Patent Application
20130287887
An aspect generally relates to (but is not limited to): a mold-tool system including (and not limited to: a valve-stem assembly configured to be: removable from a runner system while valve-actuator assembly remains connected with the manifold assembly.
The inventors have researched a problem associated with known molding systems that inadvertently manufacture bad-quality molded articles or parts. After much study, the inventors believe they have arrived at an understanding of the problem and its solution, which are stated below, and the inventors believe this understanding is not known to the public.
Valve stems are currently a wear item and may require splitting of hot runner plates to change out worn parts. This may be a lengthy process and may not be practical to perform at all customer sites. These parts are also costly. In addition to wear issues, various gate diameters and stem tip profiles may not be routinely required to manufacture different performs (that is, molded articles). With the current design may be once again time consuming and costly. One of the biggest challenges may be optimizing the injection process parameters to achieve ideal part quality and cycle times. Often stem tip temperature may be critical in ensuring good part quality. This may be largely achieved by altering stem open and close times to heat up or cool down the stem tip, limiting the flexibility of the operator by having one variable to work with, or worse, altering temperature to achieve perform quality while increasing cycle time.
According to one aspect, there is provided (to be a solution to the problem identified above, at least in part) a mold-tool system (100), comprising: a valve-stem assembly (102) being configured to be: (i) intractable with a valve-actuator assembly (202) while the valve-actuator assembly (202) remains connected with a manifold assembly (614), the manifold assembly (614) being supported by a runner system (600) of a molding system (200); and (ii) removable from the runner system (600) while the valve-actuator assembly (610) remains connected with the manifold assembly (614) inside the runner system (600).
The following advantages may be realized for the above described solution: (1) If a method of replacing stem tips is introduced from the interface of the cavity assembly of the mold assembly, it may be possible to quickly and efficiently perform stem changes at the customer sight with little down time and avoid what is now a major undertaking and usually involves sending the hot runner out for refurbishment. This may add significant value to the customer. For certain applications with a short service life, alternate materials may be used to increase service intervals. (2) It may also be a requirement for many customers to swap out various molds and cavities with a hot-runner assembly. The ability to change valve stem diameters and/or stem profile (such as tapered and/or straight) may be added value to many customers who may benefit from further tooling compatibility. (3) One of the biggest challenges may be optimizing the injection process parameters to achieve ideal part quality and cycle times. Often stem tip temperature may be critical in ensuring good part quality. By enabling customers to swap out stem tips of various materials that give thermal benefits either that heat up quicker or slower, this may give customers an additional variable to is achieve optimum part quality and cycle time. For example, a more conductive stem tip may heat quicker in the melt, and/or cool quicker at the gate, conversely, with a less conductive tip. Combining this with valve stem open/close timing may further refine the optimization process. The solution helps to facilitate changing out of vale stem tips from the cavity Interface, allowing improved access and may greatly reduce down time compared to the known systems as well as enabling “on the fly” changes versus refurbishment. With the solution provided above, the cavity plate (also called the cavity assembly) may be latched over, the old stem tips may be removed, and new stem tips are installed in one to two hours, for example.
Other aspects and features of the non-limiting embodiments will now become apparent to those skilled in the art upon review of the following detailed description of the non-limiting embodiments with the accompanying drawings.
The non-limiting embodiments will be more fully appreciated by reference to the following detailed description of the non-limiting embodiments when taken in conjunction with the accompanying drawings, in which:
The following FIGS. depict various structures for selective attachment and detachment that may be employed to permit quick change out of the valve stem. Heating and cooling of parts prior to assembly using dry ice or tooling using threads may aid in installation or removal of the valve stem. Several approaches are described below to break or deform the replacement part and leave the piston or a valve body intact.
The drawings are not necessarily to scale and may be illustrated by phantom lines, is diagrammatic representations and fragmentary views. In certain instances, details not necessary for an understanding of the embodiments (and/or details that render other details difficult to perceive) may have been omitted.
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More specifically, the mold-tool system (100) may include (and is not limited to): a valve-stem assembly (102).The valve-stem assembly (102) may be configured to be: intractable with a valve-actuator assembly (610), which is more fully depicted in
The runner system (600) may include (and is not limited to): a backing plate (602), a manifold plate (604). The backing plate (602) may be configured for connection with the stationary platen (504) of the clamp assembly (502) of the molding system (500). The manifold plate (604) may be connected with the backing plate (602). The manifold assembly (614) may be supported by the manifold plate (604). A nozzle assembly (616), which is depicted more clearly in
The mode of operation depicted in
The stem-replacement operation may include a stem-removal operation in which while the cavity assembly (702) of the mold assembly (700) is positioned set apart from the manifold plate (604), the valve-stem assembly (102) may be separated from the valve-actuator assembly (610) while the valve-actuator assembly (610) remains connected with a manifold assembly (614).
The stem-replacement operation may include a stem-insertion operation in which while the cavity assembly (702) of the mold assembly (700) is set apart from the manifold plate (604), the valve-stem assembly (102)—that is, a new valve-stem assembly (102)—may be connected to the valve-actuator assembly (610) while the valve-actuator assembly (610) remains connected with the manifold assembly (614).
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According to a first option, the separable stem tip (156) may be configured for selective connection and disconnection with the stem shaft (154), and the separable stem tip (156) has a diameter that may be different from the diameter of the stem shaft (154).
According to a second option, the separable stem tip (156) may be configured for selective connection and disconnection with the stem shaft (154), and the separable stem tip (156) may have a tip geometry that may be different from a geometry of the stem shaft (154). For example, the tip geometry may include (and is not limited to): different tip geometry configured for pressure relief, tapered, and/or round, etc.
According to a third option, the separable stem tip (156) may be configured for selective connection and disconnection with the stem shaft (154), and the separable stem tip (156) may have a thermal conductivity that may be different from the thermal conductivity of the stem shaft (154).
According to a fourth option, the separable stem tip (156) may be configured for selective connection and disconnection with the stem shaft (154), and the separable stem tip (156) may have a physical property that may be different from the physical property of the stem shaft (154), such as, and not limited to: hardness, etc.
According to a fifth option, the stem shaft (154) may be selectively connectable and disconnectable with the valve-actuator assembly (610), and the separable stem tip (156) may be configured for selective connection and disconnection with a stem shaft (154).
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There may be several reasons for changing out the valve stems, such as: (i) it may be required to use different tip diameters, (ii) it may be required to use different tip geometry for pressure relief, tapered, or round, etc, and/or (iii) different stem tip(s) or stem materials may be required, such as higher or lower thermal conductivity, higher or lower hardness, etc.
It will be appreciated that the assemblies and modules described above may be connected with each other as may be required to perform desired functions and tasks that are within the scope of persons of skill in the art to make such combinations and permutations without having to describe each and every one of them in explicit terms. There is no particular assembly, components, or software code that is superior to any of the equivalents available to the art. There is no particular mode of practicing the inventions and/or examples of the invention that is superior to others, so long as the functions may be performed. It is believed that all the crucial aspects of the invention have been provided in this document. It is understood that the scope of the present invention is limited to the scope provided by the independent claim(s), and it is also understood that the scope of the present invention is not limited to: (i) the dependent claims, (ii) the detailed description of the non-limiting embodiments, (iii) the summary, (iv) the abstract, and/or (v) description provided outside of this document (that is, outside of the instant application as filed, as prosecuted, and/or as granted). It is understood, for the purposes of this document, the phrase “includes (and is not limited to)” is equivalent to the word “comprising”. It is noted that the foregoing has outlined the non-limiting embodiments (examples). The description is made for particular non-limiting embodiments (examples). It is understood that the non-limiting embodiments are merely illustrative as examples.
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/US12/21490 | 1/17/2012 | WO | 00 | 6/25/2013 |
| Number | Date | Country | |
|---|---|---|---|
| 61436338 | Jan 2011 | US |
