Reduced Runner Injection Mold Constant Pressure
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Solution Overview
Problem
Conventional injection molding systems face challenges with cold and hot runner systems, including increased cycle times, clamp tonnage requirements, material waste, and polymer degradation due to large runner volumes, which affect productivity and part quality.
Innovation Solution
Implementing a system that maintains substantially constant pressure during the injection molding process, allowing for reduced runner sizes, which decreases the volume of material needed and minimizes polymer residence time, thereby enhancing productivity and part quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional cold or hot runner systems are used with larger runner volumes, then the runners can maintain molten state longer and ensure complete cavity filling, but cycle times increase and productivity decreases
Solution Approach 1:
The patent applies parameter changes by transitioning from conventional variable pressure injection to constant pressure injection. This parameter change allows for reduced runner sizes while maintaining complete cavity filling, thereby reducing cycle times and improving productivity without sacrificing filling reliability
2Quantity of substance
If larger runner volumes are used in conventional systems, then material flow to cavities is ensured, but clamp tonnage requirements increase
Solution Approach 1:
The patent uses parameter changes by implementing constant pressure injection molding, which enables the use of smaller runners that require less clamp tonnage while still ensuring adequate material flow to all cavities throughout the molding cycle
3Reliability
If larger runner volumes are used, then complete filling is achieved, but material waste increases
Solution Approach 1:
The patent applies parameter changes through constant pressure injection molding, which enables precise control of material injection. This allows for reduced runner sizes that minimize material waste while ensuring complete cavity filling through maintained pressure control throughout the injection process
4Temperature
If larger runner volumes are used in hot runner systems, then material remains molten, but polymer degradation increases due to extended residence time
Solution Approach 1:
The patent applies parameter changes by implementing constant pressure injection molding, which enables the use of smaller runner volumes. This reduction in runner volume decreases polymer residence time while maintaining adequate material flow and temperature through controlled pressure, thereby reducing polymer degradation
Solution Approach 2:
The patent extracts the excess runner volume from the system by using smaller runners enabled by constant pressure injection. This extraction reduces the amount of polymer subjected to prolonged heating and shear, minimizing degradation while still ensuring complete cavity filling
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
The use of substantially constant pressure in injection molding reduces runner sizes, saving space and energy, improving part quality, and reducing material waste and polymer degradation, leading to increased productivity and efficiency.
Implementation Method 1
Implementing a system that maintains substantially constant pressure during the injection molding process, allowing for reduced runner sizes
Data Source
AI summary
A runner system for a multi-cavity injection molding system, the runner system having runners of reduced size.