Upstream nozzle sensor for injection molding apparatus and methods of use

• US 10,444,092 B2
• Filed: 09/18/2018
• Issued: 10/15/2019
• Est. Priority Date: 06/30/2016
• Status: Active Grant

• Current Assignee: Imflux Inc. (The Procter & Gamble Company)
• Original Assignee: Imflux Inc. (The Procter & Gamble Company)
• Inventors: Pollard, Rick Alan, Allen, Bryan Keith, Huang, Chow-Chi, Altonen, Gene Michael
• Primary Examiner(s): Hollington, Octavia
• Application Number:
  US16/134,405
• Publication Number:
  US 20190017886A1
• Time in Patent Office: 392 Days
• Field of Search: 73862045
• CPC Class Codes: B29C 2945/7619 barrel
• CPC Class Codes: B29C 2945/76381 Injection
• CPC Class Codes: B29C 2945/76481 Strain gauges
• CPC Class Codes: B29C 2945/76498 Pressure
• CPC Class Codes: B29C 2945/76545 Flow rate
• CPC Class Codes: B29C 2945/76658 Injection unit
• CPC Class Codes: B29C 2945/76859 Injection
• CPC Class Codes: B29C 45/1603 Multi-way nozzles specially adapted therefor
• CPC Class Codes: B29C 45/2708 Gates B29C45/2703 takes precedence
• CPC Class Codes: B29C 45/30 Flow control means disposed within the sprue channel, e.g. "torpedo" construction
• CPC Class Codes: B29C 45/77 of velocity or pressure of moulding material
• CPC Class Codes: G01L 1/04 by measuring elastic deformation of gauges, e.g. of springs
• CPC Class Codes: G01L 1/2218 the supports being of the column type, e.g. cylindric, adapted for measuring a force along a single direction
• CPC Class Codes: G01L 19/147 Details about the mounting of the sensor to support or covering means

Abstract

A strain gauge nozzle adapter that may be placed between a barrel end cap and a nozzle body of an injection molding system, the strain gauge nozzle adapter having a strain gauge pin that measures strain within the strain gauge nozzle adapter for use in approximating conditions within an injection molding system, such as pressure or the location of a melt flow front. The strain gauge nozzle adapter may include a plurality of strain gauge pins. An alternative material insert in the strain gauge nozzle adapter may surround a strain gauge pin to amplify meaningful measurements obtained by the strain gauge pin so that noise measurements do not compromise the accuracy of approximation of conditions within a mold.

Claims

1. A method of injection molding, comprising:

measuring, using a strain gauge pin, a change in strain in a strain gauge nozzle adapter;

approximating at least one of a pressure or a melt flow front location within a mold cavity based on the change in strain;

comparing the approximated pressure or melt flow front location to a trigger point; and

,

if the approximated pressure or melt flow front location equals or exceeds the trigger point, activating a virtual cavity sensor, wherein upon activation, the virtual cavity sensor causes a controller to perform an action,

the method further comprising amplifying a change in an alternative material insert of the strain gauge nozzle adapter.

2. The method of injection molding of claim 1, wherein measuring the change in strain in a strain gauge nozzle adapter includes using a plurality of strain gauge pins.

3. The method of injection molding of claim 1, wherein measuring the change in strain in a strain gauge nozzle adapter includes using a secondary sensor.

4. A method of injection molding, comprising:

measuring, using a strain gauge pin, a change in strain in a strain gauge feed system adapter;

approximating at least one of a pressure or a melt flow front location within a mold cavity based on the change in strain;

comparing the approximated pressure or melt flow front location to a trigger point; and

,

if the approximated pressure or melt flow front location equals or exceeds the trigger point, activating a virtual cavity sensor, wherein upon activation, the virtual cavity sensor causes a controller to perform an action,

the method further comprising amplifying a change in an alternative material insert of the strain gauge feed system adapter.

5. The method of injection molding of claim 4, wherein measuring the change in strain in a strain gauge feed system adapter includes using a plurality of strain gauge pins.

6. The method of injection molding of claim 4, wherein measuring the change in strain in a strain gauge feed system adapter includes using a secondary sensor.