Adjustable Flow Diverter for Melt Rotation Positioning
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Solution Overview
Problem
Current methods for controlling non-homogeneous melt conditions in laminar flowing fluids within molding systems, such as those used in injection molding, often result in flow-induced cavity filling imbalances and product variations due to shear and thermal variations, leading to issues like uneven mold filling, shrinkage, and warpage, and require costly and time-consuming redesigns of fixed-geometry fluid rotation devices.
Innovation Solution
The development of adjustable fluid rotation devices that can be insitu modified to adjust the flow geometry, allowing for precise repositioning of non-homogeneous melt conditions without the need for extensive mold disassembly or remachining, using mechanisms like extendible pins or rotatable notched disks to control the flow path and achieve desired asymmetrical or symmetrical distributions across the runner.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If fixed-geometry fluid rotation devices are used to control melt flow, then flow repositioning can be achieved, but costly and time-consuming redesigns and remachining are required when adjustments are needed
Solution Approach 1:
The patent applies the dynamics principle by making the flow diverter section adjustable rather than fixed. The flow diverter can be repositioned to different angles and positions to change the flow geometry dynamically, allowing the system to adapt to different melt distribution requirements without requiring redesign or remachining of the entire device.
Solution Approach 2:
The device is segmented into adjustable components, specifically the flow diverter section that can be independently repositioned. This segmentation allows specific parts of the device to be adjusted without affecting the entire structure, enabling flexible modification of flow geometry while maintaining the overall device integrity.
2Manufacturing precision
If geometrically balanced runner systems are used, then cavity filling consistency should be improved, but flow-induced imbalances still occur due to shear and thermal variations
Solution Approach 1:
The patent applies asymmetry by intentionally creating asymmetric flow conditions through the adjustable flow diverter. Rather than relying on symmetric geometric balancing alone, the device introduces controlled asymmetric flow patterns to compensate for the inherent asymmetric shear and thermal variations that occur during melt flow, thereby achieving better filling consistency.
Solution Approach 2:
The system changes flow parameters (velocity distribution, flow direction, shear rate distribution) by adjusting the flow diverter position and angle. This allows dynamic control of melt conditions to compensate for thermal variations and shear effects, improving adaptability beyond what fixed geometric balancing can achieve.
3Manufacturing precision
If extensive mold disassembly and remachining are performed to adjust flow geometry, then precise repositioning of melt conditions can be achieved, but production time and costs increase significantly
Solution Approach 1:
The flow diverter is designed as a dynamic, adjustable component that can be repositioned without disassembly or remachining. This dynamic adjustment capability allows precise melt repositioning to be achieved quickly by simply moving the flow diverter to different positions, eliminating the time-consuming processes of mold disassembly and remachining.
4Ease of manufacture
If standard geometric balancing is applied to runner systems, then initial flow distribution is improved, but cannot compensate for flow-induced imbalances during actual molding
Solution Approach 1:
The patent transforms the static geometric balancing approach into a dynamic system by incorporating an adjustable flow diverter. This allows the system to maintain the simplicity of geometric balancing design while adding the capability to dynamically adjust flow distribution during operation, thereby compensating for flow-induced imbalances that static design cannot address.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables quick and precise adjustment of fluid flow repositioning to correct imbalances and achieve uniform melt distribution, reducing production costs and time by allowing for in-situ adjustments during operation, thereby improving mold filling consistency and product quality.
Implementation Method 1
controlling the repositioning of non-homogeneous melt conditions across the stream of a laminar flowing fluid
Implementation Method 2
significant shear and thermal variations are developed in a polymer melt as it flows through a runner
Implementation Method 3
rotate one of the mold insert halves so that the flow region is rotated to complete the flow path of the runner anywhere along the intermediate section thereby adjusting the stream of laminar flowing material in situ
Data Source
Figure 1~2
Figure 3~3D
Figure 4A~4D
AI summary
Methods and apparatus adjustably control the repositioning of non-homogeneous fluid conditions across the stream of a laminar flowing fluid to a desirable circumferential position. The invention is particularly applicable to controlling non-homogeneous melt conditions in hot or cold runner systems. Various mechanisms are provided that enable simple adjustments of a flow diverter within a fluid rotation device, making either static or dynamic adjustments, so that the degree of fluid flow repositioning in a runner system can be changed without the need for mold disassembly or retooling. Various forms of actuators effect adjustment and may be manually manipulated or manipulated through various powered devices.