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

VSEngineering 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

Engineering Contradiction:
Improveresin scorchingVSAvoidheating time when restarting
Core Design Contradiction:
Object-affected harmful factorsVSLoss of time

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.

Inventive Principle:
Principle #3Local quality

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

Engineering Contradiction:
Improveresin scorchingVSAvoidresin quality
Core Design Contradiction:
Object-affected harmful factorsVSReliability

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.

Inventive Principle:
Principle #3Local quality

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

Engineering Contradiction:
Improveenergy consumption during stopVSAvoidheating time when restarting
Core Design Contradiction:
Loss of energyVSLoss of time

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.

Inventive Principle:
Principle #35Parameter changes

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.

Methodology Applied
Scientific EffectHeating: Heating

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.

Methodology Applied
Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS7218990B2Control device for use in injection molding machine
Publication Date: 2007.05.15 TOSHIBA MASCH CO LTD
  • US7218990B2 patent drawing
  • US7218990B2 patent drawing
  • US7218990B2 patent drawing

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.