Intelligent mold cavity melt two-stage exhaust device and using method thereof
By setting a dual-stage venting device in the injection mold, combined with graded negative pressure and intelligent control, the problem of uneven gas discharge in the cavity is solved, achieving efficient gas discharge and melt overflow prevention, thus improving product quality and production stability.
Patent Information
- Application Number
- CN202610114153.1
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-01-28
- Publication Date
- 2026-03-06
AI Technical Summary
In existing injection molding processes, gas inside the cavity cannot be discharged in time, resulting in bubbles and air holes in the product. Furthermore, traditional single vents are difficult to balance the venting efficiency and anti-overflow requirements of different areas.
The system employs an intelligent mold cavity melt two-stage venting device. By setting a primary vent in the gas flow zone and a secondary vent in the gas accumulation trap zone, combined with the staged negative pressure supply and intelligent power regulation of the vacuum pump, targeted venting is achieved using a porous metal valve plate and stepped guide port design. Real-time monitoring and control are achieved through a piezoelectric thin film pressure sensor and pressure transmitter.
It achieves efficient gas discharge throughout the cavity, avoiding problems such as melt overflow and poor venting, improving production consistency and stability, and ensuring product quality.
Smart Images
Figure CN121608340A_ABST
Abstract
Description
Technical Field
[0001] This invention patent relates to the field of injection molding technology, specifically to an intelligent mold cavity melt dual-stage venting device and its usage method. Background Technology
[0002] In injection molding, a cavity is generally formed by the closing of a moving mold and a fixed mold to facilitate subsequent melt injection for workpiece manufacturing. If the air inside the cavity, the water vapor generated by melt evaporation, and the high-temperature decomposition gases cannot be discharged in time during the melt injection process, it will lead to problems such as bubbles and pores in the product, which will seriously affect the product quality. Existing venting methods mostly use a single vent structure, failing to distinguish between the gas flow area on the gentle inner wall of the cavity and the gas accumulation trap area at the angle between the inner walls of the cavity. This makes it difficult to balance the venting efficiency and anti-overflow requirements of different areas. Summary of the Invention
[0003] The purpose of this invention is to provide an intelligent mold cavity melt two-stage venting device and its usage method to solve the problems mentioned in the background art.
[0004] To solve the above-mentioned technical problems, this invention provides the following technical solution: an intelligent mold cavity melt dual-stage venting device, including a moving mold and a fixed mold. A liquid injection pipe for connecting to an external solution injection pipe is connected to one side of the outer wall of the fixed mold. Multiple primary venting holes communicating with a gas flow zone are evenly distributed at the top of the moving mold. Multiple secondary venting holes communicating with multiple gas accumulation trap zones are also provided at the top of the moving mold. The multiple primary venting holes and multiple secondary venting holes are evenly distributed at the top of the moving mold, communicating with the gas flow zone. The outlet is connected to an electrically controlled diverter valve c via a primary diverter line and a secondary diverter line, respectively. The other end of the electrically controlled diverter valve c is connected to a vacuum pump. A piezoelectric thin-film pressure sensor is embedded in the inner wall of the primary exhaust port input end, and a pressure transmitter is embedded in the inner wall of the secondary exhaust port input end. Electrically controlled valves a and b are installed on the branch lines of the primary and secondary diverter lines, respectively. The electrically controlled diverter valve c, the vacuum pump, the piezoelectric thin-film pressure sensor, the pressure transmitter, and the electrically controlled valves a and b are all connected to an external control terminal.
[0005] Furthermore, it also includes a high-pressure washer, the input end of which is connected to an external water source via a pipeline. The main pipelines of the primary and secondary diversion pipelines are respectively equipped with an electrically controlled diversion valve a and an electrically controlled diversion valve b. One end of each of the electrically controlled diversion valves a and b is connected to the output end of the high-pressure washer via a delivery pipeline. The electrically controlled diversion valves a, b, and the high-pressure washer are all connected to an external control terminal.
[0006] Furthermore, temperature sensors a and b, which are connected to an external control terminal, are embedded and installed on the inner wall of both the primary exhaust port input end and the secondary exhaust port input end.
[0007] Furthermore, the primary exhaust port input end is covered and fixed with a porous metal valve plate with a pore size in the micrometer range, and the secondary exhaust port input end is provided with a stepped guide port on the side near the inner wall of the moving mold.
[0008] Furthermore, a displacement sensor is provided at the bottom of the moving mold.
[0009] The control method for an intelligent mold cavity melt two-stage venting device based on an emergency lane autonomous control system includes the following steps: S1: The moving mold and the fixed mold close together, triggering the displacement sensor; 2S: The displacement sensor sends a mold closing signal to the external control terminal. The external control terminal starts the vacuum pump and opens all the electrically controlled valves a and b. At the same time, all three ends of the electrically controlled diverter valve c are connected. The electrically controlled diverter valves a and b are respectively connected to the primary diverter pipeline and connecting pipeline a, as well as the secondary diverter pipeline and connecting pipeline b. S3: The vacuum pump generates suction and extracts the initial air from the cavity; S4: The external solution is injected into the cavity through the injection tube. The electro-thin film air pressure sensor detects the pressure in the primary exhaust hole in real time and feeds back the air pressure value to the external control terminal to determine whether the exhaust is smooth. When the electro-thin film pressure sensor in any of the primary exhaust ports detects that the pressure has reached the predetermined extraction value, the external control terminal controls the electrically controlled valve a on the branch line of the primary shunt pipeline connected to that primary exhaust port to close. This continues until all electrically controlled valves a are closed, then proceeding to step S5. S5: The pressure transmitter detects the pressure in the secondary exhaust port in real time and feeds back the air pressure value to the external control terminal to determine whether the exhaust is unobstructed. When the pressure transmitter in any of the secondary exhaust ports detects that the gas pressure has reached the predetermined extraction value, the external control terminal controls the electrically controlled valve b on the secondary diversion pipeline branch line connected to the secondary exhaust port to close, and reduces the vacuum pump power based on the proportion of the number of electrically controlled valves b that are closed, until all electrically controlled valves b are closed, then proceed to step S6. S6: The external control terminal shuts off the vacuum pump and waits for the workpiece in the cavity to cool down. Then the moving mold and the fixed mold open, the displacement sensor sends the mold opening signal back to the external control terminal, the system resets, and prepares for the next venting process.
[0010] The beneficial effects achieved by this invention patent are as follows: To address the differences in gas distribution between the gas flow zone and the gas accumulation trap zone within the mold cavity, a staged exhaust design is adopted, featuring a primary exhaust port in the gas flow zone and a secondary exhaust port in the gas accumulation trap zone. This allows for targeted exhaust of gas from different areas. Coupled with the staged negative pressure supply and intelligent power adjustment of the vacuum pump, the suction power can be dynamically adjusted according to the exhaust requirements of different areas. The flow zone achieves rapid extraction through the primary exhaust port, while the trap zone achieves deep extraction through the secondary exhaust port, ensuring a high gas exhaust rate across the entire mold cavity and adapting to the multi-area exhaust needs of complex mold cavities.
[0011] By setting a micron-sized porous metal valve plate at the primary vent inlet, the physical property of allowing gas to pass through but not material passing through is utilized to ensure efficient gas penetration while completely blocking the melt from penetrating. This solves the problem of easy overflow or poor venting in the flow zone of traditional single vents. At the same time, a stepped guide port is set at the secondary vent inlet to gradually dissipate the kinetic energy of the melt flow and change the contact mode of the melt, avoiding direct impact of the melt on the vent inlet. This solves the problem of melt impact and overflow caused by gas accumulation in the trap zone of traditional single vents.
[0012] By integrating multi-dimensional monitoring elements such as piezoelectric thin film pressure sensors, pressure transmitters, and temperature sensors, the system can sense the exhaust status and melt proximity signals in different areas in real time. Combined with external control terminals, it can automatically close the electronically controlled valves of the exhaust ports in the corresponding areas to prevent melt from seeping into the exhaust channels. This solves the problem of traditional single exhaust ports lacking targeted protection and being prone to exhaust failure due to melt intrusion.
[0013] The displacement sensor enables precise linkage in the mold closing / opening, melt injection and molding processes, automatically completing the entire process of pre-vacuuming, graded venting, dynamic pressure adjustment and venting stop without manual intervention. This avoids the problems of traditional single vent hole relying on manual adjustment and mismatch between venting timing and filling rhythm, thus improving venting stability and production consistency. Attached Figure Description
[0014] Figure 1 This is a schematic diagram of the structure of the moving mold and the fixed mold in the mold-closing state in Embodiment 1; Figure 2 for Figure 1 A cross-sectional view along the AA direction; Figure 3 This is a schematic diagram of the porous metal valve plate in Embodiment 1; Figure 4 This is a layout diagram of the intelligent mold cavity melt dual-stage venting device in Example 1; Figure 5 This is a flowchart illustrating the usage method of the intelligent mold cavity melt dual-stage venting device in Example 2. Detailed Implementation
[0015] The present invention will be further described below with reference to the accompanying drawings.
[0016] Example 1
[0017] like Figure 1-4 As shown, this invention patent discloses an intelligent mold cavity melt dual-stage venting device, including: a moving mold 1 and a fixed mold 2. A liquid injection pipe 21 for connecting to an external solution injection pipe is connected to one side of the outer wall of the fixed mold 2. Multiple primary venting holes 3, communicating with a gas flow zone, are evenly distributed at the top of the moving mold 1. Multiple secondary venting holes 4, respectively communicating with multiple gas accumulation trap zones, are also provided at the top of the moving mold 1. The output ends of the multiple primary venting holes 3 and the multiple secondary venting holes 4 are respectively connected through a primary diversion pipeline 31 and a secondary diversion pipeline 4. The diversion line 41 is connected to the electrically controlled diversion valve c5, and the other end of the electrically controlled diversion valve c5 is connected to the vacuum pump 7. A piezoelectric diaphragm pressure sensor 34 is embedded in the inner wall of the input end of the primary exhaust port 3, and a pressure transmitter 44 is embedded in the inner wall of the input end of the secondary exhaust port 4. Electrically controlled valves a35 and b45 are respectively installed on the branch lines of the primary diversion line 32 and the secondary diversion line 42. The electrically controlled diversion valve c, the vacuum pump 7, the piezoelectric diaphragm pressure sensor 34, the pressure transmitter 44, the electrically controlled valves a35 and b45 are all connected to an external control terminal.
[0018] Furthermore, such as Figure 4 As shown, it also includes a high-pressure washer 8. The input end of the high-pressure washer 8 is connected to an external water source 81 via a pipeline. An electrically controlled diversion valve a32 and an electrically controlled diversion valve b42 are respectively installed on the main pipelines of the primary diversion pipeline 31 and the secondary diversion pipeline 41. One end of each of the electrically controlled diversion valves a32 and b42 is connected to the output end of the high-pressure washer 8 via a delivery pipeline 82. The electrically controlled diversion valves a32, b42 and the high-pressure washer 8 are all connected to an external control terminal. When cleaning of the primary exhaust port 3 and the secondary exhaust port 4 is required, the external control terminal controls the electrically controlled diversion valves a32 and b42 to connect the primary diversion pipeline 31 and the secondary diversion pipeline 41 to the delivery pipeline 82, respectively. At the same time, the electrically controlled diversion valve c5 closes the connection between the vacuum pump 7 and the primary diversion pipeline 31 and the secondary diversion pipeline 41, respectively, and starts the high-pressure cleaner 8. The high-pressure cleaner 8 delivers the cleaning agent to the primary diversion pipeline 31 and the secondary diversion pipeline 41 through the delivery pipeline 82, and then delivers the cleaning agent to the primary exhaust port 3 and the secondary exhaust port 4 through the primary diversion pipeline 31 and the secondary diversion pipeline 41, respectively, thereby achieving the cleaning of the primary exhaust port 3 and the secondary exhaust port 4.
[0019] Furthermore, such as Figure 2As shown, temperature sensors a36 and b46, which are connected to an external control terminal, are embedded on the inner walls of the input end of the primary vent 3 and the input end of the secondary vent 4, respectively. The temperature sensors a36 and b46 are configured to monitor the temperature when the melt enters the primary vent 3 or the secondary vent 4. At this time, the temperature sensors a36 and b46 feed back information to the external control terminal, which then controls the electrically controlled valves a35 and b45 on the branch lines 31 and 41 of the primary and secondary vent 3 and 4 to close, so as to prevent the vacuum pump 7 from acting on the primary and secondary vent 3 and 4 and exacerbating the problem of melt entering.
[0020] Furthermore, such as Figure 2-3 As shown, the input end of the primary exhaust port 3 is covered and fixed with a porous metal valve plate 37 with a pore size of micrometers. The porous structure of the metal valve plate 37 with a pore size of micrometers can ensure gas permeation and block the melt from passing through, thereby preventing the melt from entering the primary exhaust port 3. A stepped guide port 47 is provided on the side of the secondary vent 4 input end near the inner wall of the moving mold 1. Since the electric control valve a35 connecting the primary vent 3 is closed when the melt comes into contact with the secondary vent 4 input end, the melt in the cavity will converge towards the secondary vent 4. The kinetic energy generated by the melt flow will also be released towards the secondary vent 4. When the kinetic energy comes into contact with the stepped guide port 47, the melt flows along the inner wall of the stepped guide port 47. During the flow, multiple planes on the inner wall of the stepped guide port 47 gradually offset the kinetic energy generated by the melt flow, thereby increasing the resistance of the melt flow to avoid the risk of overflow caused by the melt directly impacting the secondary vent 4 input end.
[0021] Furthermore, such as Figure 2 As shown, a displacement sensor 11 is provided at the bottom of the moving mold 1.
[0022] Example 2
[0023] Please see Figure 5 A control method for an intelligent mold cavity melt two-stage venting device based on an emergency lane autonomous control system includes the following steps: S1: The moving mold 1 and the fixed mold 2 close together, triggering the displacement sensor 11; S2: The displacement sensor 11 sends a mold closing signal to the external control terminal. The external control terminal starts the vacuum pump 7 and opens all the electrically controlled valves a35 and b45. At the same time, all three ends of the electrically controlled diverter valve c5 are connected, and the electrically controlled diverter valves a32 and b42 are closed at the connection ends with the connected conveying pipeline 82, while maintaining the connection between the primary diverter pipeline 31 and the secondary diverter pipeline 41 and the main pipeline respectively. S3: Vacuum pump 7 generates suction and extracts the initial air from the cavity; S4: The external solution is injected into the cavity through the injection tube 21. The electro-thin film air pressure sensor 34 detects the pressure in the first-stage exhaust hole 3 in real time and feeds back the air pressure value to the external control terminal to determine whether the exhaust is smooth. When the electro-thin film pressure sensor 34 in any of the primary exhaust ports 3 detects that the air pressure has reached the predetermined extraction value, the external control terminal controls the electrically controlled valve a35 on the branch line of the primary shunt line 31 connected to that primary exhaust port 3 to close, until all electrically controlled valves a35 are closed, then proceed to step S5. S5: Pressure transmitter 44 detects the pressure inside the secondary exhaust port 4 in real time and feeds back the air pressure value to the external control terminal to determine whether the exhaust is unobstructed. When the pressure transmitter 44 inside any of the secondary exhaust ports 4 detects that the gas pressure has reached the predetermined extraction value, the external control terminal controls the electrically controlled valve b45 on the branch line of the secondary diversion line 41 connected to that secondary exhaust port 4 to close, and reduces the power of the vacuum pump 7 based on the proportion of the number of electrically controlled valves b45 that are closed, until all electrically controlled valves b45 are closed, then proceed to step S6. S6: The external control terminal shuts down the vacuum pump 7 and waits for the workpiece in the cavity to cool down. Then, the moving mold 1 and the fixed mold 2 open. The displacement sensor 11 sends the mold opening signal back to the external control terminal, and the system resets to prepare for the next venting process.
[0024] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.
Claims
1. A two-stage melt exhaust device for a mold cavity, comprising a movable mold and a fixed mold, a liquid injection pipe for connecting an external solution injection pipe is arranged on the outer wall of one side of the fixed mold, characterized in that: The moving die top end is uniformly provided with a plurality of first exhaust holes communicated with the gas flow area, the moving die top end is provided with a plurality of second exhaust holes respectively communicated with a plurality of gas aggregation trap areas, the moving die top end is uniformly provided with a plurality of first exhaust holes communicated with the gas flow area, the output ends of the plurality of first exhaust holes and the plurality of second exhaust holes are respectively communicated with an electrically controlled shunt valve c through a first shunt pipeline and a second shunt pipeline, the other end of the electrically controlled shunt valve c is communicated with a vacuum pump, a piezoelectric film air pressure sensor is embedded and installed on the inner wall of the input end of the first exhaust hole, a pressure transmitter is embedded and installed on the inner wall of the input end of the second exhaust hole, electrically controlled valves a and b are respectively installed on the branch pipelines of the first shunt pipeline and the second shunt pipeline, and the electrically controlled shunt valve c, the vacuum pump, the piezoelectric film air pressure sensor, the pressure transmitter, the electrically controlled valve a and the electrically controlled valve b are all signal connected with an external control terminal.
2. The smart mold cavity melt two-stage venting device of claim 1, wherein: Further comprising a high-pressure cleaning machine, the input end of the high-pressure cleaning machine is connected with an external water source through a pipeline, electrically controlled shunt valves a and b are respectively installed on the main pipelines of the first shunt pipeline and the second shunt pipeline, one end of each of the electrically controlled shunt valves a and b is communicated with the output end of the high-pressure cleaning machine through a conveying pipeline, and the electrically controlled shunt valves a, the electrically controlled shunt valves b and the high-pressure cleaning machine are all signal connected with an external control terminal.
3. The smart mold cavity melt two-stage venting device of claim 2, wherein: Temperature sensors a and b signal connected with the external control terminal are embedded and installed on the inner walls of the input ends of the first exhaust holes and the second exhaust holes.
4. The smart mold cavity melt two-stage venting device of claim 3, wherein: The input end of the first exhaust hole is covered and fixed with a porous metal valve plate with a pore size of microns, and the side close to the inner wall of the moving die of the input end of the second exhaust hole is provided with a stepped flow guide.
5. The smart mold cavity melt two-stage venting device of claim 4, wherein: The bottom end of the moving die is provided with a displacement sensor.
6. The method of using the smart mold cavity melt two-stage venting device of claim 4, wherein: The steps include: S1: the moving die is combined with the fixed die, and the displacement sensor is triggered; 2S: the displacement sensor feedback combines the mold signal to the external control terminal, the external control terminal starts the vacuum pump, and opens all electrically controlled valves a and b, at the same time, the three ends of the electrically controlled shunt valve c are communicated, and the electrically controlled shunt valves a and b are respectively communicated with the first shunt pipeline and the connecting pipeline a and the second shunt pipeline and the connecting pipeline b; S3: the vacuum pump generates suction and extracts the initial air in the cavity; S4: the external solution is injected into the cavity through the liquid injection pipe, the electric film air pressure sensor detects the pressure in the first exhaust hole in real time, and feeds back the air pressure value to the external control terminal to judge whether the exhaust is unobstructed; S5: the pressure transmitter detects the pressure in the second exhaust hole in real time, and feeds back the air pressure value to the external control terminal to judge whether the exhaust is unobstructed; S6: the external control terminal closes the vacuum pump, and waits for the workpiece in the cavity to be cooled, then the moving die is opened with the fixed die, the displacement sensor feedback opens the mold signal to the external control terminal, the system is reset, and the next mold exhaust process is prepared.
7. The method of claim 6, wherein the method further comprises: determining a mold cavity temperature; and determining a mold cavity pressure. When the electric film air pressure sensor detects the air pressure in any one of the first exhaust holes to the extracted predetermined value in the step S4, the external control terminal controls the electrically controlled valve a on the branch pipeline of the first shunt pipeline communicated with the first exhaust hole to be closed, until all electrically controlled valves a are closed, then step S5 is entered.
8. The smart mold cavity melt two-stage venting device of claim 9, wherein: When the pressure in any one of the secondary exhaust holes reaches the predetermined value detected by the pressure transmitter, the external control terminal controls the electrically controlled valve b in the branch line of the secondary shunt line connected to the secondary exhaust hole to be closed, and the power of the vacuum pump is reduced in proportion to the number of closed electrically controlled valves b until all the electrically controlled valves b are closed, and then step S6 is entered.