Injection molding system for vehicle lamp light guide based on active thermal control and gate cooperation

Abstract

The application discloses a vehicle lamp light guide injection molding system based on active heat control and gate cooperation, which comprises a movable mold core, a light guide and a shell formed on the movable mold core, and further comprises: a primary mold, which comprises a primary fixed mold, an inner fixed core, an outer fixed core and a forming top block, the outer fixed core is provided with a primary hot runner, and the primary hot runner is provided with a pouring convex part; a secondary mold, which comprises a secondary fixed mold, the secondary fixed mold is provided with a secondary hot runner, and the secondary hot runner has at least two secondary gates; a hot runner pouring module, which comprises a parting needle that is closed to the primary gate and the secondary gate after injection is completed; an active temperature control module, which comprises an external circulating temperature control device and is used for providing cold medium and hot medium; a mold temperature control valve group, which comprises a temperature control loop and a cooling loop, the cooling loop and the temperature control loop synchronously circulate medium and are independent of each other, so that high fluidity of the pouring material in the filling process is ensured, and rapid cooling and solidification of the gate area are realized.

Description

Technical Field

[0001] This invention relates to the field of injection molding technology, and more specifically to an injection molding system for automotive headlight light guides based on active thermal control and gate coordination. Background Technology

[0002] Modern automotive headlights face increasingly stringent requirements for optical quality and aesthetic appeal. Thick-walled light guides, as core components for achieving uniform light distribution and complex lighting effects, directly determine the final performance of the headlights due to their injection molding quality. These light guides typically have significant wall thickness, with high-gloss, translucent surfaces on the top and bottom, while the other side often features a special textured finish to create a three-dimensional light emission effect. In terms of manufacturing processes, a two-stage molding technique is commonly employed: first, the light guide is injection molded, and then a decorative shell is molded over it to achieve a seamless integration of function and aesthetics.

[0003] However, in this precise and complex production process, there are interdependent technological contradictions at each stage from casting to cooling. First, to protect the integrity of the light-transmitting and textured surfaces of the light guide, the gate cannot be located on these optical surfaces, but the available gate locations are very limited. Improper gate treatment will not only leave marks on the surface, affecting aesthetics, but may also damage the mechanical and optical properties of the light guide due to weld lines or uneven filling. Second, for light guides with large wall thickness, the molten material needs to maintain a high temperature and fluidity during injection molding to ensure complete filling and avoid internal defects; however, at the same time, the gate area, especially the hot runner pins, must be able to cool and solidify quickly to prevent dripping, stringing, or the pins being stuck by solidified plastic. This poses a near-contradictory requirement for local temperature control of the mold. In addition, how to achieve a seamless gate treatment on the covering structure during secondary molding of the decorative shell, avoiding leaving bumps or scars on the surface of the shell, is also a common technological challenge.

[0004] Currently, most molds use a uniform cooling water circuit for temperature management, making it difficult to implement differentiated and dynamic precise temperature control for different areas. The design of the gate location often compromises between concealing traces and achieving optimal filling effect. These problems collectively lead to unstable yields, long cycle times, and difficulties in simultaneously achieving optimal appearance quality and internal structure in the production of thick-walled light guides. Furthermore, from the perspective of green manufacturing and sustainable development, existing injection molding technology for automotive lighting guides presents significant resource and energy consumption issues. On the one hand, to cope with the non-uniform heat dissipation of complex components, traditional molds often employ a uniform cooling water circuit and a crude temperature control strategy, resulting in low cooling efficiency, long molding cycles, and the unnecessary consumption of cold / heat energy in unnecessary time or areas, leading to high energy consumption per unit product. On the other hand, internal defects in the product caused by process fluctuations (such as shrinkage marks and weld lines) make the one-time molding yield of thick-walled light guides unstable, generating a large amount of high-quality engineering plastic waste that cannot be directly recycled. This not only increases raw material costs but also brings environmental pressure for solid waste disposal. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the present invention aims to provide an injection molding system for automotive headlight light guide components based on active thermal control and gate coordination.

[0006] The above-mentioned technical objective of the present invention is achieved through the following technical solution: an injection molding system for automotive lamp light guide components based on active thermal control and gate coordination, comprising a moving mold core, a light guide component sequentially formed on the moving mold core, and a decorative shell covering the light guide component, further comprising: A primary mold includes a primary mold base, which has an inner core, an outer core, and a forming ejector block that cooperate with each other, and together with a moving mold core, defines a primary cavity. The outer core is provided with a primary hot runner that is obliquely connected to the primary cavity. The primary gate of the primary hot runner is located on the non-light guiding surface of the primary cavity, and a gate protrusion is formed at the gate. The gate protrusion is completely covered by a decorative shell during secondary molding. The secondary mold includes a secondary fixed mold that, together with the light guide after primary molding, defines a secondary cavity. The secondary fixed mold is provided with a secondary hot runner. The secondary hot runner has at least two secondary gates arranged around the secondary cavity and located on the non-appearance surface of the shell. A hot runner gating module includes a movable parting pin disposed within a primary hot runner and a secondary hot runner, the parting pin being configured to retract during injection to open the primary and secondary gates, and to extend after injection to close the primary and secondary gates. Active temperature control module, including: An external circulating temperature control device includes an external water supply unit and heat exchanger, an independently set heating and insulation box and a cooling and temperature control box. The water supply unit is connected to the heating and insulation box and the cooling and temperature control box respectively. The heating and insulation box is used to output the heat medium, and the cooling and temperature control box is used to output the cold medium. The mold temperature control valve assembly includes a temperature control circuit located near the primary and secondary cavities, a main control valve plate, and inlet and outlet pipes connected to the main control valve plate. The main control valve plate is connected to an external circulating temperature control device to switch the supply of cold or hot medium to the selected temperature control circuit according to the injection stage. The inlet pipe receives the cold or hot medium to the temperature control circuit. The main control valve plate is provided with an outlet three-way valve connected to the outlet pipe. The outlet three-way valve receives the cold medium from the temperature control circuit and connects to a refrigeration control box or heat exchanger according to the output temperature difference of the cold medium. The cooling circuit is arranged around the primary and secondary inlets, and the medium flows synchronously with the temperature control circuit but is independent of each other. A heat exchanger includes a heat exchange coil and a heat exchange chamber for accommodating the heat exchange coil. The heat exchange chamber is connected between a water supply unit and a heating and insulation box. The heat exchange coil is connected between the outlet end of an outlet three-way valve and a refrigeration temperature control box. The heat exchange coil receives the heated cold medium. The water supply unit outputs a room temperature medium to the heat exchange chamber, and the room temperature medium absorbs heat and is transported to the heating and insulation box.

[0007] Furthermore, the secondary hot runner extends vertically toward the secondary cavity. The secondary hot runner includes an end secondary runner and a side secondary runner extending into the moving mold core. The end secondary runner is connected to the end of the secondary cavity, and the side secondary runner is connected to the side of the secondary cavity. The end secondary runner and the side secondary runner are arranged on both sides of the light guide.

[0008] Furthermore, the secondary runner includes a branch runner connected to the secondary inlet, a sub-runner connecting the branch runner and the secondary cavity, and a runner block formed on the branch runner, wherein the runner block is provided with a runner groove forming the branch runner.

[0009] Furthermore, a first transition block and a second transition block are sequentially provided between the side secondary flow channel and the secondary inlet. The parting pin is telescopically arranged relative to the first transition block, and the second transition block is supported below the first transition block. The interior of the second transition block forms a transition gating channel that connects to the side secondary flow channel.

[0010] Furthermore, the hot runner casting module includes a casting frame and a thermal control area disposed on the casting frame. The casting frame is provided with a casting channel communicating with a primary hot runner or a secondary hot runner. The thermal control area is arranged at intervals along the casting channel. The thermal control area is provided with a heating wire and a temperature sensor acting on the casting channel, and the heating wire and temperature sensor are arranged at least on opposite sides of the casting channel.

[0011] Furthermore, the hot runner casting module also includes an outlet channel. The inlet channel and the outlet channel are connected in sequence to form a primary hot runner or a secondary hot runner. The primary inlet and the secondary inlet are located at the end of the inlet channel. A telescopic cylinder is provided outside the starting end of the inlet channel. The actuating end of the telescopic cylinder extends into the outlet channel and is connected to the parting pin. The parting pin extends into the outlet channel.

[0012] Furthermore, the gating channel is constrained within a primary mold or a secondary mold. Support blocks are provided on both the upper and lower end faces of the gating channel. The support blocks are supported on the primary mold or the secondary mold, and the support blocks are hollow and have elastic support members between them and the bottom edge of the gating channel.

[0013] Furthermore, a butterfly spring is provided between the inner core and the molded top block's closed mold engagement surface relative to the outer core and the molding top block. The butterfly spring applies a separation force to the molded top block engagement surface, and the butterfly spring remains compressed and accommodated between the molded top blocks under the action of mold closure. The molding top block is movably inserted between the inner core and the outer core, and the molding top block is provided with a connecting pipe connected to the temperature control circuit. The connecting pipe has an extension section extending along the movement direction of the molding top block.

[0014] Furthermore, the moving mold core is provided with a water-turning channel. The bottom of the automatic mold core of the water-turning channel extends towards the surface of the moving mold core, and the water-turning channel is spaced between the intersecting temperature control circuits. A baffle plate is provided in the water-turning channel, and the baffle plate forms an inlet channel and an outlet channel in the water-turning channel. A gap is provided between the baffle plate and the end of the water-turning channel for the heating medium or cold medium to connect from the inlet channel to the outlet channel.

[0015] Furthermore, it also includes: a flow channel resistance adjustment mechanism, which consists of multiple electrorheological fluid units embedded in the primary hot runner and / or secondary hot runner. The electrorheological fluid unit includes a sealed cavity and electrodes disposed therein, and the local resistance of the flow channel is adjusted in real time by changing the electric field strength between the electrodes. The signal acquisition unit includes pressure sensors and temperature sensing elements deployed at key points in the mold cavity, used to acquire cavity pressure and temperature signals in real time. In addition, a control unit is connected to the flow channel resistance adjustment mechanism, the cavity thermal field control unit and the signal acquisition unit, and is used to receive sensor signals and generate control commands for the electrorheological fluid unit and the electrochromic thin film unit.

[0016] Compared with the prior art, the present invention has the following advantages and beneficial effects: This invention sets a primary gate on the non-light-guiding surface of the primary cavity and forms a gate protrusion that can be completely covered by the shell during secondary molding. This avoids leaving gate marks on the optical surface of the light guide and ensures sufficient filling of the casting material.

[0017] Secondly, the secondary mold adopts a design with at least two secondary gates arranged on the non-appearance surface of the shell, combined with the structure of the secondary hot runner extending vertically to the secondary cavity, so that the sprue can fill the secondary cavity evenly and quickly, while avoiding leaving bumps or scars on the surface of the shell.

[0018] Furthermore, the introduction of an active temperature control module, through the cooperation of an external circulating temperature control device and a mold temperature control valve group, achieves dynamic and precise temperature control of the primary and secondary cavities. Particularly in the areas adjacent to the primary and secondary gates, independent cooling circuits are established around the primary and secondary gates, with media flowing synchronously with the temperature control circuit while remaining independent of each other. This allows for flexible temperature adjustment during injection molding based on actual needs. According to the real-time heat dissipation requirements of different areas of the mold during filling, holding pressure, and cooling stages, the flow rate, temperature, and on / off timing of the cold and hot media are dynamically adjusted, achieving on-demand cooling and heat control, avoiding ineffective energy dissipation. Simultaneously, a high-response-speed flow channel resistance adjustment mechanism and thermal control area are integrated into the runner to ensure that the filler enters the cavity at the optimal temperature, reducing the need for repeated heating or over-cooling due to uneven temperature. This effectively shortens mold cooling waiting time, improves overall molding cycle efficiency, and significantly reduces the overall energy consumption per unit of production. Regarding the product molding effect, while ensuring the temperature of the molten material in the hot runner, primary cavity, and secondary cavity, the temperature at the gate is controlled. This effectively reduces stress concentration at the gate caused by the different expansion rates between the hot runner tip and the cavity, thereby avoiding defects such as cracks and deformation that may occur at the gate. This improves the molding quality and stability of the product, ensuring high fluidity of the molten material during the filling process and achieving rapid cooling and solidification of the gate area. Attached Figure Description

[0019] Figure 1 This is a schematic diagram of the structure of the one-piece mold of the present invention; Figure 2 This is a schematic diagram of the secondary mold of the present invention; Figure 3This is a schematic diagram of the primary hot runner and moving mold core of the present invention; Figure 4 For the present invention Figure 3 Enlarged view of point A in the middle; Figure 5 For the present invention Figure 3 Enlarged view of point B in the middle; Figure 6 This is a cross-sectional view of the primary hot runner of the present invention; Figure 7 For the present invention Figure 6 Enlarged view of point C in the middle; Figure 8 This is a cross-sectional view of the secondary hot runner of the present invention; Figure 9 This is a schematic diagram of the secondary hot runner and moving mold core of the present invention; Figure 10 For the present invention Figure 9 Enlarged view at point E in the middle; Figure 11 This is a front view of the moving mold core of the present invention; Figure 12 For the present invention Figure 11 Enlarged view at point F; Figure 13 For the present invention Figure 11 Enlarged view of point G in the middle; Figure 14 This is a schematic diagram of the inner core, outer core, and forming top block of the present invention; Figure 15 This is an exploded view of the inner core, outer core, and forming top block of the present invention; Figure 16 This is an exploded view of the inner core, outer core, and forming top block of the present invention from another angle; Figure 17 This is a cross-sectional view of the inner core and the molding top block of the present invention at the mold closing interface. Figure 18 This is a cross-sectional view of the inner and outer cores of the present invention at the mold closing interface. Figure 19 This is a connection block diagram of the electrorheological fluid unit, temperature control circuit, and cooling circuit of the present invention; Figure 20 This is an overall block diagram of the external circulating temperature control device of the present invention; In the diagram: 1. Moving mold assembly; 11. Moving mold core; 12. Water inlet channel; 121. Baffle plate; 122. Inlet runner; 123. Outlet runner; 13. Connecting seat; 2. Primary mold; 21. Inner core; 22. Outer core; 23. Molding ejector block; 24. Butterfly spring; 241. Core separating ejector block; 25. Mold closing surface; 26. Connecting pipes; 22. Primary mold assembly; 23. Connecting block; 3. Primary hot runner; 31. Primary gate; 4. 41. Secondary mold plate assembly; 42. Secondary mold core; 5. Secondary hot runner; 51. Secondary gate; 52. End secondary runner; 521. Branch runner; 522. Sub-runner; 523. Runner block; 524. Runner groove; 53. Side secondary runner; 531. Middle runner; 532. Front runner; 533. Back runner; 534. First transition block; 535. Second transition block; 536. Transition runner; 6. Hot runner injection mold assembly 61. Parting pin; 611. Telescopic cylinder; 62. Inlet frame; 621. Inlet sprue; 63. Thermal control zone; 631. Heating wire; 632. Temperature sensor; 64. Inlet channel; 65. Transition channel; 66. Outlet channel; 661. Insulation section; 662. Temperature control section; 67. Support block; 671. Elastic support component; 7. Mold temperature control valve assembly; 71. Main control valve plate; 72. Inlet pipe; 73. Outlet pipe; 8. Cooling circuit; 9. Temperature control circuit; 10. Light guide; 101. Non-light guide surface; 102. Inlet protrusion; 20. Decorative shell; 100. Primary cavity; 200. Secondary cavity; 300. Control system; 310. External circulating temperature control device; 311. Water supply unit; 312. Heating and insulation box; 313. Cooling and temperature control box; 320. Control unit; 330. Signal acquisition unit; 340. Temperature sensing element; 350. Pressure sensor; 360. Electrorheological fluid unit; 400, Heat exchanger; 410, Heat exchange coil; 420, Heat exchange chamber; 430, Spray pipe; 500, Inlet solenoid valve; 510, Hot medium inlet; 520, Cold medium inlet; 530, Medium input end; 600, First outlet solenoid valve; 610, Medium output end; 620, Hot medium outlet; 630, Cold medium outlet; 640, Heat exchange inlet; 700, Second outlet solenoid valve; 710, Cold medium return end; 720, Cold medium heat exchange end. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] It should be understood that although the terms upper, middle, lower, top, one end, etc., appear in this document to describe various elements, these elements are not limited by these terms. These terms are only used to distinguish the elements from each other for ease of understanding, and are not used to define any directional or sequential restrictions.

[0022] like Figure 1-6 As shown, the automotive headlight light guide injection molding system based on active thermal control and gate coordination includes a moving mold core 11, a thick-walled light guide 10 sequentially formed on the moving mold core 11, and a trim shell 20 covering it, and further includes: A primary mold includes a primary mold 2, which has a primary mold template 27, and an inner core 21, an outer core 22, and a molding ejector block 23 housed within the primary mold template 27. The inner core 21, the outer core 22, and the molding ejector block 23 cooperate with each other and together with the moving mold core 11 define a primary cavity 100. The molding ejector block 23 is located between the inner core 21 and the outer core 22. The outer core 22 is located on the opposite outer side of the primary mold 2. The outer core 22 is provided with a primary hot runner 3 that is obliquely connected to the primary cavity 100. The primary gate 31 of the primary hot runner 3 is located on the non-light guiding surface 101 of the primary cavity 100, and the primary cavity 100 forms a gate protrusion 102 at the gate 31. The gate protrusion 102 is completely covered by the shell 20 during secondary molding. The secondary mold includes a secondary fixed mold, which has a secondary fixed template assembly 41 and a secondary fixed mold core 42 fixed within the secondary fixed template assembly 41. The secondary fixed mold core 42, the moving mold core 11, and the light guide 10 after primary molding define a secondary cavity 200. The secondary fixed mold is provided with a secondary hot runner 5, which has at least two secondary gates 51 arranged around the secondary cavity 200. The secondary gates 51 are located on the non-exterior surface of the shell 20.

[0023] In the primary mold, the primary fixed mold 2 and the moving mold core 11 close to form a primary cavity 100 to form a thick-walled light guide 10. In the secondary mold, the secondary fixed mold and the moving mold core 11 close to form a secondary cavity 200 to form a relatively thin-walled decorative shell 20 around the light guide 10. The moving mold core 11 switches between the primary fixed mold 2 and the secondary fixed mold via a transfer device in the injection molding machine. The top of the primary fixed mold plate group 27 and the secondary fixed mold plate group 41 serves as the casting input part 621. The primary hot runner 3 delivers molten material to the primary cavity 100, and the secondary hot runner 5 delivers molten material to the secondary cavity 200. The outlet channel 66 of the primary hot runner 3 is obliquely inserted into the outer core 22 from the outside of the primary mold plate group 27 and is positioned towards the moving mold core 11. The primary gate 31 is positioned directly opposite the primary cavity 100. The outlet channel 66 of the secondary hot runner 5 is vertically positioned towards the moving mold core 11, and the secondary gate 51 of the secondary hot runner 5 is located on the outside of the secondary cavity 200.

[0024] In this embodiment, there are two primary cavities 100 and two secondary cavities 200. The primary cavities 100 are symmetrically arranged on the primary mold, and the secondary cavities 200 are symmetrically arranged on the secondary mold.

[0025] The present invention also includes: The hot runner gating module 6 includes a parting pin 61 that is reciprocally movable and disposed within the primary hot runner 3 and the secondary hot runner 5. The parting pin 61 is linearly disposed within the gating channel 66 of the primary hot runner 3 and the secondary hot runner 5 and is positioned directly opposite the primary gate 31 or the secondary gate 51. The parting pin 61 is configured to retract during injection to open the primary gate 31 and the secondary gate 51, and extend after injection to close the primary gate 31 and the secondary gate 51.

[0026] An active temperature control module, which operates at least in the regions adjacent to the primary gate 31 and the secondary gate 51 in both the primary mold 2 and the secondary mold, the system comprising: An external circulating temperature control device 310 includes an external water supply unit 311 and heat exchanger 400, an independently configured heating and insulation box 312 and a cooling and temperature control box 313. The water supply unit 311 is connected to the heating and insulation box 312 and the cooling and temperature control box 313 respectively, and supplies room temperature medium to the heating and insulation box 312 and the cooling and temperature control box 313. The heating and insulation box 312 has a built-in electric heating tube and a temperature sensor 632, which can heat the medium to the process set temperature of 80-150℃ and keep it at that temperature, and can continuously output the hot medium. The cooling and temperature control box 313 has a built-in compression refrigeration unit and a temperature sensor 632, which can cool the medium to the process set temperature of 15-30℃ and control the temperature, and can continuously output the cold medium, so as to achieve precise temperature control and stable environmental conditions. The mold temperature control valve group 7 is connected to the external circulating temperature control device and the temperature control circuit 9 of the primary mold and the secondary mold. The temperature control circuit 9 is located close to the primary cavity 100 and the secondary cavity 200 and is configured to switch to supply cold or hot media to the selected circuit according to the injection stage. The inner core 21, the molding ejector block 23 and the outer core 22 constituting the primary cavity 100, the secondary mold core 42 constituting the secondary cavity 200 and the moving mold core 11 are all equipped with temperature control circuits 9, so as to provide reliable heat preservation and temperature control for the primary cavity 100 and the secondary cavity 200 during the molding process. The temperature control circuit controls the overall temperature difference of the mold through continuous and stable temperature regulation, thereby reducing the accumulation of thermal stress and ensuring the surface quality. It also includes a cooling circuit 8, which is arranged at least around the primary gate 31 and the secondary gate 51. The cooling circuit 8 and the temperature control circuit 9 have synchronous flow of medium and are independent of each other. During the primary molding process, the temperature control circuit 9 inputs hot medium and maintains the mold temperature at 120°C, while the cooling circuit 8 is circulated with cold medium at 20°C to control the temperature around the primary gate 31.

[0027] For the thick-walled light guide 10, the parting pin 61 can ensure that the primary gate 31 is fully opened during injection, allowing the sprue to flow smoothly into the primary cavity 100. This avoids insufficient filling or pressure loss due to the gate not being fully opened. Furthermore, the timed opening and closing of the parting pin 61 can be coordinated with the pressure holding stage to ensure that the shrinkage sprue effectively enters the thick-walled area, suppressing shrinkage and thus reducing shrinkage marks and porosity. Especially after the primary injection is completed, the parting pin 61 extends and closes to the primary gate 31, thereby forcing the sprue at the gate to be pressurized into the primary cavity 100.

[0028] Further reference Figure 1 and Figure 2 As shown, the mold temperature control valve group 7 is respectively installed on the surface of the moving mold group 1, the primary mold 2 and the secondary mold. The mold temperature control valve group 7 specifically includes a main control valve plate 71, and an inlet pipe 72 and an outlet pipe 73 connected to the main control valve plate 71. The inlet pipe 72 and the outlet pipe 73 are configured as multiple groups and are respectively connected to the temperature control circuit 9 of the primary cavity 100 and the secondary cavity 200.

[0029] Further reference Figure 20 As shown, in this embodiment, the main control valve plate 71 is connected to the external circulating temperature control device 310. An inlet solenoid valve 500 is configured on the inlet pipe 72. The inlet solenoid valve 500 is configured with a hot medium inlet 510 connected to the heating and insulation box 312, a cold medium inlet 520 connected to the refrigeration temperature control box 313, and a medium input end 530 connected to the inlet end of the inlet pipe 72 and the temperature control circuit 9, so as to receive cold or hot medium to the temperature control circuit 9. The outflow pipe 73 is equipped with a first outflow solenoid valve 600. The first outflow solenoid valve 600 is equipped with a medium output end 610 connected to the outflow side of the temperature control circuit 9, a hot medium outlet 620 connected to the heating and insulation box 312, a cold medium outlet 630 connected to the refrigeration and temperature control box 313, and a heat exchange inlet 640 connected to the heat exchanger 400. The hot inlet can be opened according to the temperature difference between the input and output of the cold medium. The temperature of the cold medium inlet 520 is detected in advance, and the temperature of the outflow pipe is detected. A first temperature threshold is preset, which is greater than the preset temperature of the heat exchange chamber 420.

[0030] If the actual temperature of the cold medium on the output side of temperature control circuit 9 is greater than the preset first temperature threshold, it indicates that the cold medium has overheated after passing through temperature control circuit 9. At this time, the first outflow solenoid valve 600 opens the heat exchange inlet 640, allowing the heated cold medium to enter the heat exchanger 400. If the actual temperature of the cold medium on the output side is less than the preset first temperature threshold, the first outflow solenoid valve 600 opens the cold medium outlet 630, allowing the returning cold medium to enter the refrigeration temperature control box 313. When the cold and hot media are selected as the same medium, a second temperature threshold can be preset, and the first temperature threshold is less than the second temperature threshold. The second temperature threshold is adjusted in real time according to the required medium temperature of the heating and insulation box 312. Theoretically, the difference between the second temperature threshold and the set temperature of the heating and insulation box 312 is within ±20°. If the actual temperature of the cold medium on the output side is greater than the preset second temperature threshold, the first outflow solenoid valve 600 opens the hot medium outlet 620 and directly delivers the heated hot medium to the heating and insulation box 312.

[0031] As a further implementation of the active temperature control module, a heat exchanger 400 is also included. The heat exchanger 400 is used to receive the heated cold medium. Specifically, the heat exchanger 400 includes a heat exchange coil 410 and a heat exchange chamber 420 for accommodating the heat exchange coil 410. The heat exchange chamber 420 is connected between the water supply unit 311 and the heating and insulation box 312. Under normal conditions, the water supply unit 311 supplies room temperature medium to the heat exchange chamber 420. The heat exchange coil 410 is connected between the outlet end of the first outlet solenoid valve 600 and the refrigeration temperature control box 313. The heat exchange coil 410 is specifically connected to the heat exchange inlet 640 of the first outlet solenoid valve 600. After passing through the mold heat exchange circuit, the cold medium in the cooling circuit 8 and the temperature control circuit 9 absorbs heat from the gate and cavity and its temperature rises. The heated cold medium flows back and first enters the heat exchange coil 410. The heat exchange coil 410 receives the heated cold medium and exchanges heat with the room temperature heating and insulation box 312 supply water in the heat exchange coil 410. The room temperature medium in the heat exchange cavity 420 absorbs the residual heat of the cold medium and its temperature rises. The heated cold medium in the heat exchange coil 410 decreases in temperature after heat exchange and then enters the refrigeration temperature control box 313 for secondary refrigeration. There is no need to directly refrigerate the high temperature cold medium, which greatly reduces the refrigeration energy consumption of the refrigeration temperature control box 313. Alternatively, the medium heated after heat exchange in the heat exchange chamber 420 can be directly transported to the heating and insulation box 312. Compared with heating a normal temperature water source, this reduces the heating energy consumption of the heating and insulation box 312 and realizes the resource utilization of the mold's waste heat.

[0032] Alternatively, the heated medium at room temperature can also be stored in the heat exchange chamber 420. The heat exchange chamber 420 is preferably an insulated shell or further equipped with heating components. When the heating and insulation box 312 needs to increase the output flow or increase the water storage, it can be transported through the preheated water stored in the heat exchange chamber 420, thereby reducing the heating time of the heating and insulation box 312 and realizing the rapid response of the heat medium. In addition, when the heating and insulation box 312 needs to regulate the temperature, such as when temporarily cooling, the preheated water in the heat exchange chamber 420 can also be used to achieve precise regulation of the medium temperature.

[0033] In this embodiment, the heat medium can be heat transfer oil, or hot water if the temperature range allows. The cold medium can be cold water. In order to detect the temperature of the medium in the inlet and outlet pipes, temperature sensors 632 are installed at the inlet and outlet pipes to obtain the temperature of the inlet medium and the temperature of the outlet medium, so that the first outlet solenoid valve 600 can control the outlet end to open. Temperature detection and control of the solenoid valve are conventional control methods for those skilled in the art, and will not be described in detail here.

[0034] As one way to configure the heat exchange chamber 420, the heat exchange chamber 420 can be supplied with a normal temperature medium through the water supply unit 311 to maintain a certain liquid level in the heat exchange chamber 420, specifically higher than the heat exchange coil 410.

[0035] As another configuration of the heat exchange chamber 420, a spray pipe 430 is provided inside the heat exchange chamber 420. The output end of the spray pipe 430 is located above the heat exchange coil 410, and the extension length of the spray pipe 430 inside the heat exchange chamber 420 is greater than the projected length of the heat exchange coil 410, so as to ensure the effective area of ​​the sprayed room temperature medium on the heat exchange coil 410. Of course, on this basis, a certain liquid level can also be maintained inside the heat exchange chamber 420 to ensure the efficient heat exchange of the heat exchange coil 410.

[0036] In other embodiments, the cooling circuit 8 may also be configured with the heat exchanger 400 described above, or the cold medium of the cooling circuit 8 may be connected to the heat exchange coil 410. Optionally, two adjacent sets of heat exchange coils 410 may be provided in the heat exchange chamber 420, one heat exchange coil 410 receiving the cold medium from the temperature control circuit 9, and the other heat exchange coil 410 receiving the cold medium from the cooling circuit 8. For this purpose, a second outflow solenoid valve 700 is provided on the outflow side of the cooling circuit 8 in the mold, which can control the outflow direction of the cold medium according to the temperature difference between the input side and the output side of the cooling circuit 8.

[0037] Specifically, the second outflow solenoid valve 700 can be set with the aforementioned first temperature threshold and configured with a cold medium return end 710 and a cold medium heat exchange end 720. The cold medium return end 710 is connected to the refrigeration temperature control box 313, and the cold medium heat exchange end 720 is connected to the input end of another heat exchange coil 410. If the actual temperature of the cold medium on the output side of the cooling circuit 8 is greater than the preset first temperature threshold, it indicates that the cold medium has been heated too much after passing through the cooling circuit 8. At this time, the second outflow solenoid valve 700 opens the cold medium heat exchange end 720, allowing the heated cold medium to enter the heat exchanger 400. If the actual temperature of the cold medium on the output side is less than the preset first temperature threshold, the second outflow solenoid valve 700 opens the cold medium return end 710, allowing the returned cold medium to enter the refrigeration temperature control box 313.

[0038] Preferably, the temperature control circuit 9 is disposed within the molding component that constitutes the primary cavity 100 and the secondary cavity 200. The molding component provides the molding surface, thereby constructing the primary cavity 100 and the secondary cavity 200. Specifically, it includes the aforementioned inner core 21, molding top block 23, outer core 22, secondary mold core 42, and moving mold core 11. The temperature control circuit 9 is presented as a channel passing through the molding component. One end of the channel constitutes a medium input port, and the other end constitutes a medium output port, thereby forming a circuit. The input and output of the temperature control circuit 9 within the molding component will not be described in detail here.

[0039] like Figure 3 , Figure 6 and Figure 9 As shown, as a further embodiment of the hot runner gating module 6, the hot runner gating module 6 includes a gating frame 62 and a thermal control area 63 disposed on the gating frame 62. The gating frame 62 has a hollow structure, and the gating input part 621 is disposed in the middle of the gating frame 62. The gating frame 62 is provided with a gating channel 64 communicating with the primary hot runner 3 or the secondary hot runner 5. Alternatively, the gating channel 64 constitutes part of the primary hot runner 3 or the secondary hot runner 5. The thermal control area 63 is arranged at intervals along the gating channel 64. The thermal control area 63 is provided with a heating wire 631 and a temperature sensor 632 acting on the gating channel 64. The heating wire 631 is arranged around the outline of each thermal control area 63. The temperature sensor 632 is disposed in the middle position of the thermal control area 63. The heating wire 631 and the temperature sensor 632 are arranged at least on opposite sides of the gating channel 64. The opposite sides refer to the surface and inner sides located on opposite sides of the gating frame 62.

[0040] Preferably, the heat control zone 63 is also arranged around the pouring input section 621.

[0041] The parting pin 61 is spaced apart from the gating channel 64, that is, the parting pin 61 is located between the primary gating gate 31 and the end of the gating channel 64, or between the secondary gating gate 51 and the end of the gating channel 64. In the cooperation between the parting pin 61 and the gating channel 64, the extension and retraction of the parting pin 61 and the pouring material in the gating channel 64 form a dynamic balance. When the parting pin 61 retracts, the pouring material is injected into the mold cavity at a stable flow rate. When the parting pin 61 extends, its tip contacts the front end of the pouring material at the gating gate, and cuts off the pouring material through surface tension to prevent residual pouring material from accumulating at the gating gate and forming cold slurry spots.

[0042] In this embodiment, precise temperature management of the primary hot runner 3 and secondary hot runner 5 is achieved by independently controlling the temperature in the injection channel 64. By symmetrically arranging heating wires 631 and temperature sensors 632 on both sides of the runner, the heating wires 631 preheat the hot runner from the pouring input section 621 to the initial end of the parting pin 61. Combined with real-time control of the heating wires 631 by the temperature sensors 632, the pouring temperature is regulated to ensure that the pouring reaches and remains at the preset flow temperature before entering the primary cavity 100 and secondary cavity 200. This reduces viscosity changes caused by temperature fluctuations, thereby ensuring the stability of the pouring during the movement of the parting pin 61. Furthermore, the temperature sensor 632 monitors the temperature of the thermal control zone 63 in real time and feeds the data back to the control system. When a temperature deviation from the set value is detected, the power output of the heating wires 631 is adjusted, forming a closed-loop temperature control, further ensuring the reliability of the collaborative operation between the parting pin 61 and the injection channel 64.

[0043] As an example, when the pouring temperature is detected to be lower than the set value, the temperature control circuit 9 is activated simultaneously and the medium flow rate and temperature are adjusted. The heating wire 631 works together to control the pouring temperature in the primary cavity 100 and the secondary cavity 200. If the temperature in the gate area is detected to be too high, the temperature control circuit 9 is controlled to introduce a cold medium, or the cooling circuit 8 increases the coolant flow rate to bring the temperature back to the set range.

[0044] from Figure 6 As can be seen, as a further implementation of the telescopic action of the parting pin 61, the hot runner gating module 6 also includes an outlet channel 66, an inlet channel 64 and an outlet channel 66 are connected in sequence to form a primary hot runner 3 or a secondary hot runner 5, a primary inlet 31 and a secondary inlet 51 are formed at the end of the outlet channel 66, and a telescopic cylinder 611 is provided outside the starting end of the outlet channel 66. The actuating end of the telescopic cylinder 611 extends into the outlet channel 66 and is connected to the parting pin 61, which extends into the outlet channel 66.

[0045] Further reference Figure 6 and, Figure 7 , Figure 14 and Figure 15 As shown, as a further embodiment of the cooling circuit 8, a cooling circuit 8 is provided inside the outer core 22 and is located close to the primary gate 31. The temperature control circuit 9 inside the outer core 22 is located even closer to the molding surface of the outer core 22. The outer core 22 has an inclined channel for arranging the outlet channel 66 of the primary hot runner 3. The cooling circuit 8 of the outer core 22 is arranged around the periphery of the inclined channel, while the temperature control circuit 9 of the outer core 22 extends along the length of the primary cavity 100. Therefore, the cooling circuit 8 and the temperature control circuit 9 are separated and their temperatures are controlled separately. The cooling circuit 8 effectively optimizes the cooling of the primary gate 31. When molding the thick-walled light guide 10, the high heat load caused by the high flow rate of the casting material concentrated in the gate area is a problem. Although the primary cavity 100 needs to be maintained at a relatively high mold temperature (e.g., 120°C) by the temperature control circuit 9 to facilitate the filling and curing of the thick-walled light guide 10, the cooling circuit at the primary gate 31 is still necessary. Its purpose is to reduce the risk of overheating in the primary gate 31 area caused by the continuous shearing heat generated by the high flow rate casting material, thereby avoiding thermal stress fracture of the material around the primary gate 31 due to thermal stress concentration. At the same time, it prevents the parting pin 61 from oxidation, adhesion or jamming due to long-term exposure to high temperature environment, and ensures the reliability and stability of the parting pin 61's operation.

[0046] like Figure 6 and Figure 8As shown, as a further improvement to the hot runner gating module 6, the outlet channel 66 includes an insulation section 661 and a temperature control section 662. The insulation section 661 is connected between the inlet channel 64 and the temperature control section 662, and the temperature control section 662 is connected to the primary inlet 31 or the secondary inlet 51. The parting pin 61 passes through the insulation section 661 and the temperature control section 662, and a heat insulation shell is provided outside the insulation section 661, with a heat insulation cavity spaced between the heat insulation shell and the insulation section 661. The cooling circuit 8 located inside the outer core 22 is specifically arranged around the temperature control section 662. On the side, the insulation section 661 ensures the temperature of the refractory material entering the discharge channel, while the cooling circuit 8 around the temperature control section 662 further controls the temperature of the refractory material, precisely regulating its temperature before entering the primary gate 31. This balances the flowability required for filling the thick-walled light guide 10 with the additional heat generated by the continuous shearing of the high-flow-rate refractory material, achieving optimized temperature gradient from the injection frame 62 to the primary gate 31. This not only reduces the heat load concentration in the primary gate 31 area but also reduces temperature fluctuations when the refractory material enters the cavity. Simultaneously, the stable cooling effect of the temperature control section 662 provides a gentler working environment for the parting pin 61, reducing the probability of adhesion or jamming and ensuring consistency in long-term mass production.

[0047] Specifically, the outer diameter of the parting pin 61 is smaller than the inner diameter of the pouring channel 66 to allow the pouring material to pass through. The end of the parting pin 61 matches the pouring part at the end of the pouring channel 66, thereby sealing the pouring material when the parting pin 61 extends.

[0048] Optionally, the insulation cavity can be filled with inert gas to further block heat transfer, ensuring that the refractory material in the insulation section 661 is always kept in a suitable molten state, avoiding increased flow resistance or gate blockage caused by premature cooling.

[0049] The aforementioned heat preservation section 661 and temperature control section 662 are also applied to the outside of the outlet channel 66 of the secondary hot runner 5.

[0050] During the injection molding process, the slurry enters the inlet channel 64 and the outlet channel 66 sequentially through the slurry input part 621. The temperature in the inlet channel 64 is controlled by the thermal control area 63. As the injection molding is completed, the telescopic cylinder 611 is activated and drives the parting pin 61 to extend out of the primary gate 31, thereby reducing the thickness of the injection protrusion 102 on the light guide 10. At the same time, the extension of the parting pin 61 works in coordination with the cooling circuit 8 in the outer core 22 to ensure that the area of ​​the primary gate 31 is sealed before the light guide 10 is completely cured, avoiding gate residue from affecting the appearance quality. For the secondary gate 51, the timed extension of the parting pin 61 can also control the size of the injection marks on the non-appearance surface of the trim shell 20, so that the marks are hidden in the subsequent processing area of ​​the trim shell 20, improving the overall aesthetics of the headlight. Furthermore, the driving pressure of the telescopic cylinder 611 and the extension speed of the parting pin 61 are linked and adjusted with the temperature control circuit 9. When the temperature control circuit 9 detects that the temperature at the end of the gating channel 66 is close to the curing point of the casting, the telescopic cylinder 611 drives the parting pin 61 to extend at a low speed to avoid stress concentration in the plastic part at the gate due to high-speed impact. When the temperature is still detected to be higher than the curing threshold, the telescopic cylinder 611 increases the driving speed to ensure that the parting pin 61 seals the gate in time to prevent casting leakage. The synergistic effect of the parting pin 61 and the temperature control circuit 9 covers the entire injection molding cycle, from flow control in the casting delivery stage to sealing protection in the plastic part curing stage.

[0051] Further integration Figure 6 As shown, in this embodiment, in order to further improve the temperature control of the thermal control zone 63 for the pouring material in the pouring channel 64 and the synergistic effect of the temperature control circuit 9, the detection accuracy of the temperature sensor 632 is one of the important factors.

[0052] Specifically, the gating channel 64 is constrained within the primary mold 2 or the secondary mold. Support blocks 67 are provided on the upper and lower end faces of the gating channel 64. The support blocks 67 are supported on the primary mold 2 or the secondary mold, and the support blocks 67 are hollow. An elastic support member 671 is provided between the support block 67 and the bottom edge of the transition channel 65.

[0053] Taking the primary mold 2 as an example, the primary mold 2 also includes a primary upper mold plate and a primary lower mold plate. A space for accommodating the injection frame 62 is provided between the primary upper mold plate and the primary lower mold plate. When the injection frame 62 is fixed, the injection frame 62 is spaced apart from the primary upper mold plate and the primary lower mold plate. The support block 67 is arranged within the space and the injection frame 62 is fixed by the support block 67. At the same time, a heat insulation space is provided. This heat insulation space can effectively reduce the heat conduction between the injection frame 62 and the mold plate, avoid the low temperature environment of the mold plate from interfering with the temperature of the pouring material in the injection channel 64, and ensure the stable heating effect of the heating wire 631 on the pouring material. Meanwhile, the elastic support 671 forms a flexible connection between the support block 67 and the injection frame 62. When subjected to pressure or vibration during the injection process, the elastic support 671 can act as a buffer to prevent the injection frame 62 from deforming due to force and affecting the stability of the casting. Furthermore, the hollow support block 67 provides an air insulation layer to enhance the insulation effect and provide a more precise temperature environment for the coordinated work of the parting pin 61 and the temperature control circuit 9.

[0054] It is worth mentioning that the support block 67 is arranged on the upper and lower end faces of the sprue frame 62, and applies a relative holding force to the sprue frame 62 through the elastic support member 671. When the sprue frame 62 shifts due to the mold closing force, the support block 67 can compensate for the displacement of the sprue frame 62 and maintain the stability of the sprue frame 62. In addition, the support block 67 and the elastic support member 671 reduce the contact surface of the sprue frame 62 on the primary mold 2 or the secondary mold, so as to reduce the thermal expansion and contraction stress generated by periodic heating and cooling.

[0055] from Figure 8 As can be seen, the support block 67 in the secondary mold is structurally identical to the support block 67 in the primary mold 2. The only difference is the arrangement of the casting frame 62, which will not be elaborated further here.

[0056] In the above embodiment, a transition channel 65 is also provided between the inlet channel 64 and the outlet channel 66 of the primary hot runner 3, wherein the inlet channels 64 in both the primary hot runner 3 and the secondary hot runner 5 are arranged horizontally.

[0057] from Figure 6As can be seen from the diagram, in the primary hot runner 3: the transition channel 65 connects the inlet channel 64 and the outlet channel 66, and the transition channel 65 is equipped with a thermal control area 63. The transition channel 65 is set to extend obliquely from the inside out. The oblique extension direction of the outlet channel 66 is opposite to that of the inlet channel 64 and extends towards one side of the moving mold core 11. For the thick-walled light guide 10, an additional transition channel 65 is added and its outlet channel 66 is set obliquely, so that the sprue generates a certain pressure gradient during the flow process, which helps the sprue to fill the primary cavity 100 more evenly and reduces filling defects caused by poor flow. The heat control area 63 on the transition channel 65 further enhances the precise control of the pouring temperature. At the same time, the inclined transition channel 65 further optimizes the spatial layout of the primary mold 2, so that the pouring channel 66 avoids the light-transmitting surface on the upper part of the light guide 10 without increasing the external size of the primary mold 2. This allows the primary gate 31 to be arranged on the non-light-transmitting surface on the side of the light guide 10. Meanwhile, the pouring protrusion 102 is covered by the shell 20 in the secondary mold.

[0058] Further reference Figure 9 As shown, the difference for the secondary hot runner 5 is that the shell 20 does not provide a light-transmitting surface, and the shell 20 is a thin-walled part compared to the light guide 10. Therefore, the secondary gate 51 is set on the outside of the secondary cavity 200. At the same time, there is no need for the transition channel 65 to adjust the position of the outlet channel 66. The outlet channel 66 in the secondary hot runner 5 can be configured to be vertical.

[0059] Optionally, the moving mold core 11 has two primary surfaces corresponding to the primary cavity 100 and two secondary surfaces corresponding to the secondary cavity 200. Thus, the moving mold core 11 is configured with sufficient surface area and wall thickness to construct the temperature control circuit 9. Preferably, an independent cooling temperature control circuit 9 and an independent heating temperature control circuit 9 are configured in the moving mold core 11. Thus, cold and hot media are simultaneously input into the moving mold core 11 through the mold temperature control valve group 7 and the external circulating temperature control device to further control the internal casting temperature at the bottom surface of the primary cavity 100 and the secondary cavity 200.

[0060] like Figure 4 and Figure 5 ,as well as Figures 9 to 14As shown, in a further embodiment of the secondary hot runner 5 and the secondary cavity 200, the secondary hot runner 5 extends vertically toward the secondary cavity 200. The secondary hot runner 5 includes an end secondary runner 52 and a side secondary runner 53 embedded in the moving mold core 11. There are two end secondary runners 52 and two side secondary runners 53. The two end secondary runners 52 are connected to the two ends of the secondary cavity 200, and the two side secondary runners 53 are connected to the outside of the secondary cavity 200. The two end secondary runners 52 are located on the moving mold core 11. The light guide 10 is positioned at the center line and connected to the secondary cavities 200 on both sides of the center line. The two side secondary flow channels 53 are arranged at the middle position of the light guide 10 in the length direction. Each end secondary flow channel 52 and side secondary flow channel 53 is equipped with a parting pin 61 and a gating channel 64 to ensure that the molten material fills the cavity quickly and synchronously from different directions. This reduces problems such as weld lines, trapped air and local stress concentration caused by excessively long flow paths or uneven filling, thereby improving the appearance quality, structural strength and molding stability of the shell 20.

[0061] from Figure 5 ,as well as Figures 10 to 13 As can be seen, as a further embodiment of the secondary runner 52, the secondary runner 52 includes a branch runner 521 connected to the secondary inlet 51, a sub-runner 522 connecting the branch runner 521 and the secondary cavity 200, and a runner block 523 formed on the branch runner 521. The runner block 523 is provided with a runner groove 524 forming the branch runner 521. The embedded runner block 523 facilitates the processing, maintenance and replacement of the branch runner 521, and optimizes the flow direction of the casting material, so that the casting material can be smoothly and evenly distributed to the two cavities.

[0062] from Figure 12 and Figure 13 Specifically, the sub-grate 522 is set approximately perpendicular to the runner 521, and the end of the runner 521 is approximately parallel to the surface of the adjacent secondary cavity 200. The sub-grate 522 has a tendency to slope from the bottom toward the surface of the secondary cavity 200, optimizing the incident angle of the sprue entering the thin-walled area of ​​the secondary cavity 200, effectively reducing flow resistance, and avoiding problems such as insufficient filling or air bubbles caused by uneven sprue speed. At the same time, the sub-grate 522, which slopes upward to connect to the secondary cavity 200, allows the sprue front to form a uniform spreading effect when it contacts the cavity wall, reducing weld lines caused by sprue collision and improving the smoothness and appearance consistency of the shell 20 surface. In addition, the shortened path of the sub-grate 522 can also reduce cold material residue, further ensuring the stability of molding quality in each mold.

[0063] from Figure 9 and Figure 13As can be seen, as a further embodiment of the secondary runner 53, a first transition block 534 and a second transition block 535 are sequentially provided between the secondary runner 53 and the secondary inlet 51. The second transition block 535 is vertically supported below the first transition block 534. The parting pin 61 of the secondary hot runner 5 is telescopically arranged relative to the first transition block 534. The interior of the second transition block 535 is formed with a transition gating 536 that connects to the secondary runner 53. The secondary inlet 51 is formed on the first transition block 534, and the transition gating 536 is an open groove formed on the second transition block 535. The transition gating 536 has its open side connected to the secondary gating 53, and its open side is offset from the secondary gating 51. This causes the sprue to flow in a directional direction in the offset direction of the open channel at the front edge of the secondary gating 53. When the parting pin 61 extends, its tip can accurately act on the core flow area at the front edge of the sprue. The surface tension of the parting pin 61 at the secondary gating 51 cuts off the sprue, minimizing the amount of residual sprue in the open channel and preventing cold material from being carried into the secondary cavity 200 to form surface defects. This further improves the molding quality consistency of the thin-walled area of ​​the shell 20.

[0064] In addition, the first transition block 534 is provided with a through hole for the slurry to pass through to the second transition block 535. The cooling circuit 8 is also provided around the through hole to prevent the slurry from overflowing due to abnormal viscosity reduction caused by local overheating when passing through the through hole. At the same time, the temperature of the cooling circuit 8 is linked to the output power of the heating wire 631 of the thermal control area 63. When the temperature at the through hole is higher than the set threshold, the coolant flow rate automatically increases. Combined with the real-time feedback of the temperature sensor 632, a dynamic adjustment mechanism is formed to ensure that the slurry maintains a stable flow state before entering the second transition block 535. This further ensures the accuracy of the parting pin 61 in the secondary flow channel 53 in cutting off the slurry and reduces the probability of cold slurry spots and gate residue.

[0065] The first transition block 534 is fixed on the secondary mold, and the second transition block 535 is fixed on the moving mold core 11. The two are set up in an independent modular manner, which makes it easy to disassemble and maintain the local structure of the secondary flow channel 53 on the other side.

[0066] Further reference Figure 13As shown, the transition runner 536 is arc-shaped, and the side secondary runner 53 has an intermediate runner 531 parallel to the surface of the adjacent secondary cavity 200, and a front runner 532 and a back runner 533 at both ends of the intermediate runner 531. The front runner 532 connects to the transition runner 536, and the back runner 533 connects to the secondary cavity 200. The front runner 532 and the back runner 533 are approximately perpendicular to the intermediate runner 531, and the back runner 533 has a tendency to slope from the bottom toward the secondary cavity 200. The connection position between the front runner 532 and the intermediate runner 531 is set at an arc-shaped corner. The arc-shaped corner is roughly symmetrical to the arc direction of the transition runner 536. The front runner 532, the middle runner 531 and the back runner 533 are connected by the corner, so that the side secondary runner 52 can be closer to the temperature control circuit 9 inside the moving mold core 11. The sprue achieves a smooth turn in the process of flowing through the transition runner 536 to the front runner 532, which effectively reduces the flow resistance and local pressure loss of the sprue. In addition, this arc-shaped transition side secondary runner 53 also reduces the shear stress of the sprue at the turning point and reduces the irregular pattern of the shell 20 near the secondary gate 51.

[0067] like Figure 6 As shown, specifically, the temperature control circuit 9 on the moving mold core 11 is presented as a medium channel running through the transverse and longitudinal directions. In this embodiment, the moving mold core 11 has a symmetrical structure with a high middle and low sides. The temperature control circuit 9 on the moving mold core 11 is also presented as a medium channel with the outer bottom of the moving mold core 11 inclined towards the middle. The medium channels are interconnected and form independent circuits to selectively and synchronously input cold or hot medium. In turn, a three-dimensional cross temperature control circuit 9 is formed through the medium channels, effectively covering the bottom and side wall areas of the primary cavity 100 and the secondary cavity 200. When the temperature control circuit 9 detects a local temperature deviation in the cavity, the external circulating temperature control device can quickly adjust the flow rate and temperature of the medium in the corresponding inclined channel through the mold temperature control valve group 7. For example, when the temperature in the bottom area of ​​the primary cavity 100 is low, the heating medium will be preferentially delivered to this area through the inclined channel, and the temperature will be simultaneously increased by the heating wire 631 near the parting pin 61 to ensure the uniform flow and filling of the casting at the bottom of the cavity. When there are signs of overheating on the side wall of the secondary cavity 200, the excess heat can be removed by providing a cold medium, or the cold and hot media can be input simultaneously to regulate the temperature of the temperature control circuit 9, so as to avoid deformation of the thin-walled area of ​​the shell 20 due to overheating. This effectively shortens the temperature control response time, makes the temperature adjustment of the moving mold core 11 highly matched with the action rhythm of the parting pin 61, and further enhances the synergy and stability of the entire injection molding system.

[0068] Furthermore, the projection of the temperature control loop 9 also covers the end secondary flow channel 52 and the side secondary flow channel 53 to further improve the dynamic optimization between the secondary inlet 51 and the secondary cavity 200. Preferably, multiple temperature sensing elements are set at the end secondary flow channel 52 and the side secondary flow channel 53. By recording the temperature fluctuation data at the flow branch point of the end secondary flow channel 52 and the corner of the side secondary flow channel 53 in each mold, the initial heating power and cooling flow parameters of the next mold are corrected by the temperature control loop 9, thereby improving the temperature control accuracy of the end secondary flow channel 52 and the side secondary flow channel 53.

[0069] The following is a specific implementation of the cooling circuit 8 configured on the moving mold core 11. The moving mold core 11 is provided with a water-turning channel 12. The water-turning channel 12 extends from the bottom of the moving mold core 11 toward the surface of the moving mold surface. The water-turning channel 12 is spaced between the horizontal and vertical temperature control circuits 9. A baffle plate 121 is provided in the water-turning channel 12. The baffle plate 121 forms an inlet channel 122 and an outlet channel 123 in the water-turning channel 12. The baffle plate 121 and the end of the water-turning channel 12 are provided with a gap for supplying a cooling medium or a hot medium to communicate from the inlet channel 122 to the outlet channel 123.

[0070] like Figure 6 As shown, the cooling circuit 8 inside the moving mold core 11 works in conjunction with the internal temperature control circuit 9 to control the hot and cold media. When the overall temperature of the moving mold core 11 is too high, the cooling part of the temperature control circuit 9 is linked to the water-cooling channel 12 to adjust the flow rate and input cold media to appropriately reduce the flow rate of the hot media. At the same time, the flow rate of the coolant in the main cooling circuit 8 is increased to achieve rapid temperature balance. If the local temperature control branch feedback indicates that the temperature in a specific area is insufficient, the corresponding area of ​​the water-cooling channel 12 will reduce or shut off the flow rate of the cold media to improve the local circulation efficiency of the hot media. This ensures that the moving mold core 11 is in the optimal temperature state throughout the injection molding process, providing reliable temperature control support for the high-quality molding of the headlight guide 10 and the trim shell 20.

[0071] like Figure 7 , Figures 14 to 18 As shown, in some other embodiments, a butterfly spring 24 is provided between the inner core 21 and the mold closing engagement surface 25 of the outer core 22 and the molding top block 23. The butterfly spring 24 applies a separation force to the mold closing engagement surface 25, and the butterfly spring 24 is kept compressed and accommodated between the mold closing engagement surfaces 25 under the action of mold closing. Under the action of mold parting, the primary mold 2 separates from the moving mold core 11. At this time, the inner core 21 is released under the action of the butterfly spring 24, thereby moving away from the molding top block 23 and the outer core 22 to perform an offset action, thereby relieving the excessive clamping force of the thick-walled light guide 10 in the primary cavity 100.

[0072] Specifically, the mold-closing mating surface 25 refers to the mating surface between the inner core 21 and the outer core 22, as well as the mating surface between the inner core 21 and the forming top block 23. One end of the butterfly spring 24 is embedded in the mold-closing mating surface 25, and the other end of the butterfly spring 24 is connected to a core-splitting push block 241, which abuts against the inner core 21.

[0073] In addition, the molding top block 23 is movably inserted between the inner core 21 and the outer core 22, and the molding top block 23 is provided with a connecting pipe 26 connected to the temperature control circuit 9. The temperature control circuit 9 is provided inside the molding top block 23. The connecting pipe 26 is specifically located on the top of the molding top block 23, and there are two connecting pipes 26, which are used for the medium input and output of the temperature control circuit 9, respectively. At the same time, the molding top block 23 is a movable component, and an ejection mechanism is provided between its top and the primary molding template group 27. The ejection mechanism can be a hydraulic cylinder connected to the molding top block 23. The hydraulic cylinder is vertically arranged and drives the molding top block 23 to eject. It is only necessary to apply a force to the molding top block 23 towards the light guide 10 to disengage from the primary cavity 100. This will not be elaborated in detail here. In order to avoid the vertical movement of the molding top block 23 from affecting the pipeline arrangement of the temperature control circuit 9, the connecting pipe 26 has an extension section extending along the movement direction of the molding top block 23. The extension distance of the extension section matches the movement stroke of the molding top block 23.

[0074] Further integration Figure 15 As shown, after the initial mold separation, the inner core 21, which is in a separated state, returns to a closed state with the molding top block 23 and the outer core 22 when the mold is closed. The moving mold core 11 has a connecting seat 13 arranged along the length of the light guide 10 in the middle. The inner core 21 has a connecting block 28 on its surface. The connecting block 28 is located on one side of the connecting seat 13. There is an inclined surface that is opposite to the connecting seat 13 in the mold closing direction between the connecting seat 13 and the connecting block 28. Through the cooperation between the connecting block 28 and the inclined surface of the connecting seat 13, the connecting block 28 and the inclined surface of the connecting seat 13 are pressed together when the mold is closed, so that the inner core 21 closes towards the molding top block 23. When the mold is opened, due to the mold opening force of the moving mold module and the initial mold 2 module, the connecting block 28 separates from the connecting seat 13 in the vertical direction, thereby releasing the separation gap that allows the inner core 21 to move away from the connecting direction, creating physical conditions for the release of the spring force of the butterfly spring 24.

[0075] Reference Figure 19 As shown, in some other embodiments, to control the flowability of the refractory material in the primary hot runner 3 and the secondary hot runner 5, the following further methods are included: The flow channel resistance adjustment mechanism consists of multiple electrorheological fluid units 360 embedded in the primary hot runner 3 and / or the secondary hot runner 5. Each electrorheological fluid unit 360 includes a sealed cavity and electrodes disposed therein. The local resistance of the flow channel is adjusted in real time by changing the electric field strength between the electrodes. The signal acquisition unit 330 includes a pressure sensor 350 and a temperature sensing element 340 arranged in the primary cavity 100 and the secondary cavity 200, as well as the primary hot runner 3 and the secondary hot runner 5, for real-time acquisition of pressure and temperature signals. Additionally, the control unit 320 is connected to the flow channel resistance adjustment mechanism and the signal acquisition unit 330, and is used to receive pressure signals and temperature signals and generate control commands for the electrorheological fluid unit 360.

[0076] In this embodiment, the primary cavity 100 and the secondary cavity 200 are collectively referred to as cavities, and the primary mold and the secondary mold are collectively referred to as molds.

[0077] In this embodiment, the real-time screw position signal, injection pressure signal, and cavity pressure signal of the injection molding machine are collected. The electrorheological fluid unit 360 can be optionally set at the primary gate 31 and the secondary gate 51, preferably set at the side secondary flow channel 53 and the end secondary flow channel 52, so as to avoid the influence of the electrorheological fluid unit 360 on the mold surface. The control of the electrorheological fluid unit 360 is based on the flow position of the sprue and the real-time pressure gradient of the area.

[0078] When the electrorheological fluid unit 360 is located at the primary gate 31, it is preferably located on the moving mold core 11 at the bottom corresponding to the gate protrusion 102. When the electrorheological fluid unit is located in the side secondary runner 53, it is preferably located at the bottom of the second transition block 535, which is an independent module, and forms part of the transition runner 536, or it can be embedded in the path of the intermediate runner 531, the front runner 532, or the back runner 533. When the electrorheological fluid unit is located in the end secondary runner 52, it is preferably located at the bottom of the runner block 523, forming part of the runner groove 524, or it can be located at the bottom of the sub-runner 522. For the sub-runner 522 and the back runner 533 with inclined closing openings, the electrorheological fluid unit 360 on them can further control the real-time flow resistance of the sprue.

[0079] The injection molding machine's control system 300 collects real-time screw position signals, injection pressure signals, and cavity pressure signals from the injection screw and mold. The real-time pressure gradient is determined based on these signals. The real-time pouring position and the real-time pressure gradient of each region are input into a preset flow field dynamic control model to calculate the target electric field strength values ​​for each of the multiple electrorheological fluid units 360 used to adjust the local resistance of the mold flow channel. Based on the target electric field strength values, electric field control commands are generated for the electrorheological fluid units 360 installed in the mold flow channel. The control electrorheological fluid unit 360 changes its electric field strength according to the electric field control command to adjust the viscosity and flow resistance of the electrorheological fluid in the corresponding area of ​​the flow channel, thereby establishing the electric field required by the command between the electrodes of the corresponding electrorheological fluid unit 360. This electric field causes an instantaneous change in the viscosity of the electrorheological fluid in the electrorheological fluid unit 360. Specifically, when the electric field is strengthened, the viscosity increases sharply, specifically exhibiting a near-solid state; when the electric field is weakened or removed, the viscosity decreases rapidly, restoring the fluid state. This achieves the adjustment of the flow resistance in a specific flow channel area inside the mold. The target electric field strength value refers to the specific electric field strength value that needs to be established between its electrodes to achieve the expected flow resistance adjustment effect.

[0080] Among them, the real-time screw position signal refers to the continuous electrical signal that is generated and output in real time by the rotary encoder installed on the screw drive shaft of the injection molding machine, which accurately represents the axial displacement and instantaneous speed of the screw.

[0081] Injection pressure signal refers to an electrical signal that is measured and output in real time by a pressure sensor installed on the injection molding machine and is proportional to the hydraulic pressure required to propel the injection material forward.

[0082] The cavity pressure signal refers to the electrical signal measured and output in real time by the pressure sensor 350, which directly reflects the local pressure exerted by the casting on the cavity surface. The positions of multiple pressure sensors 350 directly embedded inside the primary mold 2, the secondary mold 2, and the moving mold core 11 during mold manufacturing are specifically set in advance by those skilled in the art and will not be elaborated here. The flow position of the sprue refers to the instantaneous position of its foremost boundary in the mold cavity when the sprue is filling the cavity. Combined with the signal jump timing of multiple pressure sensors 350 distributed in different areas of the cavity, that is, the moment when the pressure value first jumps from the background value to the set threshold, the theoretical filling boundary is dynamically verified and the spatial position is calibrated in real time to obtain the real-time position of the sprue.

[0083] Real-time pressure gradient refers to the rate of pressure change per unit length along the flow path of the casting material in the mold runner system and cavity at a specific sampling time. It is obtained by retrieving the cavity pressure signal from the cavity pressure sensors 350 arranged in pairs along the main flow direction of the casting material, calculating the pressure difference between the two points, and dividing it by the physical distance between the two points along this flow path. This physical distance is preset by those skilled in the art and will not be elaborated here. The result is the real-time pressure gradient.

[0084] The flow field dynamic control model refers to a decision algorithm module pre-built and integrated into the control system 300. This model receives real-time flow position and real-time pressure gradient as core input parameters. Its internal logic is based on the fluid dynamics principles of the injection molding process and a trained machine learning algorithm (specifically selected and set by those skilled in the art according to requirements, and will not be elaborated here). The function of this model is to analyze the deviation between the current casting flow state and the preset ideal filling mode (pre-set by those skilled in the art, and will not be elaborated here), and to determine the control actions required for each electrorheological fluid unit 360 to correct this deviation, ultimately outputting the control quantity required for each unit.

[0085] The electrorheological fluid unit 360 refers to a controllable actuator integrated inside the moving mold core 11. Each electrorheological fluid unit 360 consists of a sealed micro-cavity filled with electrorheological fluid, and high-voltage electrodes are embedded in the cavity walls. When electric fields of different intensities are applied between the electrodes, the apparent viscosity of the electrorheological fluid in the cavity can undergo a reversible change, thereby altering the flow resistance experienced by the casting material flowing through the unit.

[0086] Based on the real-time position of the casting material, the real-time pressure gradient of each region, and the target electric field strength value, the injection speed adjustment amount for the injection molding machine and the timing adjustment parameters for the telescopic cylinder 611 are determined. The timing adjustment parameters for the telescopic cylinder 611 refer to the adjustment values ​​made to the triggering time of the relevant output channel in the timing controller that controls the opening and closing of the parting needle 61 to precisely coordinate with the dynamic flow resistance changes realized by the electrorheological fluid unit 360 and to more accurately control the timing of the casting material closure. The timing adjustment parameters for the telescopic cylinder 611 are calculated based on the real-time position of the casting material and the target electric field strength value using a preset valve timing coordination algorithm. Specifically, this algorithm predicts the change in flow resistance when the casting material reaches the relevant hot runner valve port after the flow resistance change, based on the specific flow channel resistance change indicated by the target electric field strength value and the current casting progress indicated by the real-time casting position. It then calculates the amount of time that the valve needle needs to be advanced or delayed, thereby obtaining the timing adjustment parameters for the telescopic cylinder 611. The valve timing coordination algorithm is preset by those skilled in the art and will not be elaborated here.

[0087] In other embodiments, thanks to the pressure sensors 350 and temperature sensing elements 340 within the primary cavity 100 and secondary cavity 200, combined with temperature signals from the thick-walled forming area corresponding to the light guide 10 and the thin-walled forming area corresponding to the shell 20 on the moving mold core 11, as well as adjacent surfaces, the cooling balance requirement parameters for each area are determined. These cooling balance requirement parameters are quantified values ​​characterizing the heat flux compensation required for the corresponding cavity surface areas of the mold to achieve synchronous or on-demand differentiated cooling of different forming areas of the light guide 10 and the shell 20. This is achieved by first acquiring the real-time cavity temperatures at multiple measurement points corresponding to the thick-walled and thin-walled forming areas, respectively. Then, the temperature difference between the thick-walled and thin-walled forming areas is calculated by comparing their average temperatures. Finally, based on the temperature difference and the preset temperature difference thermal compensation mapping relationship, the heat flux value that needs to be increased (or decreased) on the mold cavity surface corresponding to the thick-walled forming area in order to reduce the temperature difference and achieve balanced cooling is calculated. This value is the cooling balance requirement parameter. The temperature difference thermal compensation mapping relationship is determined by those skilled in the art based on heat conduction simulation and process experiments, and will not be elaborated here.

[0088] Multiple temperature control circuits 9 within the moving mold core 11, and multiple water-turning channels 12 spaced along the thick-walled forming area and the thin-walled forming area, control the hot and cold media in the temperature control circuits 9 respectively, and control the temperature variables of each area in combination with the multiple water-turning channels 12.

[0089] This specific embodiment is merely an explanation of the present invention and is not intended to limit the invention. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they are within the scope of the claims of the present invention.

Claims

1. An injection molding system for automotive headlight light guide components based on active thermal control and gate coordination, comprising a moving mold core (11), a light guide component (10) sequentially formed on the moving mold core (11), and a decorative shell (20) covering the light guide component (10), characterized in that, Also includes: A primary mold includes a primary mold (2), which has an inner core (21), an outer core (22), and a molding ejector block (23) that cooperate with each other, and together with the moving mold core (11) defines a primary cavity (100). The outer core (22) is provided with a primary hot runner (3) that is obliquely connected to the primary cavity (100). The primary gate (31) of the primary hot runner (3) is located on the non-light guiding surface (101) of the primary cavity (100), and a gate protrusion (102) is formed at the gate (31). The gate protrusion (102) is completely covered by the decorative shell (20) during secondary molding. The secondary mold includes a secondary fixed mold that defines a secondary cavity (200) together with the light guide (10) after primary molding. The secondary fixed mold is provided with a secondary hot runner (5). The secondary hot runner (5) has at least two secondary gates (51) arranged around the secondary cavity (200) and located on the non-appearance surface of the shell (20). The hot runner gating module (6) includes a movable parting pin (61) disposed in the primary hot runner (3) and the secondary hot runner (5), the parting pin (61) being configured to retract during injection to open the primary gate (31) and the secondary gate (51), and extend after injection to close the primary gate (31) and the secondary gate (51); The active temperature control module includes: An external circulating temperature control device (310) includes an external water supply unit (311) and a heat exchanger (400), an independently configured heating and insulation box (312) and a cooling and temperature control box (313). The water supply unit (311) is connected to the heating and insulation box (312) and the cooling and temperature control box (313) respectively. The heating and insulation box (312) is used to output the heat medium, and the cooling and temperature control box (313) is used to output the cold medium. The mold temperature control valve assembly (7) includes a temperature control circuit (9) located near the primary cavity (100) and the secondary cavity (200), a main control valve plate (71), and an inlet pipe (72) and an outlet pipe (73) connected to the main control valve plate (71). The main control valve plate (71) is connected to an external circulating temperature control device (310) to switch the supply of cold medium or hot medium to the selected temperature control circuit (9) according to the injection stage. The inlet pipe (72) receives cold medium or hot medium to the temperature control circuit (9). The main control valve plate (71) is provided with an outlet three-way valve connected to the outlet pipe (73). The outlet three-way valve receives cold medium from the temperature control circuit (9) and connects to the refrigeration temperature control box (313) or heat exchanger (400) according to the output temperature of the cold medium. Cooling circuit (8) is arranged around the primary inlet (31) and the secondary inlet (51), and the medium flows synchronously with the temperature control circuit (9) but is independent of each other; A heat exchanger (400) includes a heat exchange coil (410) and a heat exchange chamber (420) for accommodating the heat exchange coil (410). The heat exchange chamber (420) is connected between a water supply unit (311) and a heating and insulation box (312). The heat exchange coil (410) is connected between the outlet end of an outlet three-way valve and a refrigeration temperature control box (313). The heat exchange coil (410) receives the heated cold medium. The water supply unit (311) outputs a room temperature medium to the heat exchange chamber (420), and the room temperature medium absorbs heat and is transported to the heating and insulation box (312).

2. The injection molding system for automotive lamp light guide components based on active thermal control and gate coordination as described in claim 1, characterized in that: The secondary hot runner (5) extends vertically toward the secondary cavity (200). The secondary hot runner (5) includes an end secondary runner (52) and a side secondary runner (53) extending into the moving mold core (11). The end secondary runner (52) is connected to the end of the secondary cavity (200), and the side secondary runner (53) is connected to the side of the secondary cavity (200). The end secondary runner (52) and the side secondary runner (53) are arranged on both sides of the light guide (10).

3. The injection molding system for automotive lamp light guide components based on active thermal control and gate coordination as described in claim 2, characterized in that: The secondary runner (52) includes a runner (521) connected to the secondary inlet (51), a sub-runner (522) connecting the runner (521) and the secondary cavity (200), and a runner block (523) formed on the runner (521), wherein the runner block (523) is provided with a runner groove (524) forming the runner (521).

4. The injection molding system for automotive lamp light guide components based on active thermal control and gate coordination as described in claim 2, characterized in that: A first transition block (534) and a second transition block (535) are sequentially provided between the side secondary runner (53) and the secondary inlet (51). The parting pin (61) is telescopically arranged relative to the first transition block (534), and the second transition block (535) is supported below the first transition block (534). The interior of the second transition block (535) forms a transition runner (536) that connects to the side secondary runner (53).

5. The injection molding system for automotive headlight light guide components based on active thermal control and gate coordination as described in claim 1, characterized in that: The hot runner casting module (6) includes a casting frame (62) and a thermal control area (63) disposed on the casting frame (62). The casting frame (62) is provided with a casting channel (64) communicating with a primary hot runner (3) or a secondary hot runner (5). The thermal control area (63) is arranged at intervals along the casting channel (64). The thermal control area (63) is provided with a heating wire (631) and a temperature sensor (632) acting on the casting channel (64). The heating wire (631) and the temperature sensor (632) are arranged at least on opposite sides of the casting channel (64).

6. The injection molding system for automotive lamp light guide components based on active thermal control and gate coordination as described in claim 5, characterized in that: The hot runner casting module (6) also includes an outlet channel (66). The inlet channel (64) and the outlet channel (66) are connected in sequence to form a primary hot runner (3) or a secondary hot runner (5). The primary inlet (31) and the secondary inlet (51) are located at the end of the inlet channel (64). A telescopic cylinder (611) is provided outside the starting end of the inlet channel (64). The actuating end of the telescopic cylinder (611) extends into the outlet channel (66) and is connected to the parting needle (61). The parting needle (61) extends into the outlet channel (66).

7. The injection molding system for automotive lamp light guide components based on active thermal control and gate coordination as described in claim 5, characterized in that: The gating channel (64) is constrained within the primary mold (2) or the secondary mold. Support blocks (67) are provided on the upper and lower end faces of the gating channel (64). The support blocks (67) are supported on the primary mold (2) or the secondary mold. The support blocks (67) are hollow and are provided with elastic support members (671) between them and the bottom edge of the gating channel (64).

8. The injection molding system for automotive lamp light guide components based on active thermal control and gate coordination as described in claim 1, characterized in that: The inner core (21) is provided with a butterfly spring (24) between the outer core (22) and the molded top block (23) and the molded joint surface (25). The butterfly spring (24) applies a separation force to the molded joint surface (25), and the butterfly spring (24) is compressed and accommodated between the molded joint surfaces (25) under the action of mold closing. The molded top block (23) is movably inserted between the inner core (21) and the outer core (22), and the molded top block (23) is provided with a connecting pipe (26) connected to the temperature control circuit (9). The connecting pipe (26) has an extension section extending along the movement direction of the molded top block (23).

9. The injection molding system for automotive lamp light guide components based on active thermal control and gate coordination as described in claim 1, characterized in that: The moving mold core (11) is provided with a water-turning channel (12). The water-turning channel (12) extends from the bottom of the moving mold core (11) toward the surface of the moving mold core (11). The water-turning channel (12) is spaced between the horizontal and vertical temperature control circuits (9). The water-turning channel (12) is provided with a baffle plate (121). The baffle plate (121) forms an inlet channel (122) and an outlet channel (123) in the water-turning channel (12). The baffle plate (121) and the end of the water-turning channel (12) are provided with a gap for the heating medium or the cold medium to communicate from the inlet channel (122) to the outlet channel (123).

10. The injection molding system for automotive lamp light guide components based on active thermal control and gate coordination according to claim 1, characterized in that, Also includes: The flow channel resistance adjustment mechanism is composed of multiple electrorheological fluid units (360) embedded in the primary hot runner (3) and / or the secondary hot runner (5). The electrorheological fluid unit (360) includes a sealed cavity and electrodes disposed therein. The local resistance of the flow channel is adjusted in real time by changing the electric field strength between the electrodes. The signal acquisition unit (330) includes a pressure sensor (350) and a temperature sensing element (340) arranged in the primary mold (2), the secondary mold and the moving mold core (11) for real-time acquisition of cavity pressure signal and temperature signal; In addition, the control unit (320) is connected to the flow channel resistance adjustment mechanism and the signal acquisition unit (330) for receiving sensor signals and generating control commands for the electrorheological fluid unit (360).

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