An apparatus for controlling the rate of flow of a fluid mold material comprising: a manifold, an actuator interconnected to a valve pin, a position sensor that senses position of the valve pin, a controller that controls movement of the actuator according to instructions that instruct the actuator to drive the valve pin upstream at one or more selected intermediate velocities in response to receipt by the controller of a signal from the position sensor that the valve pin is disposed in the one or more intermediate upstream gate open positions.

An injection molding system (5) comprised of: a valve (10) comprising an actuator (1000) that includes a linear drive member (150, 154, 158) adapted to travel along a first linear path of travel (L1), a valve pin (80) adapted to travel linearly upstream and downstream within the flow passage (15) between pin upstream (81) and pin downstream (82) positions along a second linear path of travel (L2) that is non-coaxial relative to the first linear path of travel (L1), the actuator (1000) being interconnected to the valve pin (80) in an arrangement wherein movement of the linear drive member (150, 154, 158) along the first linear path of travel (L1) drives the valve pin (80) along the second linear path of travel (L2).

Injection molding system having a flow control apparatus and method that controls the movement and/or rate of movement of a valve pin over the course of an injection cycle to cause the pin to move to one or select positions and/or to control the rate of movement of the pin over the course of the injection cycle. In one embodiment the method includes steps of: a) first controllably operating the actuator to drive the valve pin upstream beginning from the first closed position (50) to be moved to and held in a first selected position (51) for a first selected period of time during the course of an injection cycle, the first selected position (51) being the full open position; b) second controllably operating the actuator to drive the valve pin, during the injection cycle, downstream beginning from the first selected position (51) to be moved to and held in a second closed position (52) for a second selected period of time; c) third controllably operating the actuator to drive the valve pin, during the injection cycle, upstream beginning from the second closed position (52) to be moved to and held in a second selected position (53) for a third selected period of time, the second selected position being an intermediate position or the full open position; and d) fourth controllably operating the actuator to drive the valve pin, during the injection cycle, downstream beginning from the second selected position (53) to be moved to a third closed position (54).

A method and apparatus for performing an injection molding cycle comprising drivably interconnecting a valve pin to an electric motor actuator and controllably operating the electric motor to drive the valve pin at one or more reduced rates of upstream or downstream travel based on either detection of the position of the pin or actuator or on a preselected length of time at which to drive the valve pin.

Injection molding apparatuses and methods wherein a valve pin is controllably driven upstream and downstream along an axis between a first closed position where the tip end of the valve pin obstructs the gate to prevent the injection fluid from flowing into the cavity, a full open position and one or more intermediate positions, wherein the valve pin is drivable to be disposed or held in a selected intermediate position for a selected period of time during the course of an injection cycle where the tip end of the valve pin restricts flow of injection fluid through the gate to the mold cavity.

A system and method for controlling an actuator which actuates an axially displaceable pin valve of an apparatus for injection molding of plastic materials, where the control system includes an electronic control unit of the actuator which adjusts at least one among position, speed and acceleration of the pin valve, and a position sensor which detects a position of a plunger of the actuator and is operatively connected to the electronic control unit. The position sensor indirectly detects the position of the plunger of the actuator.

An apparatus for controlling the rate of flow of fluid mold material comprising: a manifold, a valve pin having a pin axis, a pin connector and a stem, the valve pin being drivable into and out of open and closed positions relative to the gate, an electric actuator comprising an electric motor comprised of a motor housing that houses a drive shaft having a drive gear and a drive axis, a transmission comprised of a transmission gear having a gear axis, the drive gear, the transmission gear and the valve pin being drivably interconnected and arranged such that the drive axis and the gear axis are non-coaxially mounted or disposed relative to each other and the valve pin is drivable linearly along the pin axis, wherein one or the other of the motor housing or the transmission housing are removably attached to a top clamping or mounting plate that is mounted upstream of the manifold and fixedly interconnected to a mold.

Injection molding apparatus (1) comprising:

an actuator (14, 940, 941, 942) comprising a rotor (940r, 941r, 942r) controllably rotatable by electric power, the actuator (14, 940, 941, 942) being interconnected to a controller (16) that generates drive signals (DC),

an electrical drive device (940d, 941d, 942d) comprising an interface that receives the drive signals (DC) and controllably distributes electrical energy or power in controllably varied amounts according to the drive signals (DC) to a driver (940dr, 941dr, 942dr) that drives the rotor (940r, 941r, 942r),

a valve pin (1040, 1041, 1042) having an axis (X) and a control surface (43, 45, 102m) drivable upstream and downstream through a downstream feed channel (17, 19, 160, 940c, 941c, 942c) the downstream feed channel having a complementary surface (47, 103s) adapted to interface with the control surface (43, 45, 102m) upstream and away from the gate.

An apparatus for controlling the rate of flow of fluid mold material comprising: a manifold, a valve pin having a pin axis, a pin connector and a stem, the valve pin being drivable into and out of open and closed positions relative to the gate, an electric actuator comprising an electric motor comprised of a motor housing that houses a drive shaft having a drive gear and a drive axis, a transmission comprised of a transmission gear having a gear axis, the drive gear, the transmission gear and the valve pin being drivably interconnected and arranged such that the drive axis and the gear axis are non-coaxially mounted or disposed relative to each other and the valve pin is drivable linearly along the pin axis, wherein one or the other of the motor housing or the transmission housing are removably attached to a top clamping or mounting plate that is mounted upstream of the manifold and fixedly interconnected to a mold.

An injection molding system (5) comprised of: a valve (10) comprising an actuator (1000) that includes a linear drive member (150, 154, 158) adapted to travel along a first linear path of travel (L1), a valve pin (80) adapted to travel linearly upstream and downstream within the flow passage (15) between pin upstream (81) and pin downstream (82) positions along a second linear path of travel (L2) that is non-coaxial relative to the first linear path of travel (L1), the actuator (1000) being interconnected to the valve pin (80) in an arrangement wherein movement of the linear drive member (150, 154, 158) along the first linear path of travel (L1) drives the valve pin (80) along the second linear path of travel (L2).