Injection Molding Barrel Temperature Control for Resin Scorching
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Solution Overview
Problem
Existing injection molding machines face issues with resin scorching during temporary stops, leading to prolonged heating times and resin deterioration when temperatures are unnecessarily lowered, especially at the front part of the barrel.
Innovation Solution
A control device that allows selection between 'shift minus' and 'absolute' temperature settings to uniformly lower or set barrel temperatures, ensuring the front part is not overheated, thereby preventing scorching and maintaining resin quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If the shift minus temperature is set based on the front part control temperature to prevent scorching, then resin scorching is prevented, but the temperatures of the rear part, middle part and nozzle are unnecessarily lowered
Solution Approach 1:
The patent applies local quality by setting different temperature reduction amounts for different barrel sections. The front part (prone to scorching) receives a smaller temperature reduction (first value) compared to the rear part (less prone to scorching) which receives a larger temperature reduction (second value). This localized differential temperature control prevents scorching where needed while maintaining higher temperatures in other sections to reduce restart heating time.
2Object-affected harmful factors
If the control temperature of the front part is lowered to prevent scorching, then resin scorching is prevented, but the molten resin in the barrel may deteriorate
Solution Approach 1:
The patent implements local quality by applying different temperature control strategies to different barrel sections. The front part uses a smaller temperature reduction to prevent scorching, while the rear and middle parts maintain higher temperatures through larger temperature reductions. This ensures molten resin throughout the barrel remains within appropriate temperature ranges, preventing deterioration while still preventing scorching at the vulnerable front section.
3Loss of energy
If the temperatures of all barrel parts are uniformly lowered during temporary stop, then energy consumption is reduced, but the heating time when restarting is prolonged
Solution Approach 1:
The patent applies parameter changes by dynamically adjusting the temperature reduction amount based on the specific barrel section. Instead of a uniform temperature reduction, the system implements differentiated temperature reductions where the front part receives a smaller reduction (first value) and the rear part receives a larger reduction (second value). This optimized parameter adjustment reduces energy consumption during temporary stops while minimizing the impact on restart heating time.
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
This solution prevents resin scorching, reduces heating time when restarting, and maintains resin quality by allowing tailored temperature control based on the type of resin used, ensuring efficient operation and product integrity.
Implementation Method 1
The barrel has heaters on its outer circumference. The barrel heats and melts the synthetic resin material using the heaters.
Implementation Method 2
The barrel pushes the heated molten resin toward the forward end by the rotation of the injection screw, and injects the resin from the injection nozzle to the mold.
Data Source
AI summary
A barrel has an injection nozzle at the forward end, and an injection screw inside, and heaters in the outer circumference. The barrel injects the molten resin from the injection nozzle at the forward end by the rotation of the injection screw. In the barrel, the temperatures of each parts are controlled by a temperature control section. A controller sets a shift minus temperature to uniformly lower the temperature of the parts, and a shift absolute temperature to lower the temperatures of the parts to a predetermined temperature. An operation panel section selects the shift minus temperature or shift absolute temperature to lower the temperatures of the parts. The temperature control section lowers the temperatures of the parts of the barrel by using the temperature selected when the injection molding machine is temporarily stopped.


