed upstream from the gate (34, 1000g, 3000 gep) to the mold cavity (30, 3000), the selected valve pin (1041) having a configuration disposed along a distal axial portion (1041 d 1) of the selected valve pin (1041) such that the distal axial portion (1041 d 1) of the selected valve pin (1041) is adapted to be controllably driven upstream at a single selected upstream acceleration from a gate-closed zero velocity position until the acceleration is to a selected upstream velocity greater than zero;

Wherein the slope or taper of the tapered or sloped surface (1008) is selected to interact with the distal axial portion (1041 d) such that, starting from a gate-closed zero-velocity position, the flow rate of injection fluid (18) through the Channel Gap (CG) is controllable to a selected flow rate when the selected valve pin is controllably driven upstream with a single selected upstream acceleration increase to a selected upstream velocity greater than zero.

The downstream channel (1006) of the apparatus generally includes an upstream channel portion (1006 us) having a conical or tapered or sloped surface (1009); the tapered or sloped surface (1009) is disposed upstream relative to the downstream channel portion (1006 ds) and is sloped or angled (UAG) relative to the linear axis (a) or the circumferential surface (1041 cs) of the valve pin (1041), the angle (UAG) being greater than about 6 ° and extending along the axial length (UCT) of the downstream channel (1006) such that the stream of injection fluid (18) passes through the upstream channel portion (1006 us) without significantly restricting flow.

In the apparatus, the conical or tapered or inclined wall surface (1008), preferably, is inclined or at an Angle (AG) relative to the linear axis (a) or the circumferential surface (1041 cs) of the valve pin (1041), the Angle (AG) being about 3 ° to about 6 °.

In this apparatus, the tapered or sloped surface (1008) is typically disposed along an axial length (CT) of about 3mm to about 6 mm.

In the device, the control surface (1008) or the portion (1006 dsp) of the control surface (1008) has a minimum radial diameter (CD) that is about 0.1mm to about 0.8mm greater than the radial diameter (1041 md) of the typical distal axial portion (1041 d 1).

In the apparatus, the tapered or inclined surface (1008) is optionally inclined or angled relative to the linear axis (a) at an Angle (AG) selected to limit the flow of injection fluid into the mold cavity (30, 1000) through the passage gap (CG); by controllably positioning or driving the distal axial portion (1041 d 1) of the selected valve pin (1041) from a closed position downstream of the Channel Gap (CG) to a position upstream of the Channel Gap (CG), or from a position upstream of the Channel Gap (CG) to a travel path inside the Channel Gap (CG) downstream of the closed position of the Channel Gap (CG), the mold cavity (30, 1000) is capable of controllably accelerating or decelerating the flow rate of injection fluid (1153) through the gate relative to the acceleration or deceleration occurring at the linear or cylindrical channel surface.

The tapered or inclined surface (1008) is typically disposed along or within a distal inner surface of an insert or extension (1003) disposed within the distal end of the nozzle body (1004).

The tapered or inclined surface (1008) can be disposed or formed along or within a distal inner surface of the nozzle body (1004) or within a gate inlet portion (3000 gep) of the mold (3002).

one or more valves, each valve comprising an actuator (940, 941, 942) interconnected to a valve pin (1040, 1041, 1042) in an arrangement in which the actuator (940, 941, 942) controllably drives the valve pin (1040, 1041, 1042) interconnected thereto upstream and downstream through a downstream channel (1006) having a downstream channel portion (1006 ds), the downstream channel portion (1006 ds) having a tapered or inclined surface (1008), the surface (1008) being inclined or angled relative to a linear axis (a) along which the selected valve pin (1041) travels; and an inner surface (1010) extending along a distal portion (DS) of the downstream channel (1006), the distal portion (DS) of the downstream channel (1006) being disposed immediately downstream of the control surface (1008) and adapted to engage or cooperate with an outer surface (1041 cs) of a distal axial portion (1041 d 1) of the selected valve pin (1041) such that the selected valve pin (1041) is axially located or driven to a position where the distal axial portion (1041 d 1) is disposed within the distal portion (DS) of the downstream channel portion (1006 DS) to close the selected gate (34, 100G);

Wherein the tapered or sloped surface (1008) forms a Channel Gap (CG) disposed upstream from the gate (34, 1000G, 3000 gep) to the mold cavity (30, 3000), the selected valve pin (1041) having a configuration disposed along a distal axial portion (1041 d 1) of the selected valve pin (1041) such that the distal axial portion (1041 d 1) of the selected valve pin (1041) is adapted to controllably drive upstream at a single selected upstream acceleration starting at a position from an outer surface (1041 cs) of the distal axial portion (1041 d 1) to mate with the inner surface (1010) until a selected upstream velocity is increased above zero;

wherein the slope or taper of the tapered or sloped surface (1008) is selected to interact with the distal axial portion (1041 d) such that the distal axial portion begins at a position disposed on the outer surface (1041 cs) that mates with the inner surface (1010) to controllably drive the selected valve pin (1041) upstream at a single selected upstream acceleration to a selected upstream velocity greater than zero, the flow rate of the injection fluid (18) flowing through the Channel Gap (CG) being controllable to a selected flow rate less than the maximum flow rate.

In the apparatus, the tapered or inclined surface (1008), preferably, is inclined or angled relative to the linear axis (a) or circumferential surface (1041 cs) of the valve pin (1041), which angle is about 3 ° to about 6 °.

In the device, the minimum radial diameter (CD) of the control surface (1008) or portion (1006 dsp) of the control surface (1008) is generally greater than about 0.1mm to about 0.8mm of the radial diameter (1041 md) of the distal axial portion (1041 d 1).

Wherein the tapered or sloped surface (1008) forms a Channel Gap (CG) disposed upstream from the gate (34, 1000g, 3000 gep) to the mold cavity (30, 3000), the selected valve pin (1041) having a configuration disposed along a distal axial portion (1041 d 1) of the selected valve pin (1041) such that the distal axial portion (1041 d 1) of the selected valve pin (1041) is adapted to be controllably driven downstream at a single selected downstream deceleration from a selected gate open position (906 o) upstream of a Gate Closed (GC) position to a Gate Closed (GC) position;

wherein the slope or taper of the tapered or sloped surface (1008) is selected to interact with the distal axial portion (1041 d) such that, starting from a selected gate open position (906 o) to a Gate Closed (GC) position, the selected valve pin is controllably driven downstream at a single selected downstream deceleration such that the flow rate of injection fluid (18) flowing through the Channel Gap (CG) is controllable to the selected flow rate.

In the device, the smallest radial diameter (CD) of the tapered or sloped surface (1008) or the smallest radial diameter (CD) of the portion (1006 dsp) is about 0.1mm to about 0.8mm greater than the radial diameter (1041 md) of the distal axial portion (1041 d 1).

wherein the tapered or sloped surface (1008) forms a Channel Gap (CG) disposed upstream from the gate (34, 1000g, 3000 gep) to the mold cavity (30, 3000), the selected valve pin (1041) having a configuration disposed along a distal axial portion (1041 d 1) of the selected valve pin (1041) such that the distal axial portion (1041 d 1) of the selected valve pin (1041) is adapted to be controllably driven downstream at a single selected downstream deceleration from a selected gate open position (904 o) downstream from a gate open end-of-stroke (EOS) position to a gate open end-of-stroke (EOS) position;

Wherein the slope or taper of the tapered or sloped surface (1008) is selected to interact with the distal axial portion (1041 d) such that from a selected gate open position (904 o) to a gate open end of stroke (EOS) position, the selected valve pin is controllably driven upstream at a single selected upstream deceleration, whereby the flow of injection fluid (18) through the Channel Gap (CG) is controllable.

In the device, the minimum radial diameter (CD) of the tapered or sloped surface (1008) or the minimum radial diameter (CD) of the portion (1006 dsp) of the control surface (1008) is about 0.1mm to about 0.8mm greater than the radial diameter (1041 md) of the distal axial portion (1041 d 1).

one or more valves, each valve comprising an actuator (940, 941, 942) interconnected with a valve pin having a distal axial portion (1041 d 1) with a pin diameter or maximum radial dimension in an arrangement in which the actuator (940, 941, 942) controllably drives the valve pin (1040, 1041, 1042) interconnected therewith upstream and downstream through a downstream channel (1006) having a downstream channel portion (1006 ds);

the downstream channel portion (1006 ds) includes an inner wall surface (1008) having a selected inner radial diameter (1006 dsd) and a partial length (1006 dsl), the partial length (1006 dsl) being adapted to receive a distal axial portion (1041 d 1) of the valve pin (1041) to reciprocally drive the distal axial portion (1041 d 1) of the valve pin (1041) upstream and downstream through the partial length (1006 dsl);

The inner surface diameter or selected inner radial dimension (1006 dsd) and the pin diameter or pin maximum radial dimension (1041 d1 d) are configured to form a selected size and configuration of flow restricting gap (1006 rg) when the distal axial portion (1041 d 1) is received within the downstream channel portion (1006 ds);

the distal axial portion (1041 d 1) being adapted to be controllably driven upstream at a single selected upstream acceleration from a gate-closing zero velocity position;

wherein the limiting gap (1006 rg) of selected size and configuration is selected such that the selected valve pin (1041) is controllably driven upstream at a single selected upstream acceleration from the gate closed zero velocity position, such that the flow rate of injection fluid (18) flowing through the limiting gap (1006 rg) is controllable to the selected flow rate.

In the apparatus, the distal axial portion (1041 d 1) is generally adapted to be controllably driven upstream from a gate-closed zero speed position with a single selected upstream acceleration until the selected upstream speed is increased above zero; the limiting gap (1006 rg) of selected size and configuration is selected such that the flow rate of injection fluid (18) through the limiting gap (1006 rg) is controllable to a selected reduced flow rate relative to the maximum flow rate when the valve pin (1041) is controllably driven upstream at a single selected upstream acceleration increase to a selected speed from the gate closed zero speed position.

In the apparatus, the downstream channel portion (1006 DS) preferably includes an inner surface (1010) extending along a distal portion (DS) of the downstream channel (1006); the distal end portion (DS) of the downstream channel (1006) is disposed immediately downstream of the partial length (1006 dsl) and is adapted to engage or mate with an outer surface (1041 cs) of a distal axial portion (1041 d 1) of the selected valve pin (1041) such that the selected valve pin (1041) is closed when axially positioned or driven to a gate-closed position in which the outer surface (1041 cs) engages or mates with the inner surface (1010).

In the apparatus, the flow restricting gap (1006 rg) is adapted to restrict the flow of the injection fluid (1153) to a reduced flow rate relative to the higher flow rate; this higher flow rate occurs when the distal axial portion (1041 d 1) is disposed upstream of a partial length (1006 dsl) of the downstream channel portion (1006 ds).

The downstream channel portion (1006 ds) is typically disposed along or formed within a channel volume disposed within the distal end of the nozzle body (1004) or insert or extension (1003); an insert or extension (1003) is disposed within the distal end of the nozzle body (1004).

The downstream channel portion (1006 ds) may be disposed or formed within the gate inlet portion (3000 gep) of the mold (3002) such that the distal axial portion (1041 d 1) of the valve pin (1041) is driven axially through the channel portion (1006 ds) within the gate inlet portion (3000 gep) of the mold (3002).

The portion length (1006 dsl) of the distal axial portion (1041 d 1) along the axial travel path is typically about 1mm to about 18mm, more typically about 2mm to about 10mm, more typically about 2mm to about 8mm.

The outer or circumferential surface (1041 cs) may be linear, cylindrical, tapered or sloped.

the distal axial portion (1041 d 1) is adapted to be controllably driven downstream at a single selected downstream deceleration from a selected gate open position (906 o) upstream of the Gate Closed (GC) position to the Gate Closed (GC) position,

wherein the selected size and configuration of the restriction gap (1006 rg) is selected such that the selected valve pin is controllably driven downstream at a single selected downstream deceleration from the selected gate open position (906 o) to the Gate Closed (GC) position, such that the flow rate of injection fluid (18) through the restriction gap (1006 rg) is controllable to the selected flow rate.

the inner surface diameter or selected inner radial dimension (1006 dsd) and the pin diameter or pin maximum radial dimension (1041 d1 d) are configured to form a flow restricting gap (1006 rg) of a selected size and configuration along a portion of the length (1006 dsl) when the distal axial portion (1041 d 1) is received within the downstream channel portion (1006 ds);

the distal axial portion (1041 d 1) is adapted to be controllably driven upstream at a single selected upstream deceleration from a selected gate open position (904 o) downstream of a gate open end of stroke (EOS) position to the gate open end of stroke (EOS) position,

Wherein the limiting gap (1006 rg) of a selected size and configuration is selected such that, starting from a selected gate open position (904 o), to a gate open end of stroke (EOS) position, the selected valve pin is controllably driven upstream at a single selected upstream deceleration such that the flow rate of injection fluid (18) through the limiting gap (1006 rg) is controllable to the selected flow rate.

The distal axial portion (1041 d 1) has a partial length (1006 dsl) along the axial travel path, typically about 1mm to about 18mm, more typically about 2mm to about 10mm, and more typically about 2mm to about 8mm.

In all of the apparatus described herein, the apparatus may further comprise a position sensor (951, 952) adapted to sense the position of the valve pin (141) or the actuator (941, 942); the position sensor is interconnected with the controller (16) and adapted to send one or more signals indicative of position to the controller (16);

the controller includes instructions to control the upstream travel rate with one or more signals indicative of position at any one or more of the following rates:

(a) A selected downstream deceleration (906) from a selected position (906 o) upstream of the Gate Closing (GC) position to the Gate Closing (GC) position;

(b) A selected downstream deceleration (920) from a selected intermediate upstream position (920 o) to an intermediate zero speed position (912);

(c) A selected upstream deceleration (914) from a selected intermediate position (914 o) upstream of the Gate Closed (GC) position to an intermediate zero speed position (916);

(d) A selected downstream acceleration (908) from an end of travel (EOS) position or from an intermediate upstream zero speed position (912);

(e) A selected downstream deceleration (920) from a selected intermediate upstream position (920 o) to an intermediate zero speed position (912);

(f) A selected upstream or downstream travel constant speed or rate over any portion of the injection cycle duration;

(g) A selected zero speed within any portion of the injection cycle duration.

In another aspect of the invention, there is provided a method of performing an injection cycle, comprising:

sensing a position of the valve pin (141) or the actuator (941, 942);

using one or more signals indicative of position to control the upstream rate of travel during an injection cycle at any one or more of the following rates:

(a) A single selected upstream acceleration from a Gate Closing (GC) position to a selected upstream position downstream of the end-of-travel position;

(b) A selected downstream deceleration (906) from a selected position (906 o) upstream of the Gate Closing (GC) position to the Gate Closing (GC) position;

(c) A selected downstream deceleration (920) from a selected intermediate upstream position (920 o) to an intermediate zero speed position (912);

(d) A selected upstream deceleration (914) from a selected intermediate position (914 o) upstream of the Gate Closed (GC) position to an intermediate zero speed position (916);

(e) A selected downstream acceleration (908) from an end of travel (EOS) position or from an intermediate upstream zero speed position (912);

(f) A selected downstream deceleration (920) from a selected intermediate upstream position (920 o) to an intermediate zero speed position (912);

(g) A selected upstream or downstream travel constant speed or rate over any portion of the injection cycle duration;

(h) A selected zero speed within any portion of the injection cycle duration.

In another aspect of the invention, a method of performing an injection molding cycle in an injection molding apparatus (10) is provided. The injection molding apparatus (10) includes an injection molding machine (13) that injects a stream of injection fluid (18) into a heated manifold (40); the heating manifold (40) distributes injection fluid (18) to a distribution channel that delivers injection fluid to gates (34, 36, 1000g, 3000 gep) of a mold cavity (30, 3000) through one or more valves, each of the one or more valves including an actuator (941, 942) interconnected with a valve pin (1041, 1042) having a linear axis of travel (X);

The method comprises the following steps:

controlling the actuator (941, 942) to drive a valve pin (1041, 1042) interconnected with the actuator having a distal axial portion (1041 d 1) such that upstream and downstream pass through a downstream channel (1006) having a downstream channel portion (1006 ds), the distal axial portion (1041 d 1) having a selected distal configuration (1041 cs), the downstream channel portion (1006 ds) having a control surface (1008), the control surface (1008) having a selected control surface configuration;

the selected distal end configuration (1041 cs) of the valve pin (1041, 1042) and the selected control surface configuration of the control surface (1008) are configured to interact with each other along a selected upstream travel path (1006 dsl) of the valve pin from a Gate Closed (GC) position to limit a flow rate of injection fluid (18) through the gate (34, 36) to less than a maximum flow rate;

the actuators (941, 942) are controllably driven to drive the distal axial portion (1041 d 1) through a selected upstream travel path (1006 dsl) at a single selected upstream acceleration (900) from a gate-off (GC) zero-velocity position.

In the method, an actuator (941, 942) can be controllably driven to drive a distal axial portion (1041 d 1) at a single selected upstream acceleration (900) starting from a gate-off (GC) zero speed position until a selected constant upstream speed (902) is increased.

The selected constant upstream velocity (902) is generally less than the maximum velocity of the drivable valve pin (1041).

In the method, a single selected upstream acceleration (900) from the gate-off zero speed position is generally selected such that when the distal axial portion (1041 d 1) is driven upstream at the single selected upstream acceleration from the gate-off zero speed position, the flow of injection fluid (18) through the gates (34, 36) is controlled at a selected injection fluid (18) flow rate.

In the method, a single selected upstream acceleration (900) is typically selected such that the flow rate of the injection fluid through the downstream gate (34, 36) is reduced to a selected reduced flow rate of the injection fluid that is less than the maximum flow rate.

In the method, the selected distal configuration (1041 cs) and the selected control surface configuration of the control surface (1008) are preferably selected such that, starting from a gate-off zero speed position, the flow of injection fluid (18) through the gates (34, 36) is controlled at a selected flow rate when the distal axial portion (1041 d 1) is driven upstream at a single selected upstream acceleration.

The selected flow rate of the injection fluid (18) is preferably less than the maximum rate of injection fluid (18) injectable through the gate (34, 36). This maximum flow rate generally occurs when the distal axial portion (1041 d 1) or valve pin (1041) is withdrawn to a maximum upstream axial position or end of travel (EOS) position where the valve pin (1041) can be withdrawn.

In the method, it is also possible to start from a selected position (906 o) upstream of the Gate Closed (GC) position to selectively drive the valve pin (1041) or the distal axial portion (1041 d 1) at a downstream deceleration (906).

In the method, it is also possible to start with a selected intermediate upstream position (920 o) to an intermediate zero speed position (912) to drive the valve pin (1041) or the distal axial portion (1041 d 1) at a selected downstream deceleration (920).

In the method, it is also possible to start with a selected intermediate position (914 o) upstream of the Gate Closed (GC) position to an intermediate zero velocity position (916) to drive the valve pin (1041) or the distal axial portion (1041 d 1) at a selected upstream deceleration (914).

In the method, the valve pin (1041) or the distal axial portion (1041 d 1) can also be driven from an end of travel (EOS) position or from an intermediate upstream zero speed position (912) with a selected downstream acceleration (908).

The method preferably comprises: forming a channel or limiting gap (CG, 1006 rg) arranged upstream from the gate (34, 1000g, 3000 gep) to the mold cavity (30, 3000) and having a slope of the control surface (1008) or being configured to be conical, cylindrical, rectilinear or curvilinear; the control surface (1008) is adapted to operate in conjunction with the distal axial portion (1041 d 1) and a single selected upstream acceleration (900) such that, starting from a gate-off zero-velocity position, the flow of injection fluid (18) through the gates (34, 36) is controlled at a controllably selectable flow rate when the distal axial portion (1041 d 1) is driven upstream at the single selected upstream acceleration.

By controlling the selectable flow rate of the injection fluid (18) through the gate (34, 36), it is preferably made less than the maximum rate of injection fluid (18) injectable through the gate (34, 36).

The method may include one or both of: forming a control surface (1008) in a configuration disposed at a selected Angle (AG) relative to a linear axis of travel (X) of the valve pin (1041); and forming a control surface (1008) having a portion (1006 dsp), wherein a minimum radial diameter (CD, 1006 dsd) of the portion (1006 dsp) is greater than a maximum diameter (1041 d1 d) of the distal axial portion (1041 d 1) by a selected distance.

The method may include: an upstream channel portion (1006 us) forming a downstream channel (1006); the upstream channel portion (1006 us) of the downstream channel (1006) has a conical or tapered or sloped surface (1009) disposed upstream relative to the downstream channel portion (1006 ds) and is sloped or angled (UAG) at an angle (UAG) relative to the linear axis (a) or the circumferential surface (1041 cs) of the valve pin (1041) and extends along the axial length (UCT) of the downstream channel (1006) such that the stream of injection fluid (18) passes through the upstream channel portion (1006 us) without significantly restricting flow.

The method may include: an Angle (AG) of about 3 DEG to about 6 DEG is selected.

The method may include: an angle (UAG) greater than the Angle (AG) is selected.

The method may include: the control surface (1008) is disposed along an axial length (CT) of about 3mm to about 6mm of a travel path of the valve pin (1041).

The method may include: forming the control surface (1008) having a minimum radial diameter (CD) or the portion (1006 dsp) having a minimum radial diameter (CD, 1006 dsd), the minimum radial diameter (CD) of the control surface (1008) or the portion (1006 dsp) being about 0.1mm to about 0.8mm greater than the maximum radial diameter (1041 md) of the distal axial portion (1041 d 1).

The method preferably comprises: extending the inner surface (1010) from the downstream channel portion (1006 ds); the inner surface (1010) extends along a distal portion (DS) of the downstream channel (1006); the distal end portion (DS) of the downstream channel (1006) is disposed immediately downstream of the control surface (1008) and is adapted to engage or mate the inner surface (1010) with the outer surface (1041 cs) of the distal axial portion (1041 d 1) of the selected valve pin (1041) such that the selected gate (34, 100G) is closed when the selected valve pin (1041) is axially located or driven to a position where the distal axial portion (1041 d 1) is disposed within the distal end portion (DS) of the downstream channel portion (1006 DS).

The method preferably comprises: forming an Angle (AG) of the control surface (1008) relative to the linear axis (a); the Angle (AG) is selected to limit the flow of injection fluid through the passage gap (CG) into the mold cavity (30, 1000); by controllably positioning or driving the distal axial portion (1041 d 1) of the selected valve pin (1041) from a closed position downstream of the Channel Gap (CG) to a position upstream of the Channel Gap (CG), or from a position upstream of the Channel Gap (CG) to a travel path inside the Channel Gap (CG) downstream of the closed position of the Channel Gap (CG), the mold cavity (30, 1000) is capable of controllably accelerating or decelerating the flow rate of injection fluid (18, 1153) through the gate (34, 36) relative to acceleration or deceleration occurring at the straight or cylindrical downstream channel (1006 ds).

The method may include: a tapered or sloped or configured surface (1008) is disposed or formed along a distal inner surface of an insert or extension (1003) disposed within a distal end of a nozzle body (1004), or a tapered or sloped or configured surface (1008) is disposed therein.

The method may include: a control surface (1008) is disposed or formed along or within a distal inner surface of the nozzle body (1004) or within a gate inlet portion (3000 gep) of the mold (3002).

The method may include: the flow rate of the injection fluid (18) through the Channel Gap (CG) is controlled to a selected flow rate less than the maximum flow rate by controllably driving a selected valve pin (1041, 1042) upstream at a single selected upstream acceleration.

The method generally includes: selecting an actuator (941, 942) comprising a motor having an electrically driven rotor; the electrically driven rotor is drivingly interconnected with the valve pin in an arrangement that converts rotational movement of the rotor into linear movement of the valve pin (1041).

The method preferably comprises: arranging gates (34, 36) of one or more valves downstream of an upstream gate (32) of an upstream valve, injecting an injection fluid into the cavity (30, 300) through the upstream gate (32) of the upstream valve at a first time; and driving an actuator (941, 942) interconnected with an associated valve pin (1041, 1042) to open a gate (34, 36) arranged downstream at a second time after the first time, such that an injection fluid (18) injected through the gate (34, 36) is injected into a stream of injection fluid injected through an upstream gate (32) and travels downstream through the cavity (30, 300) past the gate (34, 36).

The method may include: between travel paths of about 1mm to about 5mm, the valve pins (1041, 1042) are driven at a single selected upstream acceleration (900) until accelerated to a selected reduced upstream velocity (902).

In the method, the valve pin (1041, 1042) is driven at a selected upstream velocity that is generally less than about 75% of the maximum velocity at which the valve pin can be driven.

In another aspect of the invention, an injection molding apparatus (10) is provided. The injection molding apparatus (10) includes: an injection molding machine (13) that injects a jet of injection fluid (18) into a heated manifold (40); a heated manifold (40) that distributes injection fluid (18) to a distribution channel that delivers injection fluid to gates (34, 36, 1000g, 3000 gep) of a mold cavity (30, 3000) through one or more valves, each of the one or more valves including an actuator (941, 942) that is interconnected with a valve pin (1041, 1042) having a linear axis of travel (X);

the apparatus further includes a controller (16) interconnected with the actuator (941, 942) including instructions instructing the actuator (941, 942) to drive a valve pin (1041, 1042) having a distal axial portion (1041 d 1) interconnected therewith upstream and downstream through a downstream channel (1006) having a downstream channel portion (1006 ds), the distal axial portion (1041 d 1) having a selected distal configuration (1041 cs), the downstream channel portion (1006 ds) having a control surface (1008), the control surface (1008) having a selected control surface configuration;

Wherein the selected distal end configuration (1041 cs) of the valve pin (1041, 1042) and the selected control surface configuration of the control surface (1008) are configured to interact with each other along a selected upstream travel path (1006 dsl) of the valve pin from a Gate Closed (GC) position to limit a flow rate of injection fluid (18) through the gate (34, 36) to less than a maximum flow rate;

the controller includes instructions that instruct the actuator (941, 942) to drive a distal axial portion (1041 d 1) of the valve pin (1041, 1042) through a selected upstream travel path (1006 dsl) at a single selected upstream acceleration (900) from a Gate Closed (GC) zero velocity position.

In another aspect of the invention, a method of performing an injection molding cycle in an injection molding apparatus (10) is provided. The injection molding apparatus (10) includes an injection molding machine (13) that injects a stream of injection fluid (18) into a heated manifold (40); a heated manifold (40) distributes injection fluid (18) to distribution channels of gates (34, 36, 1000g, 3000 gep) delivering injection fluid to a mold cavity (30, 3000) through one or more valves, each of the one or more valves including an actuator (941, 942) interconnected with a valve pin (1041, 1042) having a linear axis of travel (X);

The method comprises the following steps:

controlling the actuator (941, 942) to drive a valve pin (1041, 1042) having a distal axial portion (1041 d 1) interconnected thereto upstream and downstream through a downstream channel (1006) having a downstream channel portion (1006 ds), the distal axial portion (1041 d 1) having a selected distal configuration (1041 cs), the downstream channel portion (1006 ds) having a control surface (1008), the control surface (1008) having a selected control surface configuration;

the actuator (941, 942) is controllably driven to drive the distal axial portion (1041 d 1) at one or more of the following rates:

in the method, a selected downstream deceleration (906, 920), a selected upstream deceleration (914), and a selected downstream acceleration (908) are typically selected to control the flow of injection fluid (18) through the gate (34, 36) at a selected injection fluid (18) flow rate, or to control the injection fluid (18) flow rate through the gate (34, 36) at a selected injection fluid (18) flow rate.

In another aspect of the invention, an injection molding apparatus (10) is provided. The injection molding apparatus (10) includes: an injection molding machine (13) that injects a jet of injection fluid (18) into a heated manifold (40); a heated manifold (40) distributes injection fluid (18) to distribution channels of gates (34, 36, 1000g, 3000 gep) delivering injection fluid to a mold cavity (30, 3000) through one or more valves, each of the one or more valves including an actuator (941, 942) interconnected with a valve pin (1041, 1042) having a linear axis of travel (X);

the controller includes instructions that instruct the actuator (941, 942) to drive the distal axial portion (1041 d 1) at one or more of the following rates:

(e) A selected downstream deceleration (920) from a selected intermediate upstream position (920 o) to an intermediate zero speed position (912).

Drawings

Fig. 1 is a schematic side sectional view of an injection molding apparatus according to the present invention.

FIG. 1A is a schematic side cross-sectional view of a known valve gate having a downstream wider tapered flow channel and a cylindrical valve pin configuration.

FIG. 2 is a schematic side cross-sectional view of one embodiment of a valve arrangement for use with the present invention.

Fig. 2A is an enlarged view of the downstream end of the valve of fig. 3.

Fig. 2B is an enlarged view similar to fig. 2A showing the gate disposed at the downstream end within the die plate body.

FIG. 3 is a schematic side cross-sectional view of another embodiment of a valve arrangement for use with the present invention, showing a valve pin in a gate closed position.

FIG. 4 is a view of the valve gate of FIG. 3 showing the valve pin in an upstream gate portion open position.

FIG. 5 is a view of the valve gate of FIG. 3 showing the valve pin in an upstream gate fully open and end of stroke (EOS) position.

FIG. 5A is a schematic side cross-sectional view of another embodiment of a valve arrangement for use with the present invention, showing the valve pin in an upstream gate fully open and end of stroke (EOS) position.

FIG. 5B is a view of the valve gate of FIG. 5A showing the valve pin in an upstream gate partially open position.

FIG. 5C is a view of the valve gate of FIG. 5A showing the valve pin in a fully gate closed position.

Fig. 6A is a graph of valve pin position versus time in an injection cycle using a valve gate arrangement according to the present invention wherein a valve pin controllably accelerates when open and controllably decelerates near an end-of-travel position.

FIG. 6B is a graph of valve pin position versus time in an injection cycle using a valve according to the present invention wherein a valve pin controllably decelerates when open, decelerates near the end-of-travel position and then accelerates and then decelerates near the gate closed position.

FIG. 6C is a graph of valve pin position versus time in an injection cycle employing a valve according to the present invention wherein a valve pin controllably accelerates when open, decelerates when approaching an end-of-travel position, then accelerates when away from an end-of-travel position, decelerates when approaching a hold position, then accelerates when away from the hold position, and then decelerates when reaching a gate closed position.

FIG. 7A is a fluid flow, fill or concentration or density diagram of a sequential gate cavity using a conventional single velocity valve pin opening scheme and a valve having a conventional configuration that causes a sudden increase in melt or fluid velocity followed by a subsequent decrease in melt or fluid velocity in the surrounding area of the cavity, downstream gates labeled 2 and 3 delivering injection fluid from their associated downstream valve channels into the surrounding area of the cavity.

FIG. 7B is a graph of sprue pressure versus time measured in the downstream valves labeled 2 and 3 in FIG. 7A, utilizing a single pin velocity and conventional valve channel and pin configuration produced by the concentration or density map of FIG. 7A.

Fig. 8A is a graph of fluid flow, fill or concentration of a sequential gate cavity utilizing a conventional slow-then-fast two speed valve pin opening scheme and a valve having a conventional configuration that results in a slight decrease in the rate of flow of melt or fluid into the cavity within the surrounding area of downstream valves 2 and 3 relative to the scheme used to create fig. 7A.

FIG. 8B is a graph of sprue pressure versus time measured in the downstream valves labeled 2 and 3 in FIG. 8A, utilizing a slow-then-fast two-speed pin speed scheme and conventional valve channel and pin configurations that produce the fluid concentration or density map of FIG. 7A.

FIG. 9A is a fluid flow, fill or concentration or density map of a sequential gate mold cavity as used in the system of FIGS. 7A, 8A, but instead, utilizing a controlled upstream flow from a single rate of gate closure in accordance with the valve pin acceleration protocol of the present invention, so that the fluid or fluid delivered from valve gates 2 and 3 and the other downstream valve gates labeled 4, 5 and 6 is significantly more smoothly and uniformly distributed relative to the less uniform fluid or fluid flow or distribution resulting from the use of the pin drive scheme that results in the distribution map of FIGS. 7A and 8A.

FIG. 9B is a graph of sprue pressure versus time measured in the downstream valves labeled 2 and 3 in FIG. 9A, utilizing a controlled pin acceleration scheme and the novel valve channel and pin configuration described herein.

Detailed Description

Fig. 1 shows an injection molding apparatus 10 having a central valve 32 associated with an actuator (940) and two downstream valves 34, 36 associated with actuators (941, 942); after first opening the central valve, opening the two downstream valves 34, 36 in a predetermined sequence with respect to the mold cavity 30; each of the actuators (940, 941, 942) includes a motor having an electric drive (940 d, 941d, 942 d), respectively. The electric drives (940 d, 941d, 942 d) can be housed within the same housing (940 h, 941h, 942 h) as the drive assembly of the electric actuators (940, 941, 942); or the electrical drives (940 d, 941d, 942 d) can be housed within physically separate thermally conductive housings (941 ds).

The electrical driver (940 d, 941d, 942 d) is preferably mounted on or to the actuator housing (940 h, 941h, 942 h) such that the driver component (such as a Pulse Width Modulator (PWM)) and associated electrical components are arranged in substantial thermal communication or contact with the actuator housing (940 h, 941h, 942 h) or the heating manifold (40).

As shown in fig. 1, the injection cycle is a cascading process in which injection is generally performed in a sequence beginning first with the central nozzle 22 and gate 32 and later at a predetermined time with the lateral nozzles 20, 24 and gates 34, 36 after the injection fluid 18 flows downstream from the central gate 32 past the downstream gates 34, 36. The injection cycle is typically initiated by first opening pin 1040 of central nozzle 22 and allowing fluid material 18, 100 (typically a polymer or plastic material) to flow up to a location 100a of the cavity, which location 100a is just before the distally disposed inlet of 100b through which the inlet enters the gated cavity 34, 36 of lateral nozzle 20, 24, as shown in fig. 1. After the injection cycle is initiated, only the gate and pin 1040 of the center jet nozzle 22 will typically remain open as long as the fluid material 100b is allowed to travel to position 100p, just past positions 34, 36. Once the fluid material has just traveled past 100p of the lateral gate locations 34, 36, the center gate 32 of the center nozzle 22 will normally be closed by pin 1040. The lateral nozzle pins 1041, 1042 are then withdrawn upstream to open the lateral gates 34, 36. As described below, the acceleration or velocity of the upstream withdrawal or travel of the lateral pins 1041, 1042 can be controlled to minimize potential problems when filling the mold cavity.

In alternative embodiments, the center gate 32 and associated actuator 940 and valve pin 1040 can be maintained in an open state as, during, and after the side gates 34, 36 are opened such that fluid material enters the mold cavity 30, 3000 while passing through one or both of the center gate 32 and the side gates 34, 36.

Controlling the acceleration 900, 918, 908 or deceleration 904, 906, 920 of the pins 1041, 1042 from any axial position via the controller 16; the controller 16 controls the rate and direction at which the electric actuators 940, 941, 942 are driven.

A single selected upstream acceleration (900) is typically selected to reduce the flow rate of injection fluid through the downstream gate (34, 36) to a selected reduced flow rate; the reduced flow rate is selected to minimally reduce the flow of injection fluid through the upstream gate (32); when the downstream gates (34, 36) are opened in a sequential or cascading process, the upstream gate (32) is opened at a first time before a delayed second time during an injection cycle. A single selected upstream acceleration (900) from the Gate Closed (GC) position is typically selected to reduce the flow rate of injection fluid through the downstream gates (34, 36) to a selected reduced flow rate that is less than the maximum flow rate of injection fluid (18) flowing at the row Cheng Zhongzhi (EOS) position.

The user program controller 16 instructs the electric actuator to drive the pins 1041, 1042 with an upstream or downstream acceleration from zero to the selected travel speed via input of data on the user interface to minimize potential problems in filling the mold cavity.

Fig. 1 shows position sensors 950, 951, 952 for sensing the position of motors 940, 941, 942 and their associated valve pins (such as 1040, 1041, 1042) and feeds this position information to controller 16 for monitoring purposes. As shown, the fluid material 18 is injected from the injector into the manifold runner 19 and further downstream into the bores 44, 46 of the lateral nozzles 24, 22 and finally downstream through the gates 32, 34, 36.

Taking the example shown in fig. 3, 5C, 6A, 6B, 6C when pins 1041, 1042 are withdrawn first upstream starting from the gate closed GC zero velocity position, pins are withdrawn from zero velocity to a selected constant upstream velocity 902 at a single selected acceleration 900; the selected constant upstream velocity 902 is typically less than the maximum velocity at which the actuator can drive the valve pins 1041, 1042. Similarly, when pins 1041, 1042 have been withdrawn from upstream near the end of travel (EOS) position fully upstream, the pins can typically be controllably decelerated to zero speed at a single selected deceleration 904. Again similarly, pins 1041, 1042 can be driven starting from an end-of-travel (EOS) position with a single downstream acceleration 908 accelerating to a selected downstream constant speed 910. Again similarly, pins 1041, 1042 can be decelerated to zero speed at a selected deceleration 906 as pins 1041, 1042 approach a gate-off position fully downstream; the pin typically reaches the gate-off GC position at zero speed.

The injection fluid flow rate through the downstream channel portion (1006 ds) and gates (34, 36) is typically the maximum rate when the valve pin is disposed in an end of stroke (EOS) position for any given injection cycle. And, the injection fluid flow rate is a reduced rate; the rate of decrease is less than the maximum rate when the distal end of the valve pin (1041 d 1) is disposed within the downstream channel portion (1006 ds). The end of travel (EOS) position may not necessarily be the most upstream position from which the valve pin can be withdrawn. It is possible that the injection fluid flow rate may be higher when the valve pin is withdrawn to a position further upstream than the end of stroke (EOS) position. However, at a selected end of stroke (EOS) position downstream of the most upstream position at which the valve pin can be withdrawn, the injection fluid flow rate is the maximum rate when the valve pin reaches the selected end of stroke (EOS) position for any given injection cycle, although the valve pin may be withdrawn further upstream to the most upstream position where the injection fluid flow rate may be a higher maximum absolute value than the flow rate when the valve pin is in the end of stroke position. It is also possible that the maximum absolute flow rate of injection fluid is achieved when the valve pin is disposed in row Cheng Zhongzhi (EOS) position, although the valve pin is not disposed in the absolute most upstream position from which it can be withdrawn. It is also possible that the end of stroke (EOS) position is selected to be the absolute most upstream position where the valve pin can be withdrawn. But this is not necessary.

The movement of pins 1041, 1042 can be further controlled to slow the pins to a zero speed position 916 at a selected deceleration 914; the zero velocity position 916 is downstream of the end of stroke EOS position such that the pins 1041, 1042 remain at a selected intermediate zero velocity position 916 between the gate close GC and the end of stroke EOS for a selected period of time, fig. 6A. The pins 1041, 1042 can then accelerate 918 upstream again to an upstream speed 922. After having accelerated 918 to an upstream velocity 922, the valve pins 1041, 1042 can then decelerate 918 again to stop at a position upstream of the end of travel EOS.

As shown in fig. 2, 2A, 2B, 3, 4, 5A, 5B, 5C, the downstream valve disposed in the upstream center or downstream of the main valve includes: an actuator (941, 942) interconnected to a valve pin (1041, 1042) having a linear axis of travel (X) in the following arrangement; in this arrangement, the actuator (941, 942) is adapted to controllably drive a valve pin (1041, 1042) interconnected thereto upstream and downstream through a downstream channel (1006) having a downstream channel portion (1006 ds); the downstream channel portion (1006 ds) has a control surface (1008). The control surface (1008) may be sloped, tapered, linear or curvilinear and forms a channel or limiting gap (CG, 1006 rg). Increasing from the gate closed position to a predetermined constant velocity, in combination with a single selected acceleration of the pins 1041, 1042, pre-selecting the size or configuration of the channel or limiting gap; the predetermined constant speed is preferably less than the maximum speed at which the actuator can drive the pins 1041, 1042. The channels or limiting gaps CG, 1006rg are arranged immediately upstream of the gates 34, 1000g, 3000gep leading to the mold cavities 30, 3000.

As shown in fig. 2, 2A, 2B, 3, 4, 5A, 5B, 5C, the valve pin (1041) has a distal axial portion (1041 d 1); the distal axial portion (1041 d 1) may be controllably driven upstream and downstream via a controller 16 interconnected with the actuators 941, 942. The controller 16 includes a program containing instructions that instruct the actuators 941, 942 to drive the valve pins 1041, 1042 through a channel or restriction gap (CG, 1006 rg), and more specifically, from a gate-closed zero velocity position, controllably drive distal axial portions (1041 d 1) of the valve pins 1041, 1042 at a single selected upstream acceleration until it accelerates to a selected reduced upstream velocity that is less than the maximum velocity at which the actuator 941 can drive the valve pins (1041).

The selected magnitude or configuration of the channel or restriction gap (CG, 1006 rg) and the single selected upstream acceleration are selected in combination with each other such that, when the distal axial portion (1041 d 1) is driven at a single selected upstream acceleration to a selected upstream velocity greater than zero and less than a maximum value, the flow of injection fluid (18) through the channel gap (CG, 1006 rg) at a selected flow rate is controlled, starting from the gate closed zero velocity position.

As shown in fig. 2, 2A, 2B, 3, 4, 5A, 5B, 5C, the size or volume of the channel or restriction gap (CG, 1006 rg) is selected by selecting the Angle (AG) between the control surface (1008) and the linear axis of travel (X) of the valve pin (1041), and optionally further selecting the minimum diameter (CD, 1006 dsd) of the control surface (1008) or portion (1006 dsp) of the control surface (1008), the minimum radial diameter of the control surface (1008) or portion (1006 dsp) of the control surface (1008) being greater than the maximum diameter (1041 d1 d) of the distal axial portion (1041 d 1) by a selected distance.

In the embodiment shown in fig. 2, 2A, 2B, 3, 4, 5A, 5B, 5C, the downstream general (1006) preferably includes an upstream channel portion (1006 us); the upstream channel portion (1006 us) has a conical or tapered or inclined surface (1009) arranged upstream relative to the downstream channel portion (1006 ds) and is inclined or angled (UAG) relative to the linear axis (a) or circumferential surface (1041 cs) of the valve pin (1041). As shown, the upstream channel portion extends along an axial length (UCT) of the downstream channel (1006) such that the injection fluid (18) flows through the upstream channel portion (1006 us) without significantly restricting flow.

In the illustrated embodiment, the control surface (1008) is tapered or inclined and has a slope or an Angle (AG) of about 3 ° to about 6 ° with respect to the linear axis (a) or the circumferential surface (1041 cs) of the valve pin (1041). The angle (UAG) is greater than the Angle (AG).

Preferably, the control surface (1008) is tapered or sloped and is disposed along an axial length (CT) of about 3mm to about 6 mm.

Typically the minimum radial diameter (CD, 1006 dsd) of the control surface (1008) or the minimum radial diameter of the portion (1006 dsp) is about 0.1mm to about 0.8mm greater than the radial diameter (1041 md) of the distal axial portion (1041 d 1).

As shown, the downstream channel portion (1006 DS) has an inner surface (1010) extending along a distal portion (DS) of the downstream channel (1006); the distal end portion (DS) of the downstream channel (1006) is disposed immediately downstream of the control surface (1008) and is adapted to engage or mate with an outer surface (1041 cs) of a distal axial portion (1041 d 1) of the selected valve pin (1041) such that the selected valve pin (1041) is closed when axially positioned or driven to a position where the distal axial portion (1041 d 1) is disposed within the distal end portion (DS) of the downstream channel portion (1006 DS).

The conical or tapered or inclined surface (1008) is optionally inclined or Angled (AG) with respect to the linear axis (a); the selected Angle (AG) places a restriction on the flow of injection fluid through the passage gap (CG) into the mold cavity (30, 1000). Limiting the injection flow; the distal axial portion (1041 d 1) of the selected valve pin (1041) is controllably positioned or driven by a travel path within the Channel Gap (CG) from a closed position downstream of the Channel Gap (CG) to a position upstream of the Channel Gap (CG), or from a position upstream of the Channel Gap (CG) to a closed position downstream of the Channel Gap (CG), such that the injection fluid (1153) flow rate through the gate controllably accelerates or decelerates relative to the acceleration or deceleration occurring at the linear or cylindrical channel surface.

As shown in fig. 2, 2A, 3, 4, 5A, 5B, 5C, the control surface (1008) is generally disposed along or within a distal inner surface of an insert or extension (1003) disposed within the distal end of the nozzle body (1000, 1004).

As shown in fig. 2B, the tapered or inclined surface (1008) can be disposed or formed along or within the distal inner surface of the nozzle body (1000, 1004) or within the gate inlet portion (3000 gep) of the mold itself (3002).

By controllably driving a selected valve pin upstream at a single selected upstream acceleration, the flow rate of injection fluid (18) through the channel gap (CG, 1006 rg) is controllable to a selected flow rate that is less than the maximum flow rate.

The actuators (1041, 1042) may include an electric motor having an electrically driven rotor drivingly interconnected with a valve pin in an arrangement that converts rotational movement of the rotor into linear movement of the valve pin (1041).

In a preferred embodiment, fluid is injected through the gate (34, 36) with a controlled upstream acceleration of the valve pins 1041, 1042; gates (34, 36) are disposed downstream of the main or central upstream gate 32 of the upstream valve; an injection fluid is first injected into the cavity (30, 300) at a first time through a main or central upstream gate 32 of the upstream valve. An actuator (941, 942) driving a downstream valve pin (1041, 1042) drives the valve pin 1041, 1042 upstream at a controlled single acceleration to open the gate (34, 36) at a second time after the first time, such that after a shot of injection fluid 18 previously injected through the upstream gate 32 travels downstream past the downstream gate (34, 36), the injection fluid 18 is injected through the upstream gate 32.

The controller 16 is typically provided with instructions that instruct the valve pins to be driven at a single selected upstream acceleration between about 1mm to about 5mm of travel path until the valve pins are accelerated to a selected reduced upstream velocity.

The controller 16 is typically provided with instructions that instruct the valve pin to be driven at a selected reduced upstream velocity; the selected reduced upstream velocity is preferably less than about 75% of the maximum rate at which the actuators 941, 942 can drive the valve pins.

As shown in fig. 6A, 6B, 6C, the controller 16 may include instructions that instruct the actuators 941, 942 to controllably drive the valve pins downstream at a single selected downstream deceleration (906) from a selected gate open position (906 o) upstream of a Gate Closed (GC) position to the Gate Closed (GC) position. In this embodiment, the configuration of the control surface (1008) can be selected to interact with the distal axial portion 1041d such that, starting from a selected gate open position (906 o) to a Gate Closed (GC) position, the selected valve pins 1041, 1042 are controllably driven downstream at a single selected downstream deceleration 906 such that the flow rate of injection fluid (18) through the Channel Gap (CG) is controllable to the selected flow rate.

As shown in fig. 6B, 6C, the controller 16 may include instructions that instruct the actuators 941, 942 to controllably drive the valve pins upstream at a single selected upstream deceleration (904) from a selected gate open position (904 o) downstream of a gate open end of stroke (EOS) position to a gate open end of stroke (EOS) position. In this embodiment, the control surface (1008) is formed to have a channel Clearance (CG) configuration in combination with the configuration of the distal axial portion (1041 d 1) of the selected valve pin (1041) so that the flow of injection fluid (18) through the channel Clearance (CG) can be controlled when the valve pin 1041 reaches an end-of-stroke EOS position by controllably driving the selected valve pin 1041 at a single selected upstream deceleration (904) from the selected gate open position (904 o) to the gate open end-of-stroke (EOS) position.

As shown in fig. 6A, the controller 16 may include instructions that instruct the actuators 941, 942 to controllably drive the valve pins upstream at a single selected upstream deceleration for a selected period of time starting from a selected gate open position (914 o) downstream of a gate open end of stroke (EOS) position to a selected intermediate zero speed position (916) between Gate Closed (GC) and end of stroke (EOS). In this embodiment, the selected size and configuration of the limiting gap (1006 rg) is selected in combination with the configuration of the distal end portion (1041 d 1) of the selected valve pin (1041) such that from the selected gate open position (914 o) to the selected intermediate zero velocity position (916) between the gate closed GC and the end of travel EOS, the selected valve pin is controllably driven upstream at a single selected upstream deceleration such that the flow rate of injection fluid (18) flowing through the limiting gap (1006 rg) is controllable to the selected flow rate.

As shown in fig. 6C, the controller 16 can include instructions that instruct the actuators 941, 942 to accelerate to a selected downstream constant velocity 910 at a single selected downstream acceleration (908) to controllably drive the valve pins. In this embodiment, the control surface (1008) can be formed with a channel Clearance (CG) configuration in combination with the configuration of the distal axial portion (1041 d 1) of the selected valve pin (1041) to controllably drive the valve pins (1041, 1042) to controllably vary the flow rate of the injection fluid (18) through the restricted clearance (1006 rg) to a selected flow rate by accelerating the valve pin (1041, 1042) at a single downstream acceleration (908) to a selected downstream constant velocity 910.

Claims

1. A method of performing an injection molding cycle in an injection molding apparatus (10), the injection molding apparatus (10) comprising an injection molding machine (13) injecting a stream of injection fluid (18) into a heated manifold (40); the heating manifold (40) distributes the injection fluid (18) to a distribution channel that delivers the injection fluid to a gate (34, 36, 1000g, 3000 gep) of a mold cavity (30, 3000) through one or more valves, each of which includes an actuator (941, 942) interconnected with a valve pin (1041, 1042) having a linear axis of travel (X);

the method comprises the following steps:

controlling the actuator (941, 942) to drive the valve pin (1041, 1042) having a distal axial portion (1041 d 1) interconnected thereto upstream and downstream through a downstream channel (1006) having a downstream channel portion (1006 ds), the distal axial portion (1041 d 1) having a selected distal configuration (1041 cs), the downstream channel portion (1006 ds) having a control surface (1008), the control surface (1008) having a selected control surface configuration;

the selected distal end configuration (1041 cs) of the valve pin (1041, 1042) and the selected control surface configuration of the control surface (1008) are configured to interact with each other along a selected upstream travel path (1006 dsl) of the valve pin from a Gate Closed (GC) position to limit a flow rate of the injection fluid (18) through the gate (34, 36) to less than a maximum flow rate;

The actuators (941, 942) are controllably driven to drive the distal axial portion (1041 d 1) through a selected upstream travel path (1006 dsl) at a single selected upstream acceleration (900) from the gate-off (GC) zero-velocity position.

2. The method of claim 1, further comprising: the drive actuators (941, 942) are controllably driven to drive the distal axial portion (1041 d 1) at the single selected upstream acceleration (900) from the gate-off (GC) zero speed position until a selected constant upstream speed (902) is increased.

3. The method of each of the preceding claims wherein the selected constant upstream velocity (902) is generally less than a maximum velocity at which the valve pin (1041) can be driven.

4. The method of each of the preceding claims, wherein the single selected upstream acceleration (900) from the gate-off zero speed position is selected such that, when the distal axial portion (1041 d 1) is driven upstream at the single selected upstream acceleration from the gate-off zero speed position, the injection fluid (18) flow rate through the gates (34, 36) can be controlled at a selected injection fluid (18) flow rate.

5. The method of each of the preceding claims, wherein the single selected upstream acceleration (900) is selected such that a selected reduced flow rate of the injection fluid can be reduced to less than a maximum flow rate through a flow rate of the injection fluid of a downstream gate (34, 36).

6. The method of each of the preceding claims, wherein the selected distal configuration (1041 cs) and the selected control surface configuration of the control surface (1008) are selected in combination such that, starting from the gate-off zero speed position, the distal axial portion (1041 d 1) is driven upstream with the single selected upstream acceleration, the flow of the injection fluid (18) through the gates (34, 36) is controlled at a selected flow rate.

7. The method of each of the preceding claims, wherein the selected flow rate of the injection fluid (18) is less than a maximum rate of the injection fluid (18) injectable through the gate (34, 36).

8. The method of each of the preceding claims, wherein the maximum flow rate is a flow rate at which the distal axial portion (1041 d 1) or the valve pin (1041) is withdrawn to a maximum upstream axial position or end of travel (EOS) position at which the valve pin (1041) can be withdrawn.

9. The method of each of the preceding claims, wherein the valve pin (1041) or the distal axial portion (1041 d 1) is further driven at a selected downstream deceleration (906) from a selected position (906 o) upstream of the Gate Closed (GC) position to the Gate Closed (GC) position.

10. The method of each of the preceding claims, wherein the valve pin (1041) or the distal axial portion (1041 d 1) is further driven at the selected downstream deceleration (920) from a selected intermediate upstream position (920 o) to an intermediate zero velocity position (912).

11. The method of each of the preceding claims, wherein the valve pin (1041) or the distal axial portion (1041 d 1) is further driven at a selected upstream deceleration (914) from a selected intermediate position (914 o) upstream of the Gate Closed (GC) position to an intermediate zero velocity position (916).

12. The method of each of the preceding claims, wherein the valve pin (1041) or the distal axial portion (1041 d 1) is further driven from an end of stroke (EOS) position or from the intermediate upstream zero speed position (912) at a selected downstream acceleration (908).

13. The method of each of the preceding claims, wherein the valve pin (1041) or the distal axial portion (1041 d 1) is further driven at the selected downstream deceleration (920) from the selected intermediate upstream position (920 o) to the intermediate zero velocity position (912).

14. The method of each of the preceding claims, further comprising: -forming a sloped or configured tapered, cylindrical, linear or curved channel or restriction gap (CG, 1006 rg) arranged upstream from the gate (34, 1000g, 3000 gep) to the mold cavity (30, 3000), the channel or restriction gap (CG, 1006 rg) having a control surface (1008), the control surface (1008) being adapted to operate in combination with the distal axial portion (1041 d 1) and the single selected upstream acceleration (900) such that the flow of the injection fluid (18) through the gate (34, 36) is controllably controlled at a selectable flow rate when the distal axial portion (1041 d 1) is driven upstream at the single selected upstream acceleration from the gate closing zero speed position.

15. The method of each of the preceding claims, wherein the controllable selectable flow rate of the injection fluid (18) through the gate (34, 36) is selected to be less than a maximum rate of the injection fluid (18) injectable through the gate (34, 36).

16. The method of each of the preceding claims, further comprising: the control surface (1008) is configured to form a selected Angle (AG) relative to a linear axis (X) of travel of the valve pin (1041).

17. The method of each of the preceding claims, further comprising: -forming the control surface (1008) with a minimum radial diameter (CD) or a portion (1006 dsp) with a minimum radial diameter (CD, 1006 dsd), the minimum radial diameter (CD) of the control surface (1008) or the minimum radial diameter (CD) of the portion (1006 dsp) being larger than the maximum diameter (1041 d1 d) of the distal axial portion (1041 d 1) by a selected distance.

18. The method of each of the preceding claims, further comprising: an upstream channel portion (1006 us) forming the downstream channel (1006); an upstream channel portion (1006 us) of the downstream channel (1006) has an upstream arranged conical or tapered or inclined surface (1009) which is inclined with respect to the downstream channel portion (1006 ds) or at an angle (UAG) with respect to the linear axis (a) or a circumferential surface (1041 cs) of the valve pin (1041) and extends along an axial length (UCT) of the downstream channel (1006) such that an injection fluid (18) passing through the channel (1006) passes through the upstream channel portion (1006 us) without being significantly restricted in flow.

19. The method of each of the preceding claims, further comprising: the Angle (AG) is selected to be between about 3 ° and about 6 °.

20. The method of each of the preceding claims, further comprising: the angle (UAG) is selected to be greater than the Angle (AG) such that injection fluid (18) passing through the channel (1006) passes through the upstream channel portion (1006 us) without being significantly restricted in flow.

21. The method of each of the preceding claims, further comprising: the control surface (1008) is disposed along an axial length (CT) of between about 3mm to about 6mm of a travel path of the valve pin (1041).

22. The method of each of the preceding claims, further comprising: -forming the control surface (1008) with a minimum radial diameter (CD) or the portion (1006 dsp) with a minimum radial diameter (CD, 1006 dsd), the minimum radial diameter (CD) of the control surface (1008) or the minimum radial diameter (CD) of the portion (1006 dsp) being about 0.1mm to about 0.8mm larger than the maximum radial diameter (1041 md) of the distal axial portion (1041 d 1).

23. The method of each of the preceding claims, further comprising: extending an inner surface (1010) from the downstream channel portion (1006 ds); the inner surface (1010) extends along a distal portion (DS) of the downstream channel (1006); the distal end portion (DS) of the downstream channel (1006) is disposed immediately downstream of the control surface (1008) and is adapted to engage or mate the inner surface (1010) with an outer surface (1041 cs) of the distal axial portion (1041 d 1) of the selected valve pin (1041) such that the selected valve pin (1041) is axially located or driven to a position where the distal axial portion (1041 d 1) is disposed within the distal end portion (DS) of the downstream channel portion (1006 DS) to close the selected gate (34, 100G).

24. The method of each of the preceding claims, further comprising: -forming the Angle (AG) of the control surface (1008) with respect to the linear axis (a); -selecting said Angle (AG) to create a restriction on said injection fluid flow entering said mold cavity (30, 1000) through said passage gap (CG); the mold cavity (30, 1000) is capable of controllably accelerating or decelerating the injection fluid (18, 1153) flow rate through the gate (34, 36) relative to acceleration or deceleration occurring at the straight or cylindrical downstream channel (1006 ds) by controllably positioning or driving the distal axial portion (1041 d 1) of the selected valve pin (1041) through a travel path inside the Channel Gap (CG) from the closed position downstream of the Channel Gap (CG) to a position upstream of the Channel Gap (CG), or from a position upstream of the Channel Gap (CG) to a closed position downstream of the Channel Gap (CG).

25. The method of each of the preceding claims, further comprising: the tapered or inclined or configured surface (1008) is disposed along or formed within a distal inner surface of an insert or extension (1003) disposed within a distal end of the nozzle body (1004).

26. The method of each of the preceding claims, further comprising: the control surface (1008) is disposed or formed along or within the distal inner surface of the nozzle body (1004) or the control surface (1008) is disposed or formed within a gate entry portion (3000 gep) of the mold (3002).

27. The method of each of the preceding claims, further comprising: the flow rate of the injection fluid (18) through the Channel Gap (CG) is controlled to a selected flow rate less than a maximum flow rate by controllably driving the selected valve pin (1041, 1042) upstream at the single selected upstream acceleration.

28. The method of each of the preceding claims, further comprising: the actuator (941, 942) is selected to include an electric motor having an electrically driven rotor drivingly interconnected to the valve pin in an arrangement that converts rotational movement of the rotor to linear movement of the valve pin (1041).

29. The method of each of the preceding claims, further comprising: -arranging the gate (34, 36) of the one or more valves downstream of an upstream gate (32) of an upstream valve, injecting the injection fluid into the cavity (30, 300) through the upstream gate (32) of the upstream valve at a first time; and driving the actuator (941, 942) interconnected with the associated valve pin (1041, 1042) to open the gate (34, 36) arranged downstream at a second time after the first time, such that the injection fluid (18) injected through the gate (34, 36) is injected into a stream of injection fluid injected through the upstream gate (32) and travels downstream through the cavity (30, 300) past the gate (34, 36).

30. The method of each of the preceding claims, further comprising: the valve pins (1041, 1042) are driven through a travel path of about 1mm to about 5mm at the single selected upstream acceleration (900).

31. The method of each of the preceding claims, further comprising: the valve pin (1041, 1042) is driven at a selected upstream velocity that is less than about 75% of a maximum velocity at which the valve pin can be driven.

32. The method of any of the preceding claims, further comprising:

sensing a position of the valve pin (141) or the actuator (941, 942);

the upstream travel rate is controlled at a single selected upstream acceleration starting from a Gate Closed (GC) position during an injection cycle, using one or more signals indicative of the position, up to a selected upstream position downstream of a stroke end position.

33. An injection molding apparatus (10) includes an injection molding machine (13) that injects a stream of injection fluid (18) into a heated manifold (40); the heating manifold (40) distributes the injection fluid (18) to a distribution channel that delivers the injection fluid to a gate (34, 36, 1000g, 3000 gep) of a mold cavity (30, 3000) through one or more valves, each of which includes an actuator (941, 942) interconnected with a valve pin (1041, 1042) having a linear axis of travel (X);

The apparatus further includes a controller (16) interconnected with the actuator (941, 942) including instructions that instruct the actuator (941, 942) to drive the valve pin (1041, 1042) having a distal axial portion (1041 d 1) interconnected therewith upstream and downstream through a downstream channel (1006) having a downstream channel portion (1006 ds), the distal axial portion (1041 d 1) having a selected distal configuration (1041 cs), the downstream channel portion (1006 ds) having a control surface (1008), the control surface (1008) having a selected control surface configuration;

wherein the selected distal end configuration (1041 cs) of the valve pin (1041, 1042) and the selected control surface configuration of the control surface (1008) are configured to interact with each other along a selected upstream travel path (1006 dsl) of the valve pin from a Gate Closed (GC) position to limit a flow rate of the injection fluid (18) through the gate (34, 36) to less than a maximum flow rate;

the controller includes instructions that instruct the actuator (941, 942) to drive the distal axial portion (1041 d 1) of the valve pin (1041, 1042) through the selected upstream travel path (1006 dsl) at a single selected upstream acceleration (900) from the Gate Closed (GC) zero velocity position.

34. A method of performing an injection molding cycle in an injection molding apparatus (10), the injection molding apparatus (10) comprising an injection molding machine (13) injecting a stream of injection fluid (18) into a heated manifold (40); the heating manifold (40) distributes the injection fluid (18) to a distribution channel that delivers the injection fluid to a gate (34, 36, 1000g, 3000 gep) of a mold cavity (30, 3000) through one or more valves, each of which includes an actuator (941, 942) interconnected with a valve pin (1041, 1042) having a linear axis of travel (X);

the method comprises the following steps:

the selected distal end configuration (1041 cs) of the valve pin (1041, 1042) and the selected control surface configuration of the control surface (1008) are configured to interact with each other along a selected upstream travel path of the valve pin from a Gate Closed (GC) position to limit a flow rate of the injection fluid (18) through the gate (34, 36) to less than a maximum flow rate;

Controllably driving the actuator (941, 942) to drive the distal axial portion (1041 d 1) at one or more of the following rates:

(a) -a selected downstream deceleration (906) from a selected position (906 o) upstream of the Gate Closing (GC) position to the Gate Closing (GC) position;

(c) -a selected upstream deceleration (914) from a selected intermediate position (914 o) upstream of the Gate Closing (GC) position to an intermediate zero speed position (916);

(d) A selected downstream acceleration (908) from an end of travel (EOS) position or from an intermediate upstream zero speed position (912).

35. The method of claim 34, wherein one or more of the selected downstream deceleration (906, 920), the selected upstream deceleration (914), and the selected downstream acceleration (908) are selected to control the flow of injection fluid (18) through the gate (34, 36) at a selected injection fluid (18) flow rate or to control the injection fluid (18) flow rate through the gate (34, 36) at the selected injection fluid (18) flow rate.

36. The method of any of the preceding claims 34-35, further comprising:

sensing a position of the valve pin (141) or the actuator (941, 942);

using one or more signals indicative of the position to control the upstream travel rate during an injection cycle at any one or more of the following rates:

(a) -a selected downstream deceleration (906) from the selected position (906 o) upstream of the Gate Closing (GC) position to the Gate Closing (GC) position;

(d) -a selected downstream acceleration (908) from an end of stroke (EOS) position or from the intermediate upstream zero speed position (912);

(e) -a selected downstream deceleration (920) from said selected intermediate upstream position (920 o) to said intermediate zero speed position (912);

(g) A selected zero speed within any portion of the injection cycle duration.

37. An injection molding apparatus (10) includes an injection molding machine (13) that injects a stream of injection fluid (18) into a heated manifold (40); the heating manifold (40) distributes the injection fluid (18) to a distribution channel that delivers the injection fluid to a gate (34, 36, 1000g, 3000 gep) of a mold cavity (30, 3000) through one or more valves, each of which includes an actuator (941, 942) interconnected with a valve pin (1041, 1042) having a linear axis of travel (X);

the apparatus further includes a controller (16) interconnected with the actuator (941, 942) including instructions instructing the actuator (941, 942) to drive the valve pin (1041, 1042) having a distal axial portion (1041 d 1) interconnected therewith upstream and downstream through a downstream channel (1006) having a downstream channel portion (1006 ds), the distal axial portion (1041 d 1) having a selected distal configuration (1041 cs), the downstream channel portion (1006 ds) having a control surface (1008), the control surface (1008) having a selected control surface configuration;

Wherein the selected distal end configuration (1041 cs) of the valve pin (1041, 1042) and the selected control surface configuration of the control surface (1008) are configured to interact with each other along a selected upstream travel path (1006 dsl) of the valve pin from the Gate Closed (GC) position to limit a flow rate of the injection fluid (18) through the gate (34, 36) to less than a maximum flow rate;

the controller includes instructions that instruct the actuators (941, 942) to drive the distal axial portion (1041 d 1) at one or more of the following rates:

(d) -a selected downstream acceleration (908) from an end of stroke (EOS) position or from the intermediate upstream zero speed position (912).