A molding device for producing a molded module. The molding device has one tool part and one further tool part, which together enclose a cavity. At least one of the tool parts has at least one dividing web arranged and configured to subdivide the cavity into at least a low-pressure sub-cavity and a high-pressure sub-cavity. The tool part has at least two feed channels, of which a low-pressure feed channel opens into the low-pressure sub-cavity and has a smaller cross-section at least over a longitudinal portion than a high-pressure feed channel opening into the high-pressure sub-cavity. The low-pressure feed channel is configured to become pressure-resistantly blocked through hardening of the molding compound once a predetermined time interval has elapsed or during the interval. The high-pressure feed channel is configured to conduct a molding pressure into the cavity for a longer time interval than the low-pressure feed channel.

A hot runner injection molding apparatus, and method of use, is disclosed in which strain gauges are provided in the temperature zones of the hot runner injection molding apparatus and a hot runner controller creates a target strain profile, detects deviations from the target strain profile in any temperature zone based on the strain readings provided by the strain gauges in each temperature zone, and instructs correction of deviations from the target strain profile in any deviating temperature zone by adjusting the heat produced by a heater or heaters in the deviating temperature zone. The target strain profile may be based on a median or average of strain readings provided over time by the strain gauges in each temperature zone. A hollow installation tube for placing the strain gauges in the hot runner injection molding apparatus is also disclosed.

Methods of monitoring and controlling a molding process using a sensed change in strain provided by a strain gauge are provided. A target strain profile is created for a molding process of a molding apparatus. An upper and lower deviation limit from the target strain profile for the molding process is provided. If a sensed change in strain exceeds a deviation limit, an alarm is activated.

A hot runner process controller configured to monitor the status and operation of a hot runner system to autonomously generate information to improve the quality of injection molding process of a hot runner system having an inlet nozzle, one or more manifolds and one or more nozzles with actuator or without actuator, and one or more heating elements, the hot runner process controller is self-operating, and independent from the injection molding machine, includes: one or more sensors located on, in or at the hot runner system to detect the status and/or the operation of the hot runner system, and a processing unit and a memory. The processing unit is connected to the one or more sensors, wherein the memory stores data and program codes. The processing unit is configured to load and execute the program code to compare sensor information with the stored data and to determine if the hot runner system is in an operable status, and in case the hot runner system is in an operable status, configured to generate status information to activate the one or more heating elements and/or the one or more actuators enabling a production operation of the injection molding machine. In case the hot runner system is not in an operable status, configured to generate status information to deactivate the one or more heating elements and/or close or deactivate the one or more actuators disabling a production operation of the injection molding machine.

An injection molding apparatus (10) comprising an actuator (940, 941, 942) comprised of a driver (940dr, 941dr, 942dr) receiving electrical energy or power from an electrical drive (940d, 941d, 942d), the electrical drive (940d, 941d, 942d) comprising an interface that receives and controllably distributes electrical energy or power in controllably varied amounts during the course of an injection cycle to the driver (940dr, 941dr, 942dr), the electrical drive (940d, 941d, 942d) being housed within or by an actuator housing (940h, 941h, 942h) or being mounted on or to the housing (940h, 941h, 942h), the housing (940h, 941h, 942h) and the electrical drive (940d, 941d, 942d) being mounted on, to or in close proximity to the heated manifold (40), a cooling device (940mc, 940mc1, 940mc2, 941mc, 942mc) disposed between the heated manifold (40) and the housing (940h, 941h, 942h) adapted to substantially isolate or insulate at least the electrical drive (940d, 941d, 942d) from substantial communication with heat emanating or emitted from the heated manifold (40).

An injection molding apparatus, comprising: an injection molding machine; a distribution manifold having a distribution channel, a clamp device arranged to clamp together, under a selected clamp force, a mold system having a plurality of mold cavities one or more first downstream channels fluidly coupled to the distribution channel; one or more first gates arranged to deliver injection fluid to a first cavity; one or more second downstream channels fluidly coupled to the distribution channel; one or more second gates arranged to deliver injection fluid to a second cavity; a control system adapted to: instruct the first upstream valve and a second upstream valve; and at least one downstream valve having a valve pin having a control surface for controlling flow of injection fluid.

A sleeve heater for supplying heat to a melt delivery component of a hot runner system. The sleeve heater includes a tube-shaped body having an outer surface and an inner surface. The inner surface of the tube-shaped body defines an opening in which a melt delivery component is received. A heater wraps at least partially around the tube-shaped body and extends along a length of the tube-shaped body. A thermocouple groove is formed in the outer surface of the tube-shaped body. The thermocouple groove includes a lateral bend; and a bore that extends from the lateral bend into a thickness of the tube-shaped body. Together the bore and the latera bend maintain the position of a sensing end of a thermocouple installed therein relative to the tube-shaped body.

A hot runner process controller configured to monitor the status and operation of a hot runner system to autonomously generate information to improve the quality of injection molding process of a hot runner system having an inlet nozzle, one or more manifolds and one or more nozzles with actuator or without actuator, and one or more heating elements, the hot runner process controller is self-operating, and independent from the injection molding machine, includes: one or more sensors located on, in or at the hot runner system to detect the status and/or the operation of the hot runner system, and a processing unit and a memory. The processing unit is connected to the one or more sensors, wherein the memory stores data and program codes. The processing unit is configured to load and execute the program code to compare sensor information with the stored data and to determine if the hot runner system is in an operable status, and in case the hot runner system is in an operable status, configured to generate status information to activate the one or more heating elements and/or the one or more actuators enabling a production operation of the injection molding machine. In case the hot runner system is not in an operable status, configured to generate status information to deactivate the one or more heating elements and/or close or deactivate the one or more actuators disabling a production operation of the injection molding machine.

An injection molding apparatus having a valve pin plate coupling at least one valve pin to an actuator which, in operation, axially moves the valve pin plate between a closed position and an open position. The valve pin is coupled to the valve pin plate via a valve pin coupler. A biasing member is compressed against a support surface by the valve pin holder when the valve pin plate is in the closed position to create a supplementary coupling force coupling the valve pin to the valve pin holder.

An injection molding apparatus having a valve pin plate coupling at least one valve pin to an actuator which, in operation, axially moves the valve pin plate between a closed position and an open position. The valve pin is coupled to the valve pin plate via a valve pin coupler. A biasing member is compressed against a support surface by the valve pin holder when the valve pin plate is in the closed position to create a supplementary coupling force coupling the valve pin to the valve pin holder.