초록 ▼

According to embodiments of the present invention, there is provided a method and system for operating an injection molding machine. For example, a molding system (100) to manufacture a molded article (103) in a mold-cavity system (200) by using a molding material (101) is provided. The system (100)

According to embodiments of the present invention, there is provided a method and system for operating an injection molding machine. For example, a molding system (100) to manufacture a molded article (103) in a mold-cavity system (200) by using a molding material (101) is provided. The system (100) including pressure-control system (126) coupled with the system (200); and controller (160) operatively coupling to system (126), controller (160) having controller-usable memory (162) tangibly embodying set of controller-executable instructions (500) to direct controller (160), including mold-unpack instructions (520), including instructing controller (160) to control system (126) to reduce, after solidification, at least in part, of material (101) being located in a nub region (214) of system (200), internal pressure of material (101) received in system (200) while system (200) remains isolated from stream of flowable-molding material, beyond any reduction of internal pressure in material (101) resulting from cooling of material (101), so that reduction in internal pressure of material (101) is enough to permit safe opening of system (200) while permitting safe extraction of article (103).

대표청구항 ▼

1. A molding system being configured to manufacture a molded article in a mold-cavity system by using a molding material, the molding system comprising: a pressure-control system being coupled with the mold-cavity system; anda controller operatively coupling to the pressure-control system, the contr

1. A molding system being configured to manufacture a molded article in a mold-cavity system by using a molding material, the molding system comprising: a pressure-control system being coupled with the mold-cavity system; anda controller operatively coupling to the pressure-control system, the controller having a controller-usable memory tangibly embodying a set of controller-executable instructions being configured to direct the controller, the set of controller-executable instructions including: mold-unpack instructions, including instructing the controller to control the pressure-control system to reduce, after solidification, at least in part, of the molding material being located in a nub region of the mold-cavity system, internal pressure of the molding material received in the mold-cavity system while the mold-cavity system remains isolated from a stream of flowable-molding material, beyond any reduction of the internal pressure in the molding material resulting from cooling of the molding material, so that the reduction in the internal pressure of the molding material is enough to permit safe opening of the mold-cavity system while permitting safe extraction of the molded article from the mold-cavity system. 2. A molding system being configured to manufacture a molded article by using a mold-cavity system and using a molding material, the molding system comprising: a group of controllable systems, including: a mold-cooling system being configured to couple with the mold-cavity system;a pressure-control system being configured to couple with the mold-cavity system;a melt-preparation system being configured to couple with the mold-cavity system; anda controller being operatively coupling to the group of controllable systems, the controller having a controller-usable memory tangibly embodying a set of controller-executable instructions being configured to direct the controller to control operation of the molding system, the set of controller-executable instructions including: melt-stream disconnection instructions, instructing the controller to control the melt-preparation system to disconnect the mold-cavity system from a stream of flowable-molding material, so that the mold-cavity system becomes isolated from the stream of flowable-molding material after the mold-cavity system has received a portion of the stream of flowable-molding material;heat-reduction instructions, instructing the controller to control the mold-cooling system to remove heat from the molding material being received in the mold-cavity system after the mold-cavity system has been disconnected from the stream of flowable-molding material so that the mold-cavity system becomes isolated from the stream of flowable-molding material, and in response solidification of the molding material occurs in a gate portion of the mold-cavity system so that the molded article may be removed from the mold-cavity system; andmold-unpack instructions, including instructing the controller to control the pressure-control system to reduce, after solidification, at least in part, of the molding material being located in a nub region of the mold-cavity system, internal pressure of the molding material received in the mold-cavity system while the mold-cavity system remains isolated from the stream of flowable-molding material, beyond any reduction of the internal pressure in the molding material resulting from cooling of the molding material, so that the reduction in the internal pressure of the molding material is enough to permit safe opening of the mold-cavity system while permitting safe extraction of the molded article from the mold-cavity system. 3. The molding system of claim 2, wherein: the set of controller-executable instructions further include: mold-pack instructions, instructing the controller to control any one of: (i) the melt-preparation system, and (ii) the melt-preparation system and the pressure-control system to reduce a pressure to the molding material being contained in the mold-cavity system while the molding material becomes cooled, at least in part, in the mold-cavity system;the mold-pack instructions include: hold instructions, instructing the controller to control the molding system to apply and hold the pressure to the molding material being contained in the mold-cavity system while the molding material remains in a semi-solid state in the mold-cavity system; andcompensation instructions, instructing the controller to control the molding system to inject an additional amount of the molding material into the mold-cavity system while the molding material in the mold-cavity system remains in the semi-solid state, and the additional amount of the molding material compensating for shrinkage of the molding material being received in the mold-cavity system;the melt-stream disconnection instructions are executed: (i) after the mold-pack instructions are executed so that the mold-cavity system becomes isolated from the stream of flowable-molding material, and (ii) before the mold-unpack instructions are executed; andthe mold-unpack instructions further include: mold-volume increase instructions, instructing the controller to control the pressure-control system to increase a volume of a mold cavity of the mold-cavity system, the mold cavity receiving the molding material, increasing the volume of the mold cavity reduces the pressure within the molding material being received in the mold-cavity system while: (i) the molding material remains in the semi-solid state in the mold-cavity system, and (ii) the mold cavity remains isolated from the stream of the molding material. 4. The molding system of claim 2, wherein: the set of controller-executable instructions further include: mold-pack instructions, instructing the controller to control any one of: (i) the melt-preparation system, and (ii) the melt-preparation system and the pressure-control system to reduce a pressure to the molding material being contained in the mold-cavity system while the molding material becomes cooled, at least in part, in the mold-cavity system;the melt-stream disconnection instructions are executed: (i) before the mold-pack instructions are executed, and (ii) before the mold-unpack instructions are executed;the mold-pack instructions further include: mold-volume reduction instructions, instructing the controller to control the pressure-control system to decrease a volume of a mold cavity of the mold-cavity system, the mold cavity having the molding material, so that an additional pressure is applied to the molding material being received in the mold-cavity system while the molding material remains in a semi-solid state in the mold-cavity system, so that the volume of the mold cavity is reduced and the molding material located in the mold cavity is compressed, so that density of the molding material located in the mold-cavity system increases; andthe mold-unpack instructions further include: mold-volume increase instructions, instructing the controller to control the pressure-control system to increase the volume of the mold cavity, so that the internal pressure of the molding material being contained in the mold-cavity system is reduced while the molding material remains in the semi-solid state in the mold-cavity system, so that the molding material located in the mold-cavity system becomes decompressed and the density of the molding material decreases by expanding the volume of the mold cavity before the mold-cavity system is opened sufficiently so as to remove the molded article and while the mold-cavity system remains isolated from the stream of the molding material. 5. A molding system being configured to manufacture a molded article by using a mold-cavity system and using a molding material, the mold-cavity system having a stationary-mold assembly and a movable-mold assembly, the molding system comprising: a hot-runner system being coupled with the stationary-mold assembly;a stationary platen being configured to support the hot-runner system and the stationary-mold assembly;a movable platen being configured to support the movable-mold assembly, and being movable relative to the stationary platen;platen bars operatively extending between the stationary platen and the movable platen;a group of controllable systems, including: a platen actuator being coupled with the movable platen;bar locks lockably coupling the platen bars with the movable platen;clamp assemblies being coupled with the platen bars, the clamp assemblies being configured to apply a clamp tonnage to the platen bars;a mold-cooling system being configured to couple with the mold-cavity system;a pressure-control system being configured to couple with the mold-cavity system;a melt-preparation system being configured to couple with the mold-cavity system; anda controller being operatively coupling to the group of controllable systems, the controller having a controller-usable memory tangibly embodying a set of controller-executable instructions being configured to direct the controller to control operation of the molding system, the set of controller-executable instructions including: melt-preparation instructions, including instructing the controller to control the melt-preparation system to convert the molding material into a stream of flowable-molding material;mold-close instructions, including instructing the controller to control the platen actuator to move the movable platen toward the stationary platen thereby shutting close the mold-cavity system;mold-lock instructions, instructing the controller to control the bar locks to lock the movable platen and the platen bars so that the mold-cavity system is locked, so that portions of the mold-cavity system do not move relative to each other when the mold-cavity system is injected, under pressure, with the stream of flowable-molding material;tonnage-engage instructions, instructing the controller to control the clamp assemblies to apply the clamp tonnage to the mold-cavity system via the platen bars after the mold-cavity system is closed shut and locked;melt-stream connection instructions, instructing the controller to control the melt-preparation system to connect the mold-cavity system to the stream of flowable-molding material, so that the stream of flowable-molding material may flow into the mold-cavity system;mold-injection instructions, instructing the controller to control the melt-preparation system to inject a portion of the stream of flowable-molding material into the mold-cavity system while the clamp tonnage maintains the mold-cavity system closed;mold-pack instructions, instructing the controller to control any one of: (i) the melt-preparation system, and (ii) the melt-preparation system and the pressure-control system to reduce the pressure to the molding material being contained in the mold-cavity system while the molding material becomes cooled, at least in part, in the mold-cavity system;melt-stream disconnection instructions, instructing the controller to control the melt-preparation system to disconnect the mold-cavity system from the stream of flowable-molding material, so that the mold-cavity system becomes isolated from the stream of flowable-molding material after the mold-cavity system has received the portion of the stream of flowable-molding material;heat-reduction instructions, instructing the controller to control the mold-cooling system to remove heat from the molding material being received in the mold-cavity system after the mold-cavity system has been disconnected from the stream of flowable-molding material so that the mold-cavity system becomes isolated from the stream of flowable-molding material, and in response solidification of the molding material occurs in a gate portion of the mold-cavity system so that the molded article may be removed from the mold-cavity system;mold-unpack instructions, including instructing the controller to control the pressure-control system to reduce, after solidification, at least in part, of the molding material being located in a nub region of the mold-cavity system, internal pressure of the molding material received in the mold-cavity system while the mold-cavity system remains isolated from the stream of flowable-molding material, beyond any reduction of the internal pressure in the molding material resulting from cooling of the molding material, so that the reduction in the internal pressure of the molding material is enough to permit safe opening of the mold-cavity system while permitting safe extraction of the molded article from the mold-cavity system;tonnage-disengage instructions, instructing the controller to control the clamp assemblies to disengage the clamp tonnage from the mold-cavity system;mold-unlock instructions, instructing the controller to control the bar locks to unlock the movable platen and the platen bars so that the mold-cavity system is unlocked; andmold-open instructions, instructing the controller to control the movable platen to away from the stationary platen thereby opening the mold-cavity system, so that a molded part made in the mold-cavity system may be removed from the mold-cavity system. 6. The molding system of claim 5, wherein: the mold-pack instructions further include: hold instructions, instructing the controller to control the molding system to apply and hold the pressure to the molding material being contained in the mold-cavity system while the molding material remains in a semi-solid state in the mold-cavity system; andcompensation instructions, instructing the controller to control the molding system to inject an additional amount of the molding material into the mold-cavity system while the molding material in the mold-cavity system remains in the semi-solid state, and the additional amount of the molding material compensating for shrinkage of the molding material being received in the mold-cavity system;the melt-stream disconnection instructions are executed: (i) after the mold-pack instructions are executed so that the mold-cavity system becomes isolated from the stream of flowable-molding material, and (ii) before the mold-unpack instructions are executed; andthe mold-unpack instructions further include: mold-volume increase instructions, instructing the controller to control the pressure-control system to increase a volume of a mold cavity of the mold-cavity system, the mold cavity receiving the molding material, increasing the volume of the mold cavity reduces the pressure within the molding material being received in the mold-cavity system while: (i) the molding material remains in the semi-solid state in the mold-cavity system, and (ii) the mold cavity remains isolated from the stream of the molding material. 7. The molding system of claim 5, wherein: the melt-stream disconnection instructions are executed: (i) before the mold-pack instructions are executed, and (ii) before the mold-unpack instructions are executed;the mold-pack instructions further include: mold-volume reduction instructions, instructing the controller to control the pressure-control system to decrease a volume of a mold cavity of the mold-cavity system, the mold cavity having the molding material, so that additional pressure is applied to the molding material being received in the mold-cavity system while the molding material remains in a semi-solid state in the mold-cavity system, so that the volume of the mold cavity is reduced and the molding material located in the mold cavity is compressed, so that density of the molding material located in the mold-cavity system increases; andthe mold-unpack instructions further include: mold-volume increase instructions, instructing the controller to control the pressure-control system to increase the volume of the mold cavity, so that the internal pressure of the molding material being contained in the mold-cavity system is reduced while the molding material remains in the semi-solid state in the mold-cavity system, so that the molding material located in the mold-cavity system becomes decompressed and the density of the molding material decreases by expanding the volume of the mold cavity before the mold-cavity system is opened sufficiently so as to remove the molded article and while the mold-cavity system remains isolated from the stream of the molding material. 8. A controller for use with a molding system being configured to manufacture a molded article in a mold-cavity system by using a molding material, the molding system including a group of controllable systems including a pressure-control system being: (i) coupled with the mold-cavity system, and (ii) being operatively coupled to the group of controllable systems, the controller comprising: a controller-usable memory tangibly embodying a set of controller-executable instructions being configured to direct the controller to control operation of the molding system, the set of controller-executable instructions including: mold-unpack instructions, including instructing the controller to control the pressure-control system to reduce, after solidification, at least in part, of the molding material being located in a nub region of the mold-cavity system, internal pressure of the molding material received in the mold-cavity system while the mold-cavity system remains isolated from a stream of flowable-molding material, beyond any reduction of the internal pressure in the molding material resulting from cooling of the molding material, so that the reduction in the internal pressure of the molding material is enough to permit safe opening of the mold-cavity system while permitting safe extraction of the molded article from the mold-cavity system. 9. A controller-usable memory for use with a controller, the controller for use with a molding system being configured to manufacture a molded article in a mold-cavity system by using a molding material, the molding system including a group of controllable systems including a pressure-control system being: (i) coupled with the mold-cavity system, and (ii) being operatively coupled to the group of controllable systems, the controller-usable memory comprising: a set of controller-executable instructions being tangibly embodied in the controller-usable memory, and being configured to direct the controller to control operation of the molding system, the set of controller-executable instructions including: mold-unpack instructions, including instructing the controller to control the pressure-control system to reduce, after solidification, at least in part, of the molding material being located in a nub region of the mold-cavity system, internal pressure of the molding material received in the mold-cavity system while the mold-cavity system remains isolated from a stream of flowable-molding material, beyond any reduction of the internal pressure in the molding material resulting from cooling of the molding material, so that the reduction in the internal pressure of the molding material is enough to permit safe opening of the mold-cavity system while permitting safe extraction of the molded article from the mold-cavity system.