TWI686284B

TWI686284B - Method of injection molding using one or more external sensors as a virtual cavity sensor

Info

Publication number: TWI686284B
Application number: TW105129189A
Authority: TW
Inventors: 瑞克艾倫波拉德; 約書亞道格拉斯瑞克; 奇尼麥可奧登尼; Ｈ肯尼斯三世韓森
Original assignee: 美商艾弗洛斯公司
Priority date: 2016-09-08
Filing date: 2016-09-08
Publication date: 2020-03-01
Also published as: TW201811535A

Abstract

A injection molding method involves measuring, using at least one external sensor, a change in a parameter of a mold side of a mold cavity, approximating a condition within the mold cavity based on the change in the parameter, such as pressure within the mold cavity or flow front position, and comparing the approximated condition to a trigger point. If the approximated condition equals or exceeds the trigger point, activating a virtual cavity sensor having an optimal pre-defined pressure-time curve, and upon activation, the virtual cavity sensor tracks an approximated condition calculated from the change in parameter measurements measured by the at least one external sensor over time. In an embodiment, results of the approximated parameter tracking can be used in conjunction with an optimal pre-defined pressure-time curve.

Description

使用一或多個外部感測器作為虛擬凹穴感測器之注射模製方法 Injection molding method using one or more external sensors as virtual cavity sensors

本申請案大體上係關於注射模製，且更具體言之，係關於在鄰近於模具之分模線的模具表面之外部上使用外部感測器來估算條件(諸如注射模具中之壓力或熔體流前沿位置)之方法，且視情況，若估算條件命中或超過觸發點，則進行其他計算及/或調整注射模製製程，由此將外部感測器以及虛擬凹穴感測器用作壓力控制系統之一部分。 This application is generally about injection molding, and more specifically, to using external sensors to estimate conditions (such as pressure or melting in injection molds) on the exterior of the mold surface adjacent to the parting line of the mold Method of fluid flow front position), and depending on the situation, if the estimated condition hits or exceeds the trigger point, other calculations and/or adjustments to the injection molding process are performed, thereby using the external sensor and the virtual cavity sensor as pressure Part of the control system.

在注射模製期間，熔融熱塑性材料經由一或多個澆口流入模具之模穴中。模穴中之壓力為至關重要之向量，因為壓力不足可能會產生不當形成之部件，而壓力過量可能會對模具造成破壞。熔體流前沿處之壓力藉由例如，實現計算填充模穴之快慢程度及模製部件在凹穴中冷卻可能耗費之時間長短來提供與注射模製製程相關之整體資訊。一些注射模製製程旨在使熔體流前沿隨時間推移遵循特定壓力模式以使注射模製製程最佳化。舉例而言，為產生內部應力(將另外導致非所期望之縮小、凹陷及翹曲)得以完全消除的最終產物，一些注射模製製程維持凹穴中之氣壓與熔體流前沿處之壓力之間的壓力平衡，當熔融熱塑性材料移入模具之凹穴中時，所述凹穴中之氣壓會基於模穴幾何形狀而有所變化。對於所述注射模製系統而言，為確定期望之壓力/時間曲線是否得到正確地追蹤，測定熔體流前沿處之即時壓力為至關重要的，且若鑑別出自壓力/時間曲線有所偏離，則作出調整以校正熔體流前沿之壓力。 During injection molding, molten thermoplastic material flows into the cavity of the mold through one or more gates. The pressure in the cavity is a crucial vector, because insufficient pressure may produce improperly formed parts, and excessive pressure may cause damage to the mold. The pressure at the front of the melt flow provides overall information related to the injection molding process by, for example, calculating the speed of filling the cavity and the length of time that the molded part may take to cool in the cavity. Some injection molding processes aim to make the melt flow front follow a specific pressure pattern over time to optimize the injection molding process. For example, some injection molding processes maintain the pressure of the gas pressure in the cavity and the pressure at the front of the melt flow in order to produce the final product where internal stresses (which will otherwise lead to undesirable shrinkage, dents, and warpage) are completely eliminated. Pressure balance between the two, when the molten thermoplastic material moves into the cavity of the mold, the air pressure in the cavity will be based on the mold cavity. He shape varies. For the injection molding system, in order to determine whether the desired pressure/time curve is correctly tracked, it is important to determine the immediate pressure at the front of the melt flow, and if a deviation from the pressure/time curve is identified , An adjustment is made to correct the pressure at the front of the melt flow.

理想地，用於量測模穴中及熔體流前沿處之壓力的感測器將為間接的、容易安裝且價格低廉。直接感測器，諸如置放於模穴中之感測器，會在部件表面上留下非所期望之痕跡。舉例而言，儘管已增加對具有高光澤面層之注射模製部件之要求，但定位於模穴中之直接感測器仍具有損毀部件之高光澤面層的傾向。因此，不位於模穴中之間接感測器為較佳的。一些現用間接感測器包含分模線感測器、頂出銷感測器(ejector pin sensor)或固定銷感測器(static pin sensor)及超音波感測器。不利的是，此等間接感測器不可能始終置放於最佳位置處，有時為了進行加工以使得感測器可得到安裝，需要模具設備經歷停機期，且可為昂貴的。當前使用的用於間接量測模穴中之壓力的應變計感測器受到相同問題之困擾。舉例而言，應變計感測器已與具有頂出套筒或長心型銷之模製設備結合使用，但並非所有注射模製設備均經配置以包含頂出套筒或長心型銷。 Ideally, the sensors used to measure the pressure in the mold cavity and at the front of the melt flow will be indirect, easy to install, and inexpensive. Direct sensors, such as those placed in the mold cavity, can leave undesirable marks on the surface of the part. For example, despite the increased requirements for injection molded parts with a high gloss finish, direct sensors positioned in the mold cavity have a tendency to damage the high gloss finish of the part. Therefore, it is better to connect the sensor not in the cavity. Some current indirect sensors include a parting line sensor, an ejector pin sensor (ejector pin sensor) or a fixed pin sensor (static pin sensor), and an ultrasonic sensor. Disadvantageously, these indirect sensors cannot always be placed at the optimal location. Sometimes, in order to process so that the sensors can be installed, the mold equipment needs to go through downtime, and can be expensive. The strain gauge sensors currently used to indirectly measure the pressure in the mold cavity suffer from the same problem. For example, strain gauge sensors have been used in conjunction with molding equipment that has ejector sleeves or long heart pins, but not all injection molding equipment is configured to include ejector sleeves or long heart pins.

本發明之範疇內的實施例係關於外部感測器在注射模製製程期間估算條件，諸如模穴中或熔體流前沿之位置之壓力的用途。應變計感測器為主要論述之外部感測器類型，但能夠偵測半模移動之其他外部感測器可達成相同目的且處於本發明之範疇內。舉例而言，微波感測器、x射線感測器、超音波感測器、氣壓感測器、空氣溫度感測器、表面下溫度感測器均可取代下文所述且所描繪之應變計感測器。此外，可利用其他類型之外部計感測器代替應變計感測器，諸如電感測器、電子感測器、機械感測器、無線感測器及光纖感測器。 Embodiments within the scope of the present invention relate to the use of external sensors to estimate conditions during the injection molding process, such as the pressure in the mold cavity or the location of the melt flow front. Strain gauge sensors are the main types of external sensors discussed, but other external sensors capable of detecting half-mode movement can achieve the same purpose and are within the scope of the present invention. For example, microwave sensors, x-ray sensors, ultrasonic sensors, barometric pressure sensors, air temperature sensors, Subsurface temperature sensors can replace the strain gauge sensors described and depicted below. In addition, other types of external gauge sensors can be used instead of strain gauge sensors, such as inductive sensors, electronic sensors, mechanical sensors, wireless sensors, and fiber optic sensors.

本發明之範疇內的實施例係關於應變計感測器在注射模製製程期間估算條件，諸如模穴中或熔體流前沿之位置之壓力的用途。在諸多模具中，內部模穴壓力與位於模具之外部上的一或多個應變計所量測之應變變化之間存在直接相關性。在此類模具中，外部應變計可用於替代直接感測器以監測且調整內部模穴壓力。在其餘模具中，內部模穴壓力與位於模具之外部上的一或多個應變計所量測之應變變化之間不存在直接相關性。然而，模穴中之熔體流前沿之位置與位於模具之外部上的一或多個應變計所量測之應變變化之間仍存在直接相關性。使用應變計感測器以及虛擬凹穴感測器作為壓力控制系統之一部分以感測模穴中之參數，諸如模穴中或熔體流前沿位置之壓力，且若參數命中或超過觸發點或範圍，則調整注射模製製程。在本發明之範疇內的實施例中，將至少一個應變計感測器安裝於模具之外部上，諸如堆疊模具之模具板之外部上，其鄰近於位於兩個模側之間的分模線，所述分模線界定注射模製系統之一或多個模穴。在本發明之一些實施例中，使用兩個應變計感測器，一個鄰近於模具之分模線且接近達至模穴之噴嘴，且另一個鄰近於模具之分模線且當熔融熱塑性材料注射至模穴中時，其處於噴嘴之下游位置處。 Embodiments within the scope of the present invention relate to the use of strain gauge sensors to estimate conditions during the injection molding process, such as pressure in the mold cavity or at the location of the melt flow front. In many molds, there is a direct correlation between the internal cavity pressure and the strain change measured by one or more strain gauges located on the outside of the mold. In such molds, external strain gauges can be used instead of direct sensors to monitor and adjust the internal cavity pressure. In the remaining molds, there is no direct correlation between the internal cavity pressure and the strain changes measured by one or more strain gauges located on the outside of the mold. However, there is still a direct correlation between the position of the melt flow front in the mold cavity and the strain change measured by one or more strain gauges located on the outside of the mold. Use strain gauge sensors and virtual cavity sensors as part of the pressure control system to sense the parameters in the mold cavity, such as the pressure in the mold cavity or the position of the melt flow front, and if the parameter hits or exceeds the trigger point or Range, then adjust the injection molding process. In an embodiment within the scope of the present invention, at least one strain gauge sensor is mounted on the outside of the mold, such as the outside of the mold plate of the stacked mold, which is adjacent to the parting line between the two mold sides The parting line defines one or more cavities of the injection molding system. In some embodiments of the invention, two strain gauge sensors are used, one adjacent to the parting line of the mold and close to the nozzle reaching the cavity, and the other adjacent to the parting line of the mold and when molten thermoplastic material When injected into the cavity, it is located downstream of the nozzle.

藉由量測標準注射模製製程之過程中所出現的模具表面上之表面應變來研究應變計感測器。在典型注射模製設備中，在兩個模側之間形成模穴，所述模側在壓力下藉由按壓或夾持單元結合在一起。因此，沿模具之分模線，由按壓或夾持單元施加閉合力。當熔融熱塑性材料注射至模穴中時，熔融熱塑性材料沿模具之分模線施加張開力。理想地，熔融熱塑性材料所施加之張開力小於夾持單元所施加之閉合力。若張開力超過閉合力，則模側被迫分開且發生熔融熱塑性材料溢出或洩漏。置放於鄰近於模具之分模線的模具表面之外部上的應變計感測器能夠感測由於閉合力及張開力，模具表面上所出現的隨時間推移之表面應變變化。 The strain gauge sensor is studied by measuring the surface strain on the mold surface that occurs during the standard injection molding process. In a typical injection molding apparatus, a cavity is formed between two mold sides, which are joined together by pressing or clamping units under pressure. because Thus, along the parting line of the mold, the pressing or clamping unit applies a closing force. When the molten thermoplastic material is injected into the cavity, the molten thermoplastic material exerts an opening force along the parting line of the mold. Ideally, the opening force applied by the molten thermoplastic material is less than the closing force applied by the clamping unit. If the opening force exceeds the closing force, the die side is forced to separate and overflow or leakage of molten thermoplastic material occurs. The strain gauge sensor placed on the outside of the mold surface adjacent to the parting line of the mold can sense the change in surface strain that occurs on the mold surface over time due to the closing force and the opening force.

響應於表面應變變化，應變計感測器發出通常在-10伏至10伏範圍內之電信號。接收應變計感測器所發射之信號且供控制器使用以估算模具中之一或多個條件，諸如模穴中之壓力或熔體流前沿之位置。在其中流動通道之長度與模製部件之厚度之比較大的特定模具，亦即具有高L/t比之模具中，可基於應變計感測器所發射之信號來估算熔體流前沿處之壓力。此等近似值可適用於調整注射模製製程。舉例而言，可估算模穴中之壓力量且與最大容許模穴壓力相比較以致力於確保過量模穴壓力不會對模穴造成破壞。 In response to changes in surface strain, the strain gauge sensor emits electrical signals typically in the range of -10 volts to 10 volts. The signals emitted by the strain gauge sensors are received and used by the controller to estimate one or more conditions in the mold, such as the pressure in the mold cavity or the position of the melt flow front. In a specific mold where the length of the flow channel is larger than the thickness of the molded part, that is, a mold with a high L/t ratio, the melt flow front can be estimated based on the signal emitted by the strain gauge sensor pressure. These approximate values can be applied to adjust the injection molding process. For example, the amount of pressure in the cavity can be estimated and compared to the maximum allowable cavity pressure to ensure that excess cavity pressure does not cause damage to the cavity.

在本發明之範疇內的一些實施例中，若由控制器所計算之條件命中或超過觸發點，則應變計感測器作為其中一部分之壓力控制系統可調節注射模製系統之運作以致力於將所感測之或另一參數降至或恢復至理想範圍內之水準。除了一或多個應變計感測器以外，本發明之壓力控制系統亦包含虛擬凹穴感測器，其可以一組指令(例如，軟體程式)之形式加以實施，所述指令儲存於非暫時性機器可讀媒體上且由一或多個通用或專用處理器執行。虛擬凹穴感測器可自機器可讀記憶體讀取資料，且在一些情況下向機器可讀記憶體讀取資料寫入資料，所述記憶體儲存有表示最佳預定義壓力-時間曲線的資料，所述曲線對應於由注射模製製程及形成部件之材料所製之部件。預定義壓力時間曲線由其中時間為獨立變數且壓力為因變數之等式或關係定義。在一些實施例中，預定義壓力-時間曲線為在設定達成模穴之最大設定壓力下接近漸近線之拋物曲線。在其中控制器基於應變變化估算內部模具壓力之一些實施例中，虛擬凹穴感測器將由應變計隨時間推移之讀數所估算之即時壓力與最佳預定義壓力-時間曲線進行比較以確定注射模製製程之運作是否如所預期。結合可自注射模製設備獲得之其他資訊，諸如將熔融熱塑性材料注射至模穴中的螺桿行進之遠近程度，虛擬凹穴感測器可測定熔融熱塑性材料之黏度及模穴之填充百分比。在由應變計感測器讀數所估算之即時資料指示並未遵循最佳預定義壓力-時間曲線的情況下，虛擬凹穴感測器系統可引導注射模製設備採取校正動作，諸如藉由改變注射額外的熔融熱塑性材料之螺桿的推進速率及/或推進力，以增加熔體流前沿處或模穴中之壓力。 In some embodiments within the scope of the present invention, if the condition calculated by the controller hits or exceeds the trigger point, the strain gauge sensor as part of the pressure control system can adjust the operation of the injection molding system to Reduce or restore the sensed or another parameter to a level within the desired range. In addition to one or more strain gauge sensors, the pressure control system of the present invention also includes a virtual pocket sensor, which can be implemented in the form of a set of instructions (eg, software programs) that are stored in non-temporary Machine-readable media and executed by one or more general-purpose or special-purpose processors. The virtual pocket sensor can read data from machine-readable memory, and in some cases write data to machine-readable memory, The memory stores data representing the best pre-defined pressure-time curve, which corresponds to the parts made by the injection molding process and the materials forming the parts. The predefined pressure-time curve is defined by an equation or relationship where time is an independent variable and pressure is a dependent variable. In some embodiments, the pre-defined pressure-time curve is a parabolic curve that approaches an asymptote at a maximum set pressure to achieve mold cavity. In some embodiments where the controller estimates the internal mold pressure based on the change in strain, the virtual pocket sensor compares the instantaneous pressure estimated by the reading of the strain gauge over time with the best predefined pressure-time curve to determine the injection Whether the molding process is working as expected. Combined with other information available from injection molding equipment, such as how far the screw injects the molten thermoplastic material into the cavity, the virtual cavity sensor can measure the viscosity of the molten thermoplastic material and the filling percentage of the cavity. In the event that the real-time data estimated from the strain gauge sensor readings does not follow the best predefined pressure-time curve, the virtual pocket sensor system can guide the injection molding equipment to take corrective actions, such as by changing The advancing rate and/or advancing force of the screw injecting additional molten thermoplastic material is to increase the pressure at the front of the melt flow or in the cavity of the mold.

術語「流動前沿」係指當熔融聚合材料自模穴之噴嘴或澆口(亦即熔融聚合材料引入至模穴之點)朝向且最終至模穴之填充結束之位置前進時，如界定模穴之模具的表面所經歷，熔融聚合材料之注射的前邊緣。 The term "flow front" refers to when the molten polymeric material advances from the nozzle or gate of the mold cavity (that is, the point where the molten polymer material is introduced into the mold cavity) toward and eventually to the position where the filling of the mold cavity ends, as defined in the mold cavity The front edge of the injection of molten polymeric material is experienced by the surface of the mold.

在其中控制器基於應變變化測定熔體流前沿之位置的一些實施例中，當意識到應變感測器資料指示熔體流前沿到達模穴中之一定位置時，虛擬凹穴感測器系統可引導注射模製設備採取由預定義壓力-時間曲線引導之動作，諸如增加或調整螺桿之推進速率及/或推進力以確保模具得到恰當填充，或甚至致動模具之某一部分。 In some embodiments where the controller determines the position of the melt flow front based on the change in strain, when it is realized that the strain sensor data indicates that the melt flow front reaches a certain position in the mold cavity, the virtual cavity sensor system may Guided injection molding equipment takes actions guided by a predefined pressure-time curve, such as increasing or adjusting the screw advance rate and/or propulsion force to ensure that the mold is properly filled, or even actuating a part of the mold.

當熔體流前沿到達模穴中之預定位置時可實施的致動模具之一部分之實例為連續模壓，其詳細論述於2015年6月30日申請的且名為「連續模壓(Sequential Coining)」之美國專利申請案第62/186,722號中，所述申請案以引用之方式併入本文中。 An example of a part of the actuation mold that can be implemented when the melt flow front reaches a predetermined position in the mold cavity is continuous molding, which is discussed in detail on June 30, 2015 and is called "Sequential Coining" In US Patent Application No. 62/186,722, said application is incorporated herein by reference.

術語「流動填充混合」定義為形成待模製部件之特徵的模具之一部分的區域，其尤其易受使部件模製複雜化的多種問題中之任何一或多者的影響或使得模製部件較可能具有一或多種缺陷或經降低之機械特性，諸如短暫填充、翹曲、凹陷、脆化、溢出、空洞、未填充、薄弱(例如，低拉伸強度、扭轉強度及/或周向強度)、高應力集中、低模數、經降低之抗化學暴露性、過早疲勞、不均勻縮小及色彩、表面紋理、不透明度、半透明度或透明度之不連續性。流動填充混合之非窮盡性實例為：用於形成肋、凸起或拐角以及模具中之障礙物(諸如心型銷)的模具中之位置及轉變(諸如待模製部件之厚度變化，其可能為突然階梯式厚度變化或漸進式厚度變化，諸如遞減區域)。此等可涉及由相對較厚區域向相對較薄區域之轉變，且隨後恢復至相對較厚區域，且可涉及一或多個厚度變化。出於本發明之目的而尤其受關注之轉變為活動鉸鏈，其通常為模製部件之一體式相對較薄區域，其准許部件之一部分(諸如蓋之翻蓋)相對於部件之其餘部分旋轉。當術語流動填充混合在本文中使用時，受特定混合影響之部件區域預期可位於特定位置處、沿區域處或特定位置或區域之下游，且因此，流動填充混合不必限制於模具形狀變化之特定位置，但可延伸超過，亦即處於此類位置之下游。 The term "flow-filled mixing" is defined as the area of a part of the mold that forms the feature of the part to be molded, which is particularly susceptible to any one or more of the various problems that complicate the molding of the part or makes the molded part less May have one or more defects or reduced mechanical properties, such as transient filling, warpage, dents, embrittlement, overflow, voids, unfilled, weak (for example, low tensile strength, torsional strength and/or circumferential strength) , High stress concentration, low modulus, reduced chemical exposure resistance, premature fatigue, uneven shrinkage, and discontinuities in color, surface texture, opacity, translucency, or transparency. Non-exhaustive examples of flow-fill mixing are: position and transitions in the mold used to form ribs, bumps or corners, and obstacles in the mold (such as heart-shaped pins) (such as changes in the thickness of the parts to be molded, which may It is a sudden stepped thickness change or a progressive thickness change, such as a decreasing area). These may involve a transition from a relatively thick area to a relatively thin area, and then revert to a relatively thick area, and may involve one or more thickness changes. For the purposes of the present invention, a transformation that is of particular interest is the living hinge, which is usually a relatively thin area of one of the molded parts, which allows a part of the part (such as the flip of the lid) to rotate relative to the rest of the part. When the term flow-fill mixing is used herein, the area of a component affected by a specific mix is expected to be located at a specific location, along the area, or downstream of the specific location or area, and therefore, flow-fill mixing need not be limited to the specificity of mold shape changes Position, but can extend beyond, that is, downstream of such a position.

使用來自一或多個外部感測器，諸如應變計感測器之資料對熔體流前沿之位置進行測定亦可適用於測定熔體流前沿相對於模穴中之流動填充混合之位置。熔體流前沿已到達相對於流動填充混合之預定位置的指示可充當啟動或停止加熱模穴之一部分，諸如感應加熱流動填充混合之附近處的模穴之區域有限持續時間之信號，同時熔體流前沿穿過或沿流動填充混合通過，如2014年9月3日申請的名為「在流動混合區中局部加熱之注射模製(Injection Molding with Localized Heating in Flow Challenge Regions)」之美國專利申請案第62/045,373號中所述，所述申請案以引用之方式併入本文中。 Use data from one or more external sensors, such as strain gauge sensors, to melt The measurement of the position of the flow front can also be used to determine the position of the melt flow front relative to the flow filling and mixing in the cavity. The indication that the melt flow front has reached a predetermined position relative to the flow filling and mixing can serve as a part of starting or stopping heating of the mold cavity, such as a signal of a limited duration of the area of the mold cavity in the vicinity of induction heating of the flow filling and mixing, while the melt The flow front passes through or along the flow filling and mixing, such as the US patent application for "Injection Molding with Localized Heating in Flow Challenge Regions" filed on September 3, 2014 As mentioned in case No. 62/045,373, said application is incorporated herein by reference.

10:注射模製設備 10: Injection molding equipment

12:注射系統 12: Injection system

14:夾持系統 14: clamping system

16:熱塑性丸粒 16: Thermoplastic pellets

18:漏斗 18: funnel

20:加熱機筒 20: Heating barrel

22:往復式螺桿 22: Reciprocating screw

24:熔融熱塑性材料 24: molten thermoplastic material

25:第一模側 25: first die side

26:噴嘴 26: Nozzle

27:第二模側 27: Second mold side

28:模具 28: mold

30:澆口 30: Gate

32:模穴 32: mold cavity

34:按壓或夾持單元 34: Pressing or clamping unit

36:螺桿控制件 36: Screw control

50:控制器 50: controller

51:虛擬凹穴感測器 51: Virtual pocket sensor

52:第一應變計感測器/第一應變計/應變計感測器 52: First strain gauge sensor/First strain gauge/Strain gauge sensor

53:第二應變計感測器/應變計感測器 53: Second strain gauge sensor/strain gauge sensor

54:電線 54: Wire

56:有線連接件 56: Wired connection

125a:第一模側 125a: first die side

127c:第二模側 127c: Second mold side

127d:第二模側 127d: Second mold side

132a:模穴 132a: mold cavity

132b:模穴 132b: Mold cavity

132c:模穴 132c: Mold cavity

132d:模穴 132d: mold cavity

133:板 133: Board

135a:模芯 135a: core

135b:模芯 135b: core

135c:模芯 135c: core

135d:模芯 135d: core

137:板 137: Board

154:應變計感測器 154: Strain gauge sensor

210:注射模製設備 210: Injection molding equipment

224:熔融熱塑性材料 224: molten thermoplastic material

230:澆口 230: Gate

232:模穴 232: Mold cavity

256:應變感測器 256: Strain sensor

258:傳統凹穴感測器 258: Traditional cavity sensor

300:方法 300: Method

302:步驟 302: Step

304:步驟 304: Step

306:步驟 306: Step

308:步驟 308: Step

310:步驟 310: Step

312:步驟 312: Step

儘管本說明書藉由特別指出且清楚主張視為本發明之標的物的申請專利範圍作出結論，但咸信本發明將自結合附圖之以下描述得到較為充分之理解。出於較為清晰地顯示其他元件之目的，圖式中之一些可藉由省略選定元件來進行簡化。除了當對應書面描述中可作出明確描述時以外，一些圖式中之元件的所述省略並不一定指示例示性實施例中之任一者中的特定元件存在或不存在。所有附圖均未必按比例繪製。 Although this specification concludes by specifically pointing out and clearly claiming the scope of the patent application regarded as the subject matter of the present invention, Xianxin's present invention will be more fully understood from the following description in conjunction with the accompanying drawings. For the purpose of showing other components more clearly, some of the drawings may be simplified by omitting selected components. Except when an explicit description can be made in the corresponding written description, the omission of elements in some drawings does not necessarily indicate the presence or absence of specific elements in any of the exemplary embodiments. All drawings are not necessarily drawn to scale.

圖1半示意性地展示根據本發明建構之注射模製設備，其中兩個應變計感測器位於鄰近於模側之間的分模線的模側之外部表面上，第一應變計感測器位於達至模穴之噴嘴的附近處的第一模側上，且第二應變計感測器位於噴嘴之下游處的第二模側上；圖2展示多凹穴注射模製系統之堆疊模具，其包含一對界定兩個模側之板，所述板中之至少一者具有位於鄰近於模側之間的分模線的其外表面上之應變計感測器，其展示於在模穴上施加任何力之前時；圖3展示當夾持單元(未圖示)在臨將熔融熱塑性材料注射至模穴中之前或在開始注射時施加閉合力時，圖2中所示的多凹穴注射模製系統之堆疊模具；圖4展示圖3中所示的多凹穴注射模製系統之堆疊模具中所存在的模穴、模芯及第一及第二模側。 Fig. 1 shows semi-schematically an injection molding apparatus constructed in accordance with the present invention, in which two strain gauge sensors are located on the outer surface of the mold side adjacent to the parting line between the mold sides, the first strain gauge senses The sensor is located on the first mold side near the nozzle that reaches the mold cavity, and the second strain gauge sensor is located on the second mold side downstream of the nozzle; Figure 2 shows the stacking of the multi-cavity injection molding system A mold, which includes a pair of plates defining two mold sides, at least one of which has a strain gauge sensor on its outer surface located on a parting line adjacent to the mold sides, which is shown in Before any force is applied to the cavity; FIG. 3 shows the stacking mold of the multi-cavity injection molding system shown in FIG. 2 when a clamping unit (not shown) applies a closing force immediately before injecting molten thermoplastic material into the mold cavity or at the beginning of injection Figure 4 shows the cavity, core and first and second mold sides present in the stacked mold of the multi-cavity injection molding system shown in Figure 3.

圖5展示圖3至圖5中所示的多凹穴注射模製系統之堆疊模具中的圍繞模穴之板及第一模側。 FIG. 5 shows the plate surrounding the cavity and the first mold side in the stacked molds of the multi-cavity injection molding system shown in FIGS. 3 to 5.

圖6A至圖6B展示圖3至圖5中所示的多凹穴注射模製系統之堆疊模具中的圍繞模穴之板及圍繞模芯之板。 6A to 6B show the plate surrounding the cavity and the plate surrounding the core in the stacked molds of the multi-cavity injection molding system shown in FIGS. 3 to 5.

圖7A至圖7B展示當夾持單元(未圖示)施加閉合力且熔融熱塑性材料注入模穴中時施加張開力時，圖3至圖6中所示的多凹穴注射模製系統之堆疊模具；圖8以圖形方式展示當注射模製系統可基於來自應變計之反饋來控制以達成期望壓力-時間曲線時，可經本發明之虛擬凹穴感測器系統所利用的拋物線形預定義壓力-時間曲線之曲線圖；圖9展示利用應變計感測器以及多個模穴的雙層堆疊注射模製設備；且圖10展示使用來自應變計感測器之讀數以用於調整內部熔體壓力(IMP)之例示性方法的流程圖，其可在例如圖1之控制器中加以實施。 FIGS. 7A to 7B show the stacked molds of the multi-cavity injection molding system shown in FIGS. 3 to 6 when a clamping unit (not shown) applies a closing force and an opening force is applied when molten thermoplastic material is injected into the cavity FIG. 8 graphically shows that when the injection molding system can be controlled based on the feedback from the strain gauge to achieve the desired pressure-time curve, the parabolic pre-defined pressure that can be utilized by the virtual cavity sensor system of the present invention − A graph of the time curve; Figure 9 shows a double-layer stacked injection molding apparatus using a strain gauge sensor and multiple mold cavities; and Figure 10 shows the use of readings from the strain gauge sensor for adjusting the internal melt pressure (IMP) is a flowchart of an exemplary method, which may be implemented in, for example, the controller of FIG.

詳細參照圖式，圖1展示用於製造呈高容積之熱塑性部件的例示性注射模製設備10(例如，101類注射模具或「超高產率模具」、102 類(中等至高產率模具)或103類(中等產率模具))。注射模製設備10通常包含注射系統12及夾持系統14。熱塑性材料可以熱塑性丸粒16之形式引入至注射系統12中。熱塑性丸粒16可置放於漏斗18中，其將熱塑性丸粒16饋入至注射系統12之加熱機筒20中。在饋入至加熱機筒20中之後，可藉由推桿，諸如往復式螺桿22將熱塑性丸粒16推進至加熱機筒20之末端。加熱機筒20之加熱及往復式螺桿22對熱塑性丸粒16之擠壓使得熱塑性丸粒16熔融，形成熔融熱塑性材料24。通常在約130℃至約410℃之溫度下加工熔融熱塑性材料。 Referring to the drawings in detail, FIG. 1 shows an exemplary injection molding apparatus 10 (eg, injection mold 101 or "ultra-high-yield mold", 102) for manufacturing thermoplastic parts having a high volume. Category (medium to high yield mold) or category 103 (medium yield mold)). The injection molding apparatus 10 generally includes an injection system 12 and a clamping system 14. The thermoplastic material may be introduced into the injection system 12 in the form of thermoplastic pellets 16. The thermoplastic pellets 16 may be placed in a hopper 18, which feeds the thermoplastic pellets 16 into the heating barrel 20 of the injection system 12. After feeding into the heating barrel 20, the thermoplastic pellets 16 can be pushed to the end of the heating barrel 20 by a push rod, such as a reciprocating screw 22. The heating of the heating barrel 20 and the extrusion of the thermoplastic pellets 16 by the reciprocating screw 22 cause the thermoplastic pellets 16 to melt, forming a molten thermoplastic material 24. The molten thermoplastic material is usually processed at a temperature of about 130°C to about 410°C.

往復式螺桿22促使熔融熱塑性材料24朝向噴嘴26而形成熱塑性材料之注射，所述材料將經由一或多個澆口注射至模具28之模穴32中。可經由澆口30注射熔融熱塑性材料24，其引導熔融熱塑性材料24流至模穴32。模穴32形成於模具28之第一模側25與第二模側27之間且第一模側25與第二模側27在壓力下經按壓或夾持單元34結合在一起。按壓或夾持單元34在模製製程期間施加夾持力，其超過作用於分離兩個半模25、27的注射壓力所施加之力，由此在熔融熱塑性材料24注射至模穴32中時，使第一模側25與第二模側27結合在一起。在典型高可變壓注射模製機中，通常施加30,000psi或大於30,000psi之壓力，因為夾持力與注射壓力直接相關。為支撐此等夾持力，夾持系統14可包含模具框架及模具基座。 The reciprocating screw 22 urges the molten thermoplastic material 24 toward the nozzle 26 to form an injection of thermoplastic material that will be injected into the cavity 32 of the mold 28 through one or more gates. Molten thermoplastic material 24 may be injected via gate 30, which directs molten thermoplastic material 24 to mold cavity 32. The mold cavity 32 is formed between the first mold side 25 and the second mold side 27 of the mold 28 and the first mold side 25 and the second mold side 27 are combined together by a pressing or clamping unit 34 under pressure. The pressing or clamping unit 34 applies a clamping force during the molding process, which exceeds the force applied by the injection pressure acting on the two mold halves 25, 27, thus when the molten thermoplastic material 24 is injected into the cavity 32 So that the first mold side 25 and the second mold side 27 are combined together. In a typical high-variable-pressure injection molding machine, a pressure of 30,000 psi or more is usually applied because the clamping force is directly related to the injection pressure. To support these clamping forces, the clamping system 14 may include a mold frame and a mold base.

當熔融熱塑性材料24之注射注入模穴32中後，往復式螺桿22停止向前行進。熔融熱塑性材料24呈模穴32之形式且熔融熱塑性材料24在模具28中冷卻直到熱塑性材料24固化為止。當熱塑性材料24固化後，按壓單元34將第一模側25與第二模側27鬆開，第一模側25與第二模側 27彼此分離，且最終部件可自模具28推出。模具28可包含複數個模穴32以增加總產率。複數個模穴的凹穴之形狀可彼此相同、相似或不同。(複數個模穴可視為模穴族)。 After the injection of molten thermoplastic material 24 is injected into the cavity 32, the reciprocating screw 22 stops moving forward. The molten thermoplastic material 24 is in the form of a cavity 32 and the molten thermoplastic material 24 is cooled in the mold 28 until the thermoplastic material 24 solidifies. After the thermoplastic material 24 is cured, the pressing unit 34 releases the first mold side 25 and the second mold side 27, and the first mold side 25 and the second mold side 27 are separated from each other, and the final part can be ejected from the mold 28. The mold 28 may include a plurality of mold cavities 32 to increase the overall yield. The shapes of the cavity of the plurality of mold cavities may be the same, similar or different from each other. (Plurality of mold cavities can be regarded as mold aristocrats).

控制器50與第一應變計感測器52及螺桿控制件36通信相連。第一應變計52位於接近第一模側25與第二模側27之間的分模線的第一模側25之外表面上且在噴嘴26之附近處。控制器50可包含微處理器(或另一適合之處理單元，或若干此類單元)、非暫時性記憶體及一或多個通信鏈路。控制器50亦可視情況連接至第二應變計感測器53，所述第二應變計感測器53位於接近第一模側25與第二模側27之間的分模線的第二模側27之外表面上且位於噴嘴26之下游處。儘管兩個應變計感測器用於圖1中所描繪之實施例中，但本發明之範疇內的其他實施例亦可僅採用一個應變計感測器或可使用大於兩個之應變計感測器。此外，本發明之範疇內的實施例可使用位於模側上之其他位置處的應變計感測器。 The controller 50 is in communication with the first strain gauge sensor 52 and the screw control 36. The first strain gauge 52 is located on the outer surface of the first mold side 25 near the parting line between the first mold side 25 and the second mold side 27 and in the vicinity of the nozzle 26. The controller 50 may include a microprocessor (or another suitable processing unit, or several such units), non-transitory memory, and one or more communication links. The controller 50 is also optionally connected to a second strain gauge sensor 53 which is located in the second mode close to the parting line between the first die side 25 and the second die side 27 The side 27 is on the outer surface and located downstream of the nozzle 26. Although two strain gauge sensors are used in the embodiment depicted in FIG. 1, other embodiments within the scope of the present invention may use only one strain gauge sensor or may use more than two strain gauge sensors Device. In addition, embodiments within the scope of the present invention may use strain gauge sensors located elsewhere on the die side.

應變計感測器52及53感測模具之表面應變，如根據圖2至圖4所較為深入論述。來自應變計感測器52及53之資料可通信至計算模具之表面應變變化的處理器。來自應變計感測器52、53之電信號可沿一或多個電路徑，諸如電線54(圖1中以實線形式描繪)行進，強度範圍為0伏至10伏。控制器50可經由有線連接件56連接至螺桿控制件36。在其他實施例中，控制器50可經由無線連接件、機械連接件、液壓連接件、氣動連接件或本領域中一般熟習此項技術者已知的將使得控制器50與螺桿控制件36通信的任何其他類型之通信連接件連接至螺桿控制件36。 The strain gauge sensors 52 and 53 sense the surface strain of the mold, as discussed in more depth according to FIGS. 2 to 4. The data from the strain gauge sensors 52 and 53 can be communicated to a processor that calculates changes in the surface strain of the mold. The electrical signals from the strain gauge sensors 52, 53 can travel along one or more electrical paths, such as wires 54 (depicted in solid lines in FIG. 1), with an intensity ranging from 0 volts to 10 volts. The controller 50 may be connected to the screw control 36 via a wired connection 56. In other embodiments, the controller 50 may communicate with the screw control 36 via a wireless connection, a mechanical connection, a hydraulic connection, a pneumatic connection, or known in the art to those skilled in the art. Any other type of communication connection is connected to the screw control 36.

控制器50可使用由第一應變計感測器52及第二應變計感測器53提供之資訊所計算的表面應變變化來估算條件，諸如模穴中或尤其其中流動通道之長度與模製部件之厚度之比較大特定模具中，熔融熱塑性材料24之熔體流前沿處之壓力或熔體流前沿位置。此等近似值可隨後用於調整注射模製製程。舉例而言，可估算模穴32中之壓力量且與最大容許模穴壓力相比較以確保過量模穴壓力不會對模穴32造成破壞。若模穴32中之壓力量經估算危險地接近最大容許模穴壓力或甚至超過遠低於最大容許模穴壓力之安全臨限值，則控制器50可引導螺桿控制件36停止注射熔融熱塑性材料。其他近似值可用於控制模製製程，使得材料黏度、模具溫度、熔體溫度之變化及其他影響填充速率之變化可用於引起控制器50對注射模製系統進行調整。可在模製週期期間立即作出此等調整或可在後續週期中進行校正。此外，可在多個週期內將近似值平均化，且隨後用於使控制器50對模製製程作出調整。 The controller 50 can use the surface strain changes calculated by the information provided by the first strain gauge sensor 52 and the second strain gauge sensor 53 to estimate conditions such as the length and molding of the flow channel in the mold cavity or in particular The thickness of the part is relatively large. In a specific mold, the pressure at the melt flow front of the molten thermoplastic material 24 or the position of the melt flow front. These approximations can then be used to adjust the injection molding process. For example, the amount of pressure in the cavity 32 can be estimated and compared to the maximum allowable cavity pressure to ensure that excess cavity pressure does not cause damage to the cavity 32. If the amount of pressure in the mold cavity 32 is estimated to be dangerously close to the maximum allowable mold cavity pressure or even exceed a safe threshold far below the maximum allowable mold cavity pressure, the controller 50 may direct the screw control 36 to stop the injection of molten thermoplastic material . Other approximations can be used to control the molding process so that changes in material viscosity, mold temperature, melt temperature, and other changes that affect the filling rate can be used to cause the controller 50 to adjust the injection molding system. These adjustments can be made immediately during the molding cycle or can be corrected in subsequent cycles. In addition, the approximation can be averaged over multiple cycles and then used to make the controller 50 make adjustments to the molding process.

此外，控制器50與虛擬凹穴感測器51通信，所述虛擬凹穴感測器51以程式或一組軟體指令形式加以實施。然而，更一般而言，虛擬凹穴感測器可實施於硬體(例如，以特殊應用積體電路(ASIC)形式)、韌體、軟體或其任何適合之組合中。在本發明中，術語「虛擬凹穴感測器」可指測定製程變數，諸如壓力之值，而無需直接量測此製程變數的模組。應變計感測器52與53及虛擬凹穴感測器51共同形成壓力控制系統，其生成與策略性控制模穴32中之壓力相關的資料。如本文所用，術語「壓力控制系統」係指可包含軟體實施組件及硬體實施組件之任何適合的組件之群，其基於指示另一製程變數之信號生成指示模穴中之條件之信號。 In addition, the controller 50 communicates with a virtual pocket sensor 51, which is implemented in the form of a program or a set of software instructions. However, more generally, the virtual pocket sensor can be implemented in hardware (eg, in the form of an application specific integrated circuit (ASIC)), firmware, software, or any suitable combination thereof. In the present invention, the term "virtual cavity sensor" may refer to a module that measures a process variable, such as a pressure value, without directly measuring the process variable. The strain gauge sensors 52 and 53 and the virtual cavity sensor 51 together form a pressure control system that generates data related to the strategic control of the pressure in the mold cavity 32. As used herein, the term "pressure control system" refers to any suitable group of components that can include software implementation components and hardware implementation components that generate signals indicative of conditions in the mold cavity based on signals indicative of another process variable.

舉例而言，若基於由第一應變計感測器52及第二應變計感測器53提供之表面應變資訊，與控制器50相關聯之處理器測定模穴中之壓力超過觸發點(或超出預定可接受範圍)，則虛擬凹穴感測器51傳信控制器調整螺桿控制件36以使模穴中之壓力返回至低於觸發點之水準(或處於預定可接受範圍內)。作為另一實例，若基於第一應變計感測器52及第二應變計感測器53所提供之表面應變資訊，與控制器50相關聯之處理器測定熔體流前沿已前進超過觸發點(其可與模具之填充百分比相關)，則虛擬凹穴感測器51傳信控制器調整螺桿控制件36以使模穴中之壓力返回至預定可接受之最終壓力或範圍，其可涉及降低壓力以避免過度填充模穴，且因此防止不合需要之溢料。 For example, if based on the surface strain information provided by the first strain gauge sensor 52 and the second strain gauge sensor 53, the processor associated with the controller 50 determines that the pressure in the mold cavity exceeds the trigger point (or If it exceeds the predetermined acceptable range), the virtual cavity sensor 51 signals the controller to adjust the screw control 36 to return the pressure in the mold cavity to a level lower than the trigger point (or within a predetermined acceptable range). As another example, if based on the surface strain information provided by the first strain gauge sensor 52 and the second strain gauge sensor 53, the processor associated with the controller 50 determines that the melt flow front has advanced beyond the trigger point (It can be related to the filling percentage of the mold), then the virtual cavity sensor 51 signals the controller to adjust the screw control 36 to return the pressure in the mold cavity to a predetermined acceptable final pressure or range, which may involve reducing The pressure avoids overfilling the mold cavity and therefore prevents undesirable flash.

圖2至圖7展示利用應變計感測器154之堆疊多凹穴注射模製系統。如圖3中所示，堆疊多凹穴注射模製系統在第一模側125中具有模穴132且在第二模側127中具有互補模芯135。圖2至圖7中所描繪之堆疊多凹穴注射模製系統在四個第一模側125(125a、125b、125c、125d)中總共具有四個模穴132(132a、132b、132c、132d)且在四個第二模側127(127a、127b、127c、127d)中具有四個模芯135(135a、135b、135c、135d)，但第一模側125中之模穴132或第二模側127中之模芯135中之一或多者自圖3至圖5省略以使其他元件在圖式中可見。本發明之範疇內的堆疊多凹穴注射模製系統在第一模側125中可具有超過四個或小於四個之模穴132且在第二模側127中可具有超過四個或小於四個之模芯135。 2 to 7 show a stacked multi-cavity injection molding system using strain gauge sensors 154. FIG. As shown in FIG. 3, the stacked multi-cavity injection molding system has mold cavities 132 in the first mold side 125 and complementary mold cores 135 in the second mold side 127. The stacked multi-cavity injection molding system depicted in FIGS. 2 to 7 has a total of four mold cavities 132 (132a, 132b, 132c, 132d) in the four first mold sides 125 (125a, 125b, 125c, 125d) ) And four mold cores 135 (135a, 135b, 135c, 135d) in the four second mold sides 127 (127a, 127b, 127c, 127d), but the mold cavity 132 or the second in the first mold side 125 One or more of the cores 135 in the mold side 127 are omitted from FIGS. 3 to 5 to make other elements visible in the drawings. A stacked multi-cavity injection molding system within the scope of the present invention may have more than four or less than four cavity 132 in the first mold side 125 and more than four or less than four in the second mold side 127的之模芯135.

如圖4中所示，模穴132a、132b、132c及132d由板133包圍。如圖5中所示，第二模側127中之模芯135由板137包圍。在圖2至圖7中所描繪之實施例中，應變計感測器154位於板133之外部上而鄰近於板133與板137之間的模具之分模線。在本發明之範疇內的其他實施例中，可使用超過一個應變計感測器154，且一或多個應變計感測器可置放於板133、板137上、第一模側125中之任一者上或第二模側127中之任一者上。在圖2至圖7中所述應變計感測器154位於接近板133之拐角處。然而，在一些實施例中，應變計感測器154可置放在接近板133之中間處，由於作用於模穴132之力，其經歷之應變變化要比可由導銷(guide pin/leader pin)支撐的板之拐角大。在一些實施例中，基於哪一板經歷較多應變而確定是否置放應變計感測器154或板133或137，其受由剛性較小之材料製成，較薄的或具有較多穿過其之切口而降低其硬度之板的影響。在一些實施例中，板137經歷較多應變且因此成為應變計感測器154之主要位置。在一些實施例中，干擾組件或特徵，諸如冷卻通道之連接件可能會影響應變計感測器154之位置。在其中模具具有超過一個分模線之一些實施例中，應變計感測器154可置放在最接近較直接經歷由熔融熱塑性材料之注射所產生之張開力的分模線處，在一些實施例中，所述分模線為模製部件自其推出之分模線。若可能，則將應變計感測器置放在內部模穴壓力與應變計之應變變化讀數之間存在直接相關性的位置處。此類位置最可能存在於簡單模具中。若不存在此類位置，則其中負荷轉移至多個部件的複雜模具之情況下較可能的為，將應變計感測器置放在熔體流前沿之位置與應變計之應變變化讀數之間存在直接相關性的位置處。試誤法可用於測定應變計之最佳位置。可藉由在填充模穴時繪製由應變計獲得之量測結果而使各模具將具有可映射之唯一或接近唯一之標記。圖上之各種標誌，諸如峰、最低點、谷、局部最小值，或局部最大值可指示例如熔體流前沿位置。本申請案中所述之應變計感測器包含圖1至圖4中所描繪之應變計感測器52、53及154，其可選自多種市售應變計感測器。舉例而言，本發明之範疇內的實施例中將研究Kistler「表面應變感測器」9232A型或Rocktest Telemac之「表面安裝應變計」型號SM-5A或SM-5B。所述應變計感測器經設計用以快速且容易安裝，因為其可具有可焊接於注射模製設備或可在注射模製設備之表面中旋擰之錨定塊。 As shown in FIG. 4, the mold cavities 132 a, 132 b, 132 c, and 132 d are surrounded by the plate 133. As shown in FIG. 5, the core 135 in the second mold side 127 is surrounded by the plate 137. Depicted in Figures 2 to 7 In an embodiment, the strain gauge sensor 154 is located on the outside of the plate 133 and is adjacent to the parting line of the mold between the plate 133 and the plate 137. In other embodiments within the scope of the present invention, more than one strain gauge sensor 154 may be used, and one or more strain gauge sensors may be placed on the board 133, the board 137, and the first mold side 125 Either one or on the second die side 127. The strain gauge sensor 154 is located near the corner of the board 133 in FIGS. 2 to 7. However, in some embodiments, the strain gauge sensor 154 can be placed near the middle of the plate 133. Due to the force acting on the mold cavity 132, the strain change experienced by the strain gage 132 is greater than that by a guide pin (leader pin) ) The corners of the supported plates are large. In some embodiments, it is determined whether to place the strain gauge sensor 154 or the plate 133 or 137 based on which plate experiences more strain, which is made of a material with less rigidity, is thinner or has more wear The effect of a board whose hardness is reduced through its cut. In some embodiments, the plate 137 experiences more strain and therefore becomes the main location of the strain gauge sensor 154. In some embodiments, interfering components or features, such as cooling channel connections, may affect the position of the strain gauge sensor 154. In some embodiments where the mold has more than one parting line, the strain gauge sensor 154 may be placed closest to the parting line that more directly experiences the opening force generated by the injection of molten thermoplastic material, in some embodiments In this, the parting line is the parting line from which the molded part is pushed out. If possible, place the strain gauge sensor where there is a direct correlation between the internal cavity pressure and the strain gauge reading of the strain gauge. Such locations are most likely to exist in simple molds. If there is no such location, in the case of a complex mold where the load is transferred to multiple parts, it is more likely that the strain gauge sensor is placed between the position of the melt flow front and the strain change reading of the strain gauge. The position of direct correlation. The trial and error method can be used to determine the optimal position of the strain gauge. By drawing the measurement results obtained by the strain gauge when filling the mold cavity, each mold will have a unique or near-unique mark that can be mapped. Various signs on the map, such as peaks, most Low points, valleys, local minimums, or local maximums may indicate, for example, the position of the melt flow front. The strain gauge sensors described in this application include the strain gauge sensors 52, 53, and 154 depicted in FIGS. 1 to 4, which can be selected from a variety of commercially available strain gauge sensors. For example, in embodiments within the scope of the present invention, the Kistler "surface strain sensor" model 9232A or Rocktest Telemac's "surface mounted strain gauge" model SM-5A or SM-5B will be studied. The strain gauge sensor is designed to be fast and easy to install because it may have an anchor block that can be welded to the injection molding device or that can be screwed in the surface of the injection molding device.

圖2展示在注射模製系統處於打開條件下時，任何力施加於模穴132上之前時之堆疊多凹穴注射模製系統。在沒有外力作用於板133之情況下，其具有基線厚度X₁。同樣，板133在其建構中具有內在基線應變，其可能為零。應變計感測器154基於所感測的板133之基線應變來偵測應變，例如με₁。 FIG. 2 shows the stacked multi-cavity injection molding system before any force is applied to the cavity 132 when the injection molding system is in the open condition. In the absence of an external force to the plate 133, the base having a thickness X _1. Likewise, plate 133 has an inherent baseline strain in its construction, which may be zero. The strain gauge sensor 154 detects strain based on the sensed baseline strain of the plate 133, for example, με ₁ .

圖6A展示在按壓或夾持單元(未描繪)所施加之閉合力下的模穴132。在閉合力下，板133形狀略微變化。舉例而言，板133之厚度(先前為X₁)由量△X變為新厚度X₂。板133中之應變亦有所變化。應變計感測器54響應於此變化偵測出應變，例如με₂。一般而言，閉合力引起壓縮應變。然而，此可能並不始終如此，要視所用特定注射模製設備及應變計感測器154位置而定。因此，應變計感測器154隨時間推移所偵測到之應變變化可為正或負，或本發明之系統可基於隨時間推移應變變化之絕對值進行運作。圖6B為具有應變計感測器之圖6A部分的放大視圖。 FIG. 6A shows the mold cavity 132 under the closing force applied by the pressing or clamping unit (not depicted). Under the closing force, the shape of the plate 133 changes slightly. For example, the thickness of the plate 133 (previously X ₁ ) changes from the amount ΔX to the new thickness X ₂ . The strain in plate 133 also changes. The strain gauge sensor 54 detects strain in response to this change, for example με ₂ . In general, the closing force causes compressive strain. However, this may not always be the case, depending on the specific injection molding equipment used and the position of the strain gauge sensor 154. Therefore, the strain change detected by the strain gauge sensor 154 over time may be positive or negative, or the system of the present invention may operate based on the absolute value of the strain change over time. 6B is an enlarged view of the portion of FIG. 6A with a strain gauge sensor.

圖7A展示按壓或夾持單元(未描繪)所施加之閉合力及當熱塑性熔融材料注入至模穴132中時其所施加之張開力下的模穴132。板133 對力之組合作出響應。舉例而言，板133之厚度(當未向模穴32施加力時為X₁且當向模穴132僅施加閉合力時為X₂)由量△X變為新厚度X₃。由向閉合力添加張開力所產生之位移亦引起表面應變變化，且應變計感測器154響應於此變化偵測出應變，例如με₃。一般而言，張開力引起鬆弛拉伸應變。然而，此可能並不始終如此，要視所用特定注射模製設備及應變計感測器154位置而定。因此，應變計感測器154所偵測之應變變化可為正或負。視應變計感測器154所處位置而定，應變計感測器154可偵測拉伸應變變化或壓縮應變變化。啟動虛擬凹穴感測器，諸如圖1中所描繪之虛擬凹穴感測器51之預設觸發點通常出現在如圖7A中所描繪，模穴132經歷張開力及閉合力兩者時，因為此為注射模製製程期間熔融熱塑性材料實際上正注入至模穴132中以形成部件時之時間段。圖7B為具有應變計感測器之圖7A部分的放大視圖。 7A shows the closing force applied by the pressing or clamping unit (not depicted) and the mold cavity 132 under the opening force applied by the thermoplastic molten material when it is injected into the mold cavity 132. The plate 133 responds to the combination of forces. For example, the thickness of the plate 133 (when no force is applied to the mold cavity 32 of the X ₁ and the cavity 132 when a closing force is applied to only X ₂₎ the amount of change to the new thickness △ X X _3. The displacement caused by adding the opening force to the closing force also causes a change in the surface strain, and the strain gauge sensor 154 detects the strain in response to this change, for example με ₃ . Generally speaking, the opening force causes relaxed tensile strain. However, this may not always be the case, depending on the specific injection molding equipment used and the position of the strain gauge sensor 154. Therefore, the strain change detected by the strain gauge sensor 154 may be positive or negative. Depending on where the strain gauge sensor 154 is located, the strain gauge sensor 154 can detect changes in tensile strain or changes in compressive strain. The virtual cavity sensor is activated, and the preset trigger point of the virtual cavity sensor 51 such as that depicted in FIG. 1 usually appears as depicted in FIG. 7A, when the mold cavity 132 experiences both an opening force and a closing force, because This is the time period during which the molten thermoplastic material is actually being injected into the cavity 132 to form the part during the injection molding process. 7B is an enlarged view of the portion of FIG. 7A with a strain gauge sensor.

圖8描繪可由虛擬凹穴感測器51使用之最佳預定義壓力-時間曲線。獨立(水平)軸表示時間，且相關(垂直)軸表示壓力。原點為預設觸發點，其可出現在或接近當熔融熱塑性材料開始進入模穴32、132或232且施加可由應變計感測器偵測之張開力時。在一些實施例中，最佳預定義壓力-時間曲線為拋物線形，其中漸近線位於設定在完全形成部件時出現之最大壓力處。在一些實施例中，壓力-時間曲線由以下兩個變數定義：1)模穴填充至75%之時間，及2)最大壓力設定。在一些實施例中，虛擬凹穴感測器51將由應變計感測器隨時間推移之讀數所估算之即時壓力與最佳預定義壓力-時間曲線進行比較以確定注射模製製程之運作是否如所預期。結合可自注射模製設備10或210獲得之其他資訊，諸如如藉由連接至螺桿22之機制所量測，往復式螺桿22行進之遠近程度，虛擬凹穴感測器51可測定熔融熱塑性材料24或224之黏度及模穴32、132或232之填充百分比。在由應變計感測器52、53、154或256讀數所估算之即時資料指示並未遵循最佳預定義壓力-時間曲線的情況下，虛擬凹穴感測器51可引導注射模製設備10或210採取校正動作，諸如藉由注射額外的熔融熱塑性材料24或224，以增加熔體流前沿處或模穴32、132或232中之壓力。採取所述校正動作之例示性方法將參照圖10在下文加以論述。在其他實施例中，虛擬凹穴感測器51測定熔體流前沿之位置是否已到達或穿過模穴32、132或232中之觸發位置，其可與呈一定填充百分比之模穴32、132或232相關，且可引導注射模製設備10或210採取由最佳預定義壓力時間曲線所引導之動作，諸如增加(或降低)額外的熔融熱塑性材料24或224之注射速率以增加(或降低)熔體流前沿處或模穴32、132或232中之壓力；啟動一或多個局部加熱元件以對模穴32、132、232之一或多個區域進行加熱或致動模穴之一部分(例如，以達成模壓)。在上文所論述之實例中，除了測定估算壓力以外，虛擬凹穴感測器51亦使注射模製設備10或210採取校正動作。在另一實施例中，虛擬凹穴感測器51僅生成指示模穴中之壓力的信號，且另一組件鑒於虛擬凹穴感測器51之輸出及可能存在之其他信號或預設值測定是否引導注射模製設備10或210採取校正動作。此組件作為例如圖1之控制器50之一部分加以實施。更一般而言，與使用應變計感測器讀數估算壓力、比較讀數與預定義曲線及測定是否應採取校正動作相關之功能可以任何適合方式分配於控制器50、虛擬凹穴感測器51等中。 FIG. 8 depicts the best predefined pressure-time curve that can be used by the virtual pocket sensor 51. The independent (horizontal) axis represents time, and the related (vertical) axis represents pressure. The origin is a preset trigger point, which may occur at or near when molten thermoplastic material begins to enter the cavity 32, 132, or 232 and exerts an opening force that can be detected by the strain gauge sensor. In some embodiments, the best predefined pressure-time curve is parabolic, where the asymptote is located at the maximum pressure set when the part is fully formed. In some embodiments, the pressure-time curve is defined by the following two variables: 1) the time to fill the mold cavity to 75%, and 2) the maximum pressure setting. In some embodiments, the virtual pocket sensor 51 compares the instantaneous pressure estimated by the strain gauge sensor readings over time with the best predefined pressure-time curve to determine whether the injection molding process is performing as As expected. In combination with other information available from the injection molding equipment 10 or 210, such as measured by a mechanism connected to the screw 22, the reciprocating screw 22 rows In the near and far extent, the virtual cavity sensor 51 can measure the viscosity of the molten thermoplastic material 24 or 224 and the filling percentage of the cavity 32, 132 or 232. The virtual pocket sensor 51 can guide the injection molding apparatus 10 in the case where the real-time data estimated by the readings of the strain gauge sensors 52, 53, 154 or 256 indicate that the best predefined pressure-time curve is not followed Or 210 takes corrective action, such as by injecting additional molten thermoplastic material 24 or 224 to increase the pressure at the front of the melt flow or in the mold cavity 32, 132, or 232. An exemplary method of taking the corrective action will be discussed below with reference to FIG. 10. In other embodiments, the virtual cavity sensor 51 determines whether the position of the melt flow front has reached or passed through the trigger position in the mold cavity 32, 132 or 232, which can match the mold cavity 32, 132 or 232, and can guide the injection molding apparatus 10 or 210 to take actions guided by the best predefined pressure-time curve, such as increasing (or decreasing) the injection rate of additional molten thermoplastic material 24 or 224 to increase (or Reduce) the pressure at the front of the melt flow or in the cavity 32, 132 or 232; activate one or more local heating elements to heat or actuate one or more regions of the cavity 32, 132, 232 One part (for example, to achieve molding). In the example discussed above, in addition to measuring the estimated pressure, the virtual pocket sensor 51 also causes the injection molding apparatus 10 or 210 to take corrective action. In another embodiment, the virtual cavity sensor 51 only generates a signal indicating the pressure in the cavity, and another component is determined in view of the output of the virtual cavity sensor 51 and other signals or preset values that may exist Whether to guide the injection molding apparatus 10 or 210 to take corrective action. This component is implemented as part of the controller 50 of FIG. 1, for example. More generally, functions related to the use of strain gauge sensor readings to estimate pressure, compare readings with predefined curves, and determine whether corrective actions should be taken can be assigned to the controller 50, virtual pocket sensor 51, etc. in any suitable manner in.

圖9展示圖1中所描繪的注射模製設備10之替代配置。在圖6中，注射模製設備210具有雙層堆疊模製配置。存在多個模穴232且可彼此堆疊。為容納堆疊配置，熔融熱塑性材料224流經兩個澆口230進入模穴232中。可在或接近注射模製設備10之分模線處利用複數個應變感測器256。相對於僅具有配備應變感測器之單一模穴232，多個模穴232中具有複數個應變感測器256之益處在於，虛擬凹穴感測器51(圖1中所描繪)可測定模穴232中之每一者的填充百分比。此為至關重要的，因為在特定模製配置中，一些模穴232可比其他模穴232填充得早或晚，使得單一模穴232之填充百分比並不一定表示全部複數個模穴232之填充百分比。此外，模穴232中可存在傳統凹穴感測器258。此等傳統凹穴感測器258可向控制器50(圖1中所描繪)提供可用於對注射模製製程啟動特定變化之資訊，其不由虛擬凹穴感測器51控制。除了傳統凹穴感測器258以外，注射模製設備210中具有複數個應變計感測器256之一個益處在於，在特定模穴232歸因於停機對模穴232進行維護而未填充有熔融熱塑性材料224之情況下，傳統凹穴感測器258並不提供對既定模穴232之任何量測。然而，位於模穴232上之應變計感測器256仍提供可用於測定，例如停機模穴232是否經歷可導致破壞模穴232之壓力水準的應變變化資訊。 9 shows an alternative configuration of the injection molding apparatus 10 depicted in FIG. In FIG. 6, the injection molding apparatus 210 has a two-layer stacked molding configuration. There are multiple mold cavities 232 and can be mutually Stacked. To accommodate the stacked configuration, molten thermoplastic material 224 flows through two gates 230 into cavity 232. A plurality of strain sensors 256 may be used at or near the parting line of the injection molding apparatus 10. Compared to having only a single cavity 232 equipped with a strain sensor, the benefit of having multiple strain sensors 256 in multiple cavity 232 is that the virtual cavity sensor 51 (depicted in FIG. 1) can determine the mode The fill percentage of each of the holes 232. This is important because in a specific molding configuration, some cavity 232 can be filled earlier or later than other cavity 232, so that the filling percentage of a single cavity 232 does not necessarily indicate the filling of all multiple cavity 232 percentage. In addition, a conventional cavity sensor 258 may be present in the mold cavity 232. These conventional pocket sensors 258 may provide the controller 50 (depicted in FIG. 1) with information that can be used to initiate specific changes to the injection molding process, which are not controlled by the virtual pocket sensor 51. In addition to the conventional cavity sensor 258, one benefit of having a plurality of strain gauge sensors 256 in the injection molding apparatus 210 is that the specific cavity 232 is not filled with melt due to downtime for maintenance of the cavity 232 In the case of a thermoplastic material 224, the conventional cavity sensor 258 does not provide any measurement of a given cavity 232. However, the strain gauge sensor 256 located on the mold cavity 232 still provides information that can be used to determine, for example, whether the shutdown mold cavity 232 experiences strain changes that can cause a pressure level to damage the mold cavity 232.

圖10展示用於在熱塑性材料注入至模穴32(參見圖1)中時調整注射熔體壓力(IMP)之例示性方法300。控制器50可實施此方法以動態調整經由例如有線連接件56供應至螺桿控制件36之信號。 FIG. 10 shows an exemplary method 300 for adjusting the injection melt pressure (IMP) when a thermoplastic material is injected into the cavity 32 (see FIG. 1). The controller 50 can implement this method to dynamically adjust the signal supplied to the screw control member 36 via, for example, a wired connection 56.

方法300開始於步驟302，其中獲得IMP之初始值。在步驟304處，獲得來自應變計感測器(例如，應變計感測器52)之量測結果。在一些實施例中，在步驟304處接收來自多個應變計感測器之量測結果。使用來自一或多個應變計感測器(步驟306)之量測結果測定近似凹穴壓力。例如虛擬凹穴感測器51可實施步驟304及306。 The method 300 starts at step 302, where an initial value of IMP is obtained. At step 304, the measurement results from the strain gauge sensor (eg, strain gauge sensor 52) are obtained. In some embodiments, measurement results from multiple strain gauge sensors are received at step 304. Measure approximate cavity pressure using measurements from one or more strain gauge sensors (step 306) force. For example, the virtual pocket sensor 51 may implement steps 304 and 306.

隨後，在步驟308處，使用在步驟306處所測定之近似凹穴壓力來測定IMP之調整值。為此目的，控制器50及/或虛擬凹穴感測器51可接收來自操作器(例如，「藉由響應於凹穴中所偵測到之各M單元下降之N單元調整IMP」、來自根據一定公式之預定義查詢表或任何其他適合物中的合適映射之指示。在步驟310處，將調整值作為反饋添加至當前IMP值以執行反饋迴路控制流程。 Subsequently, at step 308, the adjusted value of IMP is determined using the approximate pocket pressure measured at step 306. For this purpose, the controller 50 and/or the virtual pocket sensor 51 may receive from the operator (e.g., "adjust the IMP by N units in response to the detection of each M unit falling in the pocket", from An indication of a suitable mapping in a predefined lookup table or any other suitable according to a certain formula. At step 310, the adjustment value is added as feedback to the current IMP value to execute the feedback loop control process.

若在步驟312處測定已滿足一定預定義條件，諸如應變計量測結果提供指示熔體流前沿已到達填充結束或模穴中之另一預定位置之資料，則方法300完成。否則，流程返回至步驟304以等待來自應變計感測器之新讀數。舉例而言，重新執行步驟304之時序可為預配置或經操作器控制的。僅舉例而言，可連續或幾乎連續接收來自應變計感測器之新讀數，當在本文中使用彼等術語時，其包含每一毫秒、每兩毫秒、每三毫秒、每四毫秒、每五毫秒或任何其他自填充開始至填充結束可需要之時間劃分的遞增，所述時間劃分適合於進行應變計量測、將彼等量測結果與符合預定或期望壓力與時間值之資料點進行比較且調整IMP以致力於抵消任何偏差。可在填充中或在特定時間間隔期間以相等或不等時間遞增獲取讀數，同時填充模穴。 If it is determined at step 312 that certain predefined conditions have been met, such as the strain gauge measurement results providing data indicating that the melt flow front has reached the end of filling or another predetermined location in the cavity, then the method 300 is completed. Otherwise, the flow returns to step 304 to wait for a new reading from the strain gauge sensor. For example, the timing of re-executing step 304 may be pre-configured or controlled by the operator. By way of example only, new readings from strain gauge sensors can be received continuously or almost continuously. When these terms are used in this document, they include every millisecond, every two milliseconds, every three milliseconds, every four milliseconds, every Five milliseconds or any other increment of time division that may be needed from the beginning of filling to the end of filling, the time division is suitable for strain measurement, the results of their measurements and data points that meet predetermined or expected pressure and time values Compare and adjust IMP to work to offset any deviations. Readings can be taken in increments of equal or unequal time during filling or during specific time intervals while filling the mold cavity.

本文所揭示之實施例中之任一者之部分或全部可與此項技術中已知的其他注射模製實施例之部分或全部進行組合，包含下文所述之彼等實施例。 Part or all of any of the embodiments disclosed herein can be combined with part or all of other injection molding embodiments known in the art, including those described below.

本發明之實施例可與針對在低恆定壓力下注射模製之實施例一起使用，所述實施例如2012年5月21日申請的，名為「在低恆定壓力下進行注射模製之設備及方法(Apparatus and Method for Injection Molding at Low Constant Pressure)」(申請人案號12127)且作為US 2012-0294963公開之美國專利申請案13/476,045中所揭示，所述申請案以引用之方式併入本文中。 Embodiments of the present invention can be used with embodiments directed to injection molding at low constant pressure, such as those filed on May 21, 2012, entitled "Under Low Constant Pressure Apparatus and Method for Injection Molding at Low Constant Pressure" (Applicant Case No. 12127) and disclosed in US Patent Application 13/476,045 published as US 2012-0294963, said application The case is incorporated by reference.

本發明之實施例可與針對壓力控制之實施例一起使用，所述實施例如2012年5月21日申請的，名為「低恆定壓力注射模製設備之交替壓力控制(Alternative Pressure Control for a Low Constant Pressure Injection Molding Apparatus)」(申請人案號12128)，現為專利US 8,757,999之美國專利申請案13/476,047中所揭示，所述申請案以引用之方式併入本文中。 The embodiment of the present invention can be used together with an embodiment for pressure control, such as the "Alternative Pressure Control for a Low Constant Pressure Injection Molding Equipment" filed on May 21, 2012. Constant Pressure Injection Molding Apparatus)” (Applicant Case No. 12128), which is currently disclosed in US Patent Application 13/476,047 of US 8,757,999, which is incorporated herein by reference.

本發明之實施例可與針對非自然平衡饋料系統之實施例一起使用，所述實施例如2012年5月21日申請的，名為「針對注射模製設備之非自然平衡饋料系統(Non-Naturally Balanced Feed System for an Injection Molding Apparatus)」(申請人案號12130)，現為專利US 8,911,228之美國專利申請案13/476,073中所揭示，所述申請案以引用之方式併入本文中。 The embodiment of the present invention can be used together with an embodiment for a non-naturally balanced feeding system, such as the "Non-naturally balanced feeding system for injection molding equipment (Non -Naturally Balanced Feed System for an Injection Molding Apparatus)" (Applicant Case No. 12130), which is now disclosed in US Patent Application 13/476,073 of US 8,911,228, which is incorporated herein by reference.

本發明之實施例可與針對在低，實質上恆定壓力下注射模製之實施例一起使用，所述實施例如2012年5月21日申請的，名為「低，實質上恆定壓力下之注射模製方法(Method for Injection Molding at Low,Substantially Constant Pressure)」(申請人案號12131Q)且作為US 2012-0295050公開之美國專利申請案13/476,197中所揭示，所述申請案以引用之方式併入本文中。 Embodiments of the present invention may be used with embodiments directed to injection molding at low, substantially constant pressure, such as those filed on May 21, 2012, entitled "Low, Substantially Constant Pressure Injection "Method for Injection Molding at Low, Substantially Constant Pressure" (Applicant Case No. 12131Q) and disclosed in US Patent Application 13/476,197 published as US 2012-0295050, which is cited by reference Incorporated in this article.

本發明之實施例可與針對在低，實質上恆定壓力下注射模製之實施例一起使用，所述實施例如2012年5月21日申請的，名為「低，實質上恆定壓力下之注射模製方法(Method for Injection Molding at Low,Substantially Constant Pressure)」(申請人案號12132Q)且作為US 2012-0295049公開之美國專利申請案13/476,178中所揭示，所述申請案以引用之方式併入本文中。 Embodiments of the present invention may be compatible with injection molding at low, substantially constant pressure The examples are used together, and the example is applied for on May 21, 2012, and is entitled "Method for Injection Molding at Low, Substantially Constant Pressure" (Applicant's case No. 12132Q) and disclosed in US Patent Application 13/476,178 published as US 2012-0295049, which is incorporated herein by reference.

本發明之實施例可與針對共注射製程之實施例一起使用，所述實施例如2013年2月22日申請的，名為「高熱導性共注射模製系統(High Thermal Conductivity Co-Injection Molding System)」(申請人案號12361)且作為US 2013-0221572公開之美國專利申請案13/774,692中所揭示，所述申請案以引用之方式併入本文中。 The embodiment of the present invention can be used together with an embodiment for a co-injection process, such as the application filed on February 22, 2013, called "High Thermal Conductivity Co-Injection Molding System" )" (Applicant case number 12361) and disclosed in US Patent Application 13/774,692 published as US 2013-0221572, which is incorporated herein by reference.

本發明之實施例可與針對伴隨簡化冷卻系統之模製的實施例一起使用，所述實施例如2013年2月12日申請的，名為「具有含有外來冷卻流體之簡化蒸發冷卻系統或簡化冷卻系統的注射模具(Injection Mold Having a Simplified Evaporative Cooling System or a Simplified Cooling System with Exotic Cooling Fluids)」(申請人案號12453M)，現為專利US 8,591,219之美國專利申請案13/765,428中所揭示，所述申請案以引用之方式併入本文中。 Embodiments of the present invention can be used with embodiments directed to moldings that accompany simplified cooling systems, such as those filed on February 12, 2013, entitled "Simplified Evaporative Cooling System or Simplified Cooling with Exotic Cooling Fluid Injection Mold Having a Simplified Evaporative Cooling System or a Simplified Cooling System with Exotic Cooling Fluids" (Applicant Case No. 12453M), which is now disclosed in US Patent Application 13/765,428 of US 8,591,219. The application is incorporated herein by reference.

本發明之實施例可與針對模製薄壁部件之實施例一起使用，所述實施例如2012年8月31日申請的，名為「用於薄壁部件之實質上恆定壓力注射模製之方法及設備(Method and Apparatus for Substantially Constant Pressure Injection Molding of Thinwall Parts)」(申請人案號12487D)，現為專利US 8,828,291之美國專利申請案13/601,514中所揭示，所述申請案以引用之方式併入本文中。 Embodiments of the present invention can be used with embodiments for molding thin-walled parts, such as the method of "substantially constant pressure injection molding for thin-walled parts" filed on August 31, 2012. And Apparatus (Method and Apparatus for Substantially Constant Pressure Injection Molding of Thinwall Parts)" (Applicant Case No. 12487D), which is now disclosed in US Patent Application 13/601,514 of US 8,828,291, which is cited by reference Incorporated in this article.

本發明之實施例可與針對具有故障安全機制的模製之實施例一起使用，所述實施例如2012年11月8日申請的，名為「具有故障安全壓力機制之注射模具(Injection Mold With Fail Safe Pressure Mechanism)」(申請人案號12657)且作為US 2014-0127338公開之美國專利申請案13/672,246中所揭示，所述申請案以引用之方式併入本文中。 The embodiment of the present invention can be used together with an embodiment for molding with a fail-safe mechanism, such as the application "Injection Mold With Fail with a fail-safe pressure mechanism" filed on November 8, 2012. Safe Pressure Mechanism) (Applicant Case No. 12657) and disclosed in US Patent Application 13/672,246 published as US 2014-0127338, which is incorporated herein by reference.

本發明之實施例可與針對高產率模製之實施例一起使用，所述實施例如2012年11月20日申請的，名為「運作高產率注射模製機之方法(Method for Operating a High Productivity Injection Molding Machine)」(申請人案號12673R)且作為US 2013-0221575公開之美國專利申請案13/682,456中所揭示，所述申請案以引用之方式併入本文中。 The embodiment of the present invention can be used together with an embodiment for high-yield molding, such as the "Method for Operating a High Productivity" filed on November 20, 2012, entitled "Method for Operating a High Productivity" Injection Molding Machine)" (Applicant Case No. 12673R) and disclosed in US Patent Application 13/682,456 published as US 2013-0221575, which is incorporated herein by reference.

本發明之實施例可與針對模製特定熱塑性材料之實施例一起使用，所述實施例如2013年11月20日申請的，名為「熱塑性聚合物與氫化蓖麻油之組合物之模製方法(Methods of Molding Compositions of Thermoplastic Polymer and Hydrogenated Castor Oil)」(申請人案號12674M)且作為US 2014-0145374公開之美國專利申請案14/085,515中所揭示，所述申請案以引用之方式併入本文中。 The embodiments of the present invention can be used together with an embodiment for molding a specific thermoplastic material, such as the method of molding a composition called "Thermoplastic Polymer and Hydrogenated Castor Oil", which was applied on November 20, 2013 ( Methods of Molding Compositions of Thermoplastic Polymer and Hydrogenated Castor Oil)" (Applicant Case No. 12674M) and disclosed in US Patent Application 14/085,515 published as US 2014-0145374, which is incorporated herein by reference in.

本發明之實施例可與針對澆道系統之實施例一起使用，所述實施例如2013年11月21日申請的，名為「注射模具系統之經尺寸減小之澆道(Reduced Size Runner for an Injection Mold System)」(申請人案號12677M)且作為US 2014-0141117公開之美國專利申請案14/085,515中所揭示，所述申請案以引用之方式併入本文中。 The embodiment of the present invention can be used together with an embodiment for a runner system, such as the one filed on November 21, 2013, entitled "Reduced Size Runner for an injection mold system (Reduced Size Runner for an Injection Mold System)" (Applicant Case No. 12677M) and disclosed in US Patent Application 14/085,515 published as US 2014-0141117, which is incorporated herein by reference.

本發明之實施例可與針對移動模製系統之實施例一起使用，所述實施例如2014年5月13日申請的，名為「具有可變位置模製凹穴之低恆定壓力注射模製系統(Low Constant Pressure Injection Molding System with Variable Position Molding Cavities)」(申請人案號12896)且作為US 2014-0335219公開之美國專利申請案14/275,944中所揭示，所述申請案以引用之方式併入本文中。 The embodiment of the present invention can be used with an embodiment directed to a mobile molding system, such as the "Low Constant Pressure Injection Molding System with Variable Position Molding Cavity" filed on May 13, 2014 (Low Constant Pressure Injection Molding System with Variable Position Molding Cavities)" (applicant case number 12896) and disclosed in US Patent Application 14/275,944 published as US 2014-0335219, which is incorporated by reference In this article.

本發明之實施例可與針對注射模具控制系統之實施例一起使用，所述實施例如2014年2月10日申請的，名為「考慮注射模製運作期間之材料特性變化的注射模製機及方法(Injection Molding Machines and Methods for Accounting for Changes in Material Properties During Injection Molding Runs)」(申請人案號13020)，現為專利US 8,980,146之美國專利申請案14/176,505中所揭示，所述申請案以引用之方式併入本文中。 The embodiment of the present invention can be used with an embodiment directed to an injection mold control system, such as an injection molding machine filed on February 10, 2014, entitled "In consideration of changes in material properties during injection molding operations and Methods (Injection Molding Machines and Methods for Accounting for Changes in Material Properties During Injection Molding Runs)" (Applicant Case No. 13020), which is now disclosed in US Patent Application No. 14/176,505 of US 8,980,146. The way of quotation is incorporated herein.

本發明之實施例可與針對注射模具控制系統之實施例一起使用，所述實施例如2014年7月31日申請的，名為「考慮注射模製運作期間之材料特性變化的注射模製機及方法(Injection Molding Machines and Methods for Accounting for Changes in Material Properties During Injection Molding Runs)」(申請人案號13021M)且作為US 2015-003518公開之美國專利申請案14/448,648中所揭示，所述申請案以引用之方式併入本文中。 The embodiment of the present invention can be used with an embodiment directed to an injection mold control system, such as an injection molding machine filed on July 31, 2014, entitled "In consideration of changes in material properties during injection molding operations and Method (Injection Molding Machines and Methods for Accounting for Changes in Material Properties During Injection Molding Runs)" (Applicant Case No. 13021M) and disclosed in US Patent Application No. 14/448,648 published as US 2015-003518. Incorporated by reference.

本發明之實施例可與針對注射模具控制系統之實施例一起使用，所述實施例如2014年7月31日申請的，名為「考慮注射模製運作期間之材料特性變化的注射模製機及方法(Injection Molding Machines and Methods for Accounting for Changes in Material Properties During Injection Molding Runs)」(申請人案號13022)且作為US 2015-0115491公開之美國專利申請案14/448,726中所揭示，所述申請案以引用之方式併入本文中。 The embodiment of the present invention can be used with an embodiment directed to an injection mold control system, such as an injection molding machine filed on July 31, 2014, entitled "In consideration of changes in material properties during injection molding operations and Method (Injection Molding Machines and Methods for Accounting for Changes in Material Properties During Injection Molding Runs)” (Applicant Case No. 13022) and disclosed in US Patent Application 14/448,726 published as US 2015-0115491, which is incorporated by reference Into this article.

本發明之實施例可與針對使用注射模製以形成包覆模製製品之實施例一起使用，所述實施例如2014年12月19日申請的，名為「形成包覆模製製品之方法(Methods of Forming Overmolded Articles)」(申請人案號13190)且作為US 2015-0174803公開之美國專利申請案14/577,310中所揭示，所述申請案以引用之方式併入本文中。 Embodiments of the present invention may be used with embodiments directed to the use of injection molding to form overmolded products, such as those filed on December 19, 2014, entitled "Method for Forming Overmolded Products ( Methods of Forming Overmolded Articles)" (Applicant Case No. 13190) and disclosed in US Patent Application 14/577,310 published as US 2015-0174803, which is incorporated herein by reference.

本發明之實施例可與針對控制模製製程之實施例一起使用，所述實施例如1998年3月17日頒予的，名為「用於將熔融材料注射至模穴中之方法及設備(Method and Apparatus for Injecting a Molten Material into a Mold Cavity)」(申請人案號12467CC)之美國專利5,728,329中所揭示，所述專利以引用之方式併入本文中。 Embodiments of the present invention can be used with embodiments directed to controlling the molding process, such as those issued on March 17, 1998, entitled "Method and Equipment for Injecting Molten Materials into Mold Cavities ( Method and Apparatus for Injecting a Molten Material into a Mold Cavity) (Applicant Case No. 12467CC) is disclosed in US Patent 5,728,329, which is incorporated herein by reference.

本發明之實施例可與針對控制模製製程之實施例一起使用，所述實施例如1998年2月10日頒予的，名為「注射控制系統(Injection Control System)」(申請人案號12467CR)之美國專利5,716,561中所揭示，所述專利以引用之方式併入本文中。 The embodiment of the present invention can be used together with an embodiment directed to controlling the molding process, such as the "Injection Control System" granted on February 10, 1998 (Applicant Case No. 12467CR ) Is disclosed in US Patent 5,716,561, which is incorporated herein by reference.

本發明之實施例可與針對模製預成型件之實施例一起使用，所述實施例如名為「塑膠製品形成設備及其使用方法(Plastic Article Forming Apparatus and Methods for Using the Same)」(申請人案號13242P)之美國專利申請案61/952281中所揭示，所述申請案以引用之方式併入本文中。 Embodiments of the present invention can be used with embodiments directed to molded preforms, such as "Plastic Article Forming Apparatus and Methods for Using the Same" (Applicant No. 13242P) is disclosed in US Patent Application 61/952281, which is incorporated herein by reference.

本發明之實施例可與針對模製預成型件之實施例一起使用，所述實施例如名為「塑膠製品形成設備及其使用方法(Plastic Article Forming Apparatus and Methods for Using the Same)」(申請人案號13243P)之美國專利申請案61/952283中所揭示，所述申請案以引用之方式併入本文中。 Embodiments of the present invention can be used with embodiments directed to molded preforms, such as "Plastic Article Forming Apparatus and Methods for Using the Same" (Applicant No. 13243P) is disclosed in US Patent Application 61/952283, which is incorporated herein by reference.

本發明之實施例可與針對硬焊饋料系統之實施例一起使用，所述實施例如名為「注射模製機之饋料系統(Feed System for an Injection Molding Machine)」(申請人案號13488P)之美國專利申請案62/032,071中所揭示，所述申請案以引用之方式併入本文中。 The embodiment of the present invention can be used with an embodiment for a brazing feeding system, such as "Feed System for an Injection Molding Machine" (Applicant Case No. 13488P ) Is disclosed in US Patent Application 62/032,071, which is incorporated herein by reference.

本發明之實施例可與針對非硬焊饋料系統之實施例一起使用，所述實施例如名為「注射模製機之饋料系統(Feed System for an Injection Molding Machine)」(申請人案號13498P)之美國專利申請案62/042,577中所揭示，所述申請案以引用之方式併入本文中。 The embodiment of the present invention can be used with an embodiment for a non-brazing feed system, such as "Feed System for an Injection Molding Machine" (Applicant Case No. 13498P) is disclosed in US Patent Application 62/042,577, which is incorporated herein by reference.

本發明之實施例可與針對注射模製機之加熱模具之實施例一起使用，所述實施例如名為「在流動混合區中局部加熱之注射模製(Injection Molding with Localized Heating in Flow Challenge Regions)」(申請人案號13509P)之美國專利申請案62/045,373中所揭示，所述申請案以引用之方式併入本文中。 Embodiments of the present invention can be used with embodiments of heated molds for injection molding machines, such as "Injection Molding with Localized Heating in Flow Challenge Regions" "(Applicant Case No. 13509P) is disclosed in US Patent Application 62/045,373, which is incorporated herein by reference.

本發明之實施例可與針對改造注射模製機之實施例一起使用，所述實施例如名為「經改造之注射模製機(Retrofitted Injection Molding Machines)」(申請人案號13553P)之美國專利申請案62/053,499中所揭示，所述申請案以引用之方式併入本文中。 Embodiments of the present invention can be used with embodiments directed to retrofitting injection molding machines, such as the US patent entitled "Retrofitted Injection Molding Machines" (Applicant Case No. 13553P) It is disclosed in the application 62/053,499, which is incorporated herein by reference.

本發明之實施例可與針對連續注射模製之實施例一起使用，所述實施例如名為「用於連續注射模製之系統及方法(System and Method for Continuous Injection Molding)」(申請人案號13638P)之美國專利申請案62/084,778中所揭示，所述申請案以引用之方式併入本文中。 Embodiments of the invention can be used with embodiments for continuous injection molding, the Examples of implementation are disclosed in US Patent Application 62/084,778 entitled "System and Method for Continuous Injection Molding" (Applicant Case No. 13638P), which is cited by reference Is incorporated into this article.

本發明之實施例可與針對連續共注射模製之實施例一起使用，所述實施例如名為「伴隨連續注射模製之共注射(Co-Injection with Continuous Injection Molding)」(申請人案號13639P)之美國專利申請案62/084,787中所揭示，所述申請案以引用之方式併入本文中。 The embodiment of the present invention can be used with an embodiment for continuous co-injection molding, which is called "Co-Injection with Continuous Injection Molding" (Applicant Case No. 13639P ) Is disclosed in US Patent Application 62/084,787, which is incorporated herein by reference.

本發明之實施例可與針對伴隨模壓之注射模製之實施例一起使用，所述實施例如名為「連續模壓(Sequential Coining)」(申請人案號13935P)之美國專利申請案62/186,722中所揭示，所述申請案以引用之方式併入本文中。 Embodiments of the present invention can be used with embodiments directed to injection molding accompanied by molding, such as in US Patent Application 62/186,722 named "Sequential Coining" (Applicant Case No. 13935P) As disclosed, the application is incorporated herein by reference.

本發明之實施例可與針對注射模製控制之實施例一起使用，所述實施例如名為「伴隨恆速流動前沿控制之注射模製方法(Method of Injection Molding with Constant-Velocity Flow Front Control)」(申請人案號13936P)之美國專利申請案62/186,739中所揭示，所述申請案以引用之方式併入本文中。 Embodiments of the present invention can be used with embodiments directed to injection molding control, such as "Method of Injection Molding with Constant-Velocity Flow Front Control" (Applicant case number 13936P) is disclosed in US Patent Application 62/186,739, which is incorporated herein by reference.

本發明之實施例可與針對在特定裝置條件下注射模製之實施例一起使用，所述實施例如名為「伴隨洩漏止迴環之注射模製(Injection Molding with a Leaking Check Ring)」(申請人案號13957P)之美國專利申請案62/192,616中所揭示，所述申請案以引用之方式併入本文中。 Embodiments of the present invention can be used with embodiments directed to injection molding under specific device conditions, such as "Injection Molding with a Leaking Check Ring" (Applicant No. 13957P) is disclosed in US Patent Application 62/192,616, which is incorporated herein by reference.

本文所揭示之尺寸及值不應理解為嚴格地限於所述之精確數值。實際上，除非另外說明，否則各所述尺寸均欲意謂所述值與圍繞所述值之功能等效範圍兩者。舉例而言，揭示為「40mm」之尺寸欲意謂「約40mm」。 The dimensions and values disclosed herein should not be understood to be strictly limited to the precise numerical values described. In fact, unless stated otherwise, each such dimension is intended to mean both the stated value and the functionally equivalent range surrounding that stated value. For example, the size revealed as "40mm" It means "about 40mm".

除非明確排除或以其他方式限制，否則本文中所引用之每一文獻，包含任何交叉引用或相關專利或申請案及本申請案主張其優先權或權益之任何專利申請案或專利，均以全文引用之方式併入本文中。任何文獻之引用均不承認其為本文所揭示或所主張之任何發明的先前技術或其單獨或與任何其他參考文獻組合教示、表明或揭示任何此類發明。此外，此文獻中之術語的任何含義或定義與以引用之方式併入之文獻中之同一術語的任何含義或定義矛盾的情況下，應以此文獻中賦予所述術語之含義或定義為准。 Unless expressly excluded or otherwise restricted, each document cited in this document, including any cross-references or related patents or applications and any patent applications or patents in which this application claims priority or interest, is in full text The way of quotation is incorporated herein. The citation of any document does not admit that it is the prior art of any invention disclosed or claimed herein or teaches, indicates or discloses any such invention alone or in combination with any other reference. In addition, in the event that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to the term in this document shall prevail .

儘管已說明且描述本發明之特定實施例，但對熟習此項技術者將顯而易見的是，可在不偏離本發明之精神及範疇之情況下進行各種其他改變及修改。因此，意欲在隨附申請專利範圍中涵蓋處於本發明之範疇內的所有此類改變及修改。 Although specific embodiments of the invention have been illustrated and described, it will be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Therefore, it is intended to cover all such changes and modifications within the scope of the present invention within the scope of the accompanying patent application.

10:注射模製設備 10: Injection molding equipment

12:注射系統 12: Injection system

14:夾持系統 14: clamping system

16:熱塑性丸粒 16: Thermoplastic pellets

18:漏斗 18: funnel

20:加熱機筒 20: Heating barrel

22:往復式螺桿 22: Reciprocating screw

24:熔融熱塑性材料 24: molten thermoplastic material

25:第一模側 25: first die side

26:噴嘴 26: Nozzle

27:第二模側 27: Second mold side

28:模具 28: mold

30:澆口 30: Gate

32:模穴 32: mold cavity

34:按壓或夾持單元 34: Pressing or clamping unit

36:螺桿控制件 36: Screw control

50:控制器 50: controller

51:虛擬凹穴感測器 51: Virtual pocket sensor

54:電線 54: Wire

56:有線連接件 56: Wired connection

Claims

一種注射模製熱塑性材料之方法，所述方法包括：使用至少一個應變計感測器(52)量測模穴(32)之模側中的應變變化；基於所述應變變化估算所述模穴中之壓力或熔體流前沿位置中之至少一者；將所述估算模穴中之壓力或熔體流前沿位置與觸發點進行比較，該觸發點出現在或接近當熔融熱塑性材料開始進入模穴且施加可由應變計感測器偵測之張開力時；若所述估算模穴中之壓力或熔體流前沿位置等於或超過所述觸發點，則啟動虛擬凹穴感測器(51)；其中當啟動時，所述虛擬凹穴感測器追蹤由應變變化量測結果所計算的估算模穴中之壓力，且將所述估算模穴中之壓力之追蹤結果與最佳預定義壓力-時間曲線進行比較，所述應變變化量測結果由所述至少一個應變計感測器隨時間推移加以量測，該最佳預定義壓力-時間曲線為在設定達成模穴之最大設定壓力下接近漸近線之拋物曲線。 A method for injection molding a thermoplastic material, the method comprising: using at least one strain gauge sensor (52) to measure a strain change in a mold side of a mold cavity (32); estimating the mold cavity based on the strain variation At least one of the pressure or the melt flow front position; compare the pressure or melt flow front position in the estimated cavity with the trigger point that occurs at or near the point when the molten thermoplastic material begins to enter the mold When an opening force that can be detected by the strain gauge sensor is applied; if the pressure in the estimated mold cavity or the melt flow front position is equal to or exceeds the trigger point, the virtual cavity sensor (51) is activated; When activated, the virtual cavity sensor tracks the pressure in the estimated cavity calculated from the strain change measurement results, and the tracking result of the pressure in the estimated cavity is the best predefined pressure- Time curve for comparison, the strain change measurement result is measured by the at least one strain gauge sensor over time, the best pre-defined pressure-time curve is close to the maximum set pressure to achieve the mold cavity Parabolic curve of asymptote.

如請求項1之方法，其中當啟動時，所述虛擬凹穴感測器使得控制器(50)進行包括以下至少一者的動作：增加熔融熱塑性材料之擠壓速率；降低熔融熱塑性材料之擠壓速率；增加熔融熱塑性材料之注射力；降低熔融熱塑性材料之注射力；致動所述模穴之一部分；或啟動所述模穴中之加熱元件。 The method of claim 1, wherein when activated, the virtual pocket sensor causes the controller (50) to perform actions including at least one of: increasing the extrusion rate of the molten thermoplastic material; decreasing the extrusion of the molten thermoplastic material Pressure rate; increase the injection force of molten thermoplastic material; reduce the injection force of molten thermoplastic material; actuate part of the cavity; The heating element in the cavity.

如請求項1之方法，所述方法進一步包括：其中，若所述估算模穴中之壓力之追蹤結果與所述最佳預定義壓力-時間曲線之比較指示並未遵循所述最佳預定義壓力-時間曲線，則調整注射模製製程。 As in the method of claim 1, the method further includes: wherein, if the comparison of the tracking result of the pressure in the estimated cavity with the optimal predefined pressure-time curve indicates that the optimal predefined is not followed Pressure-time curve, then adjust the injection molding process.

如請求項3之方法，其中調整注射模製製程包括注射額外的熔融熱塑性材料。 The method of claim 3, wherein adjusting the injection molding process includes injecting additional molten thermoplastic material.

如請求項3之方法，其中調整注射模製製程包括增加熔融熱塑性材料之擠壓速率。 The method of claim 3, wherein adjusting the injection molding process includes increasing the extrusion rate of the molten thermoplastic material.

如請求項3之方法，其中調整注射模製製程包括降低熔融熱塑性材料之注射速率。 The method of claim 3, wherein adjusting the injection molding process includes reducing the injection rate of the molten thermoplastic material.

如請求項3之方法，其中調整注射模製製程包括增加熔融熱塑性材料之注射力。 The method of claim 3, wherein adjusting the injection molding process includes increasing the injection force of the molten thermoplastic material.

如請求項3之方法，其中調整注射模製製程包括降低熔融熱塑性材料之注射力。 The method of claim 3, wherein adjusting the injection molding process includes reducing the injection force of the molten thermoplastic material.

如請求項1之方法，其中當啟動時，所述虛擬凹穴感測器測定注入至所述模穴中的熔融熱塑性材料之黏度。 The method of claim 1, wherein when activated, the virtual pocket sensor determines The viscosity of the molten thermoplastic material entering the cavity.

如請求項1之方法，其中當啟動時，所述虛擬凹穴感測器測定已填充有熔融熱塑性材料的所述模穴之百分比。 The method of claim 1, wherein when activated, the virtual cavity sensor measures the percentage of the mold cavity that has been filled with molten thermoplastic material.

如請求項1之方法，所述方法包括：使用至少一個傳統凹穴感測器量測所述模穴中之模穴壓力變化。 As in the method of claim 1, the method includes: using at least one conventional cavity sensor to measure a change in mold cavity pressure in the mold cavity.

如請求項1之方法，所述方法包括：使用複數個應變計感測器量測複數個模穴之複數個模側中之應變變化；且其中當啟動時，所述虛擬凹穴感測器針對所述複數個模穴中之每一者測定已填充有熔融熱塑性材料的模穴之百分比。 The method of claim 1, the method comprising: measuring strain changes in the plurality of mold sides of the plurality of mold cavities using a plurality of strain gauge sensors; and wherein when activated, the virtual cavity sensor The percentage of mold cavities that have been filled with molten thermoplastic material is determined for each of the plurality of mold cavities.

如請求項12之方法，所述方法包括：使用至少一個傳統凹穴感測器量測所述複數個模穴中之每一者中的模穴壓力。 As in the method of claim 12, the method includes using at least one conventional cavity sensor to measure the cavity pressure in each of the plurality of cavity.

如請求項13之方法，所述方法包括：確保經由使用所述至少一個應變計感測器，所述至少一個傳統凹穴感測器所量測之模穴壓力中無一者超過最大模穴壓力。 The method of claim 13, the method comprising: ensuring that by using the at least one strain gauge sensor, none of the mold cavity pressures measured by the at least one conventional cavity sensor exceeds the maximum mold cavity pressure.

如請求項1之方法，其中該觸發點出現在該模側經歷張開力及閉合力兩者時。 The method of claim 1, wherein the trigger point occurs when the die side experiences both an opening force and a closing force.