WO2021159122A4 - Low-pressure molding system - Google Patents
Low-pressure molding system Download PDFInfo
- Publication number
- WO2021159122A4 WO2021159122A4 PCT/US2021/017256 US2021017256W WO2021159122A4 WO 2021159122 A4 WO2021159122 A4 WO 2021159122A4 US 2021017256 W US2021017256 W US 2021017256W WO 2021159122 A4 WO2021159122 A4 WO 2021159122A4
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- pressure
- control signal
- melt
- thermoplastic material
- mold cavity
- Prior art date
Links
- 238000000465 moulding Methods 0.000 title claims 10
- 238000000034 method Methods 0.000 claims abstract 28
- 238000001125 extrusion Methods 0.000 claims abstract 22
- 239000000463 material Substances 0.000 claims abstract 10
- 239000012815 thermoplastic material Substances 0.000 claims 13
- 239000000155 melt Substances 0.000 claims 11
- 239000004033 plastic Substances 0.000 claims 4
- 238000004891 communication Methods 0.000 claims 2
- 239000012530 fluid Substances 0.000 claims 2
- 238000002347 injection Methods 0.000 claims 2
- 239000007924 injection Substances 0.000 claims 2
- 238000001746 injection moulding Methods 0.000 claims 2
- 238000005259 measurement Methods 0.000 claims 2
- 238000010137 moulding (plastic) Methods 0.000 claims 2
- 238000010438 heat treatment Methods 0.000 claims 1
- 238000012544 monitoring process Methods 0.000 claims 1
- 238000003303 reheating Methods 0.000 claims 1
- 238000013329 compounding Methods 0.000 abstract 1
- 239000012778 molding material Substances 0.000 abstract 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/76—Measuring, controlling or regulating
- B29C45/77—Measuring, controlling or regulating of velocity or pressure of moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/0001—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor characterised by the choice of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76494—Controlled parameter
- B29C2945/76498—Pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2945/00—Indexing scheme relating to injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould
- B29C2945/76—Measuring, controlling or regulating
- B29C2945/76822—Phase or stage of control
- B29C2945/76859—Injection
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0012—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds having particular thermal properties
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mechanical Engineering (AREA)
- Injection Moulding Of Plastics Or The Like (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
The present invention relates to extrusion molding machines and methods of producing extrusion molded parts and, more particularly, to extrusion molding machines that adjust operating parameters of the extrusion molding machine during an extrusion molding run to account for changes in material properties and pressures of the extrusion material and methods of accounting for changes in extrusion molding material properties during an extrusion molding run and/or compounding of materials.
Claims
AMENDED CLAIMS received by the International Bureau on 02 September 2021 (02.09.2021)
1 . A method of plastic molding at a substantially constant, relatively low pressure, comprising:
(a) using a rotating screw to introduce a molten thermoplastic material into an at least one mold cavity of a molding apparatus, for extrusion molding at a low, substantially constant melt pressures; and,
(b) while maintaining the melt pressure substantially constant at less than 6000 psi, wherein: the thermoplastic material has a melt flow index of about 0.1 g/10 min to about 500 g/10 min.
2. The method of claim 1 , wherein the molding apparatus comprises a means for building back pressure, such as a breaker plate or a pressure relief valve in a manifold having heated runners in fluid communication with the at least one mold cavity, wherein the melt pressure of the molten thermoplastic material is maintained substantially constant while the molten thermoplastic material is transported from an entry point through the back pressure building means to the heated runners.
3. The method of claim 1 , wherein the filling of the molten thermoplastic material into the at last one mold cavity includes applying a pressure to the molten thermoplastic material, and wherein maintaining the constant melt pressure includes monitoring the melt pressure of the molten thermoplastic material upon entering into the at least one mold cavity and the melt pressure of the molten thermoplastic material during filling of the at least one mold cavity, and adjusting the pressure applied to the molten thermoplastic material entering into the at least one mold cavity to maintain said constant melt pressure.
74
4. The method of claim 1 , wherein the molding apparatus includes a pressure relief valve disposed between a breaker plate and the at least one mold cavity, the pressure relief valve having a predetermined set point at the substantially constant melt pressure and maintaining the substantially constant melt pressure on molten thermoplastic material through the pressure relief valve at a melt pressure higher than the predetermined set point, the pressure relief valve reducing the melt pressure of the thermoplastic material as it passes through the pressure relief valve and enter into the at least one mold cavity to maintain said constant melt pressure.
5. The method of claim 1 , wherein the molding apparatus automatically adjusting an extrusion molding process to compensate for variations in the flowability and/or temperature variations of a molten plastic material, the method including: providing an extrusion molding machine with at least one mold cavity; providing a molding controller, which includes a pressure control output that is configured to generate a control signal, which, at least partially determines an extrusion molding pressure and/or temperature for the extrusion molding process of the extrusion molding machine; measuring a first control signal generated from the pressure control output and/or temperature output at a first time in an extrusion molding cycle; measuring a second control signal generated from the pressure control output and/or temperature output at a second time in the same extrusion molding cycle, subsequent to the first time; comparing the first control signal generated from the pressure control output and/or temperature output and the second control signal generated from the pressure control output and/or temperature output to obtain a comparison result; and determining a third control signal for the pressure control output and/or temperature output, based at least in part on the comparison result, at a third time that is subsequent to the second time.
75
9. The method of claim 5, wherein the comparison result is a flow factor (FF) that is used as a soft sensor melt viscosity input by the controller.
10. The method of claim 9, wherein the FF is determined by the formula:
FF=(CS1-CS2)/T; where CS1 is the first control signal;
CS2 is the second control signal; and T is the time difference between CS1 and CS2.
11 . The method of claim 10, wherein the third control signal is proportional to the flow factor.
12. The method of claim 10, wherein T is between 0.1 milliseconds and 10 milliseconds.
13. The method of claim 5, wherein the comparison result is used as a basis for a viscosity change index (VCI) that is used as a soft sensor melt viscosity input to by the controller.
14. The method of claim 13, wherein the VCI is determined by the following formula:
VCI=(CS1-CS2)/S where CS1 is a first control signal;
CS2 is a second control signal; and
S is the position difference for the melt moving machine component.
17. The method of claim 5, wherein the comparing of the first control signal and the second control signal includes comparing the first control signal and the second control signal to optimal control signals based on an optimal pressure curve, the method including: measuring a first control signal generated from a pressure control output of the controller at a first time in an extrusion molding cycle using a control signal measurement device;
76
measuring a second control signal generated from the pressure control output of the controller at a second time in the same extrusion molding cycle, subsequent to the first time using the control signal measurement device; comparing the first control signal generated from the pressure control output of the controller and the second control signal generated from the pressure control output of the controller to obtain a comparison result; and determining a third control signal for the pressure control output, based at least in part on the comparison result, at a third time that is subsequent to the second time.
18. The method of claim 5, wherein the providing of the extrusion molding machine includes providing a rotating screw melt moving machine component; and further including: measuring a first position of the melt moving machine component at the first time; measuring a second position of the melt moving machine component at the second time; determining a position difference between the first position and the second position; and wherein the comparing includes comparing the first control signal and the second control signal, based, at least in part, on the position difference, to obtain the comparison result.
21 . The method of claim 1 further including having a constant low-pressure extrusion in an injection molding machine given the constant low-pressure molding allowing a traditional injection unit to have much larger and more homogenous plasticizing output extruding the plastic into the at least one mold cavity.
22. The method of claim 21 further including having a constant low-pressure extrusion in an injection molding machine wherein the breaker plate and/or pressure valve is being built in to a manifold being bolted on to the mold in the machine and/or being part of such mold built into a hot runner manifold.
77
23. The method of claim 21 , further including combining extruding plasticized material into the at least one cavity with injecting the plasticized material into said at least one cavity, thereby increasing the material that can be introduced into the at least one cavity in the machine and applying a constant low-pressure extrusion of the material using a space in front of the screw to hold a cushion of melted plasticized material while the mold opens and closes during a holding pressure phase of the molding process.
24. A method of plastic molding at a substantially constant, relatively low pressure, comprising:
(a) filling a molten thermoplastic material into an at least one mold cavity of a molding apparatus, having a hot runner system using a low and constant plastic pressure, and reduces pressure loss within the mold as it fills; and,
(b) while filling the at least one mold cavity with the molten thermoplastic material, maintaining the melt pressure substantially constant at less than 6000 psi,
25. The method of claim 24, wherein the method includes filling of an unbalanced manifold, with the manifold feeding heated runners in fluid communication with the at least one mold cavity.
26. The method of claim 24 further including a hot runner system having at least one cold runner portion in a mold component that is reheated during every molding cycle before injection of the next portion of molten plastic material.
27. The method of claim 26 further including reheating the at least one cold runner portion using conductive heating.
Priority Applications (5)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| MX2022009758A MX2022009758A (en) | 2020-02-09 | 2021-02-09 | Low-pressure molding system. |
| JP2022548217A JP2023513686A (en) | 2020-02-09 | 2021-02-09 | Low pressure molding system |
| EP21710663.2A EP4100228A1 (en) | 2020-02-09 | 2021-02-09 | Low-pressure molding system |
| CA3166795A CA3166795A1 (en) | 2020-02-09 | 2021-02-09 | Low-pressure molding system |
| GB2213037.1A GB2607831A (en) | 2020-02-09 | 2021-02-09 | Low-pressure molding system |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US202062972053P | 2020-02-09 | 2020-02-09 | |
| US62/972,053 | 2020-02-09 | ||
| US69/972,053 | 2020-02-09 |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| WO2021159122A1 WO2021159122A1 (en) | 2021-08-12 |
| WO2021159122A8 WO2021159122A8 (en) | 2021-10-14 |
| WO2021159122A4 true WO2021159122A4 (en) | 2021-11-25 |
Family
ID=74860405
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/US2021/017256 WO2021159122A1 (en) | 2020-02-09 | 2021-02-09 | Low-pressure molding system |
Country Status (6)
| Country | Link |
|---|---|
| EP (1) | EP4100228A1 (en) |
| JP (1) | JP2023513686A (en) |
| CA (1) | CA3166795A1 (en) |
| GB (1) | GB2607831A (en) |
| MX (1) | MX2022009758A (en) |
| WO (1) | WO2021159122A1 (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US12070885B2 (en) * | 2022-06-10 | 2024-08-27 | Reynolds Consumer Products LLC | Method for manufacturing renewable film and products |
Family Cites Families (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US133229A (en) * | 1872-11-19 | hyatt | ||
| BR112013028817A2 (en) * | 2011-05-20 | 2017-01-31 | Procter & Gamble | method for substantially constant low pressure injection molding |
| US20190337211A1 (en) * | 2018-05-03 | 2019-11-07 | University Of Massachusetts | Distributive and dispersive mixing devices |
-
2021
- 2021-02-09 WO PCT/US2021/017256 patent/WO2021159122A1/en unknown
- 2021-02-09 JP JP2022548217A patent/JP2023513686A/en active Pending
- 2021-02-09 MX MX2022009758A patent/MX2022009758A/en unknown
- 2021-02-09 EP EP21710663.2A patent/EP4100228A1/en active Pending
- 2021-02-09 GB GB2213037.1A patent/GB2607831A/en active Pending
- 2021-02-09 CA CA3166795A patent/CA3166795A1/en active Pending
Also Published As
| Publication number | Publication date |
|---|---|
| GB2607831A (en) | 2022-12-14 |
| WO2021159122A8 (en) | 2021-10-14 |
| GB202213037D0 (en) | 2022-10-19 |
| WO2021159122A1 (en) | 2021-08-12 |
| JP2023513686A (en) | 2023-04-03 |
| CA3166795A1 (en) | 2021-08-12 |
| EP4100228A1 (en) | 2022-12-14 |
| MX2022009758A (en) | 2023-03-13 |
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