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.

A foam article, such as a cushioning element for an article of footwear, apparel or sporting equipment is provided that comprises a foam component, such as a midsole, having a number of beneficial physical characteristics. The cushioning element is a low-density foamed component with a surface skin that encases the remaining foam volume. The cushioning element has a number of foam volumes, arranged to achieve a more consistent foam component. Additionally, the cushioning element includes a series of concentric ridges extending radially outwardly from injection gate vestige locations, and a number of striation bands near the perimeter of the cushioning element. The location of the gate vestiges can be beneficially arranged to produce intersecting flow boundaries that are located away from key strain areas of the cushioning element. The cushioning element is more environmentally-friendly, requiring less energy to produce while still providing acceptable energy return and low density.

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 apparatus and method for actuating a valve stem between an open position and a closed position and for taking one or more valve gated nozzle out of service is disclosed. The hot runner includes a valve gated nozzle having a valve stem, the valve stem coupled to a piston that is held against an actuation plate via pressurized air. When a valve stem becomes stuck in a gate of the hot runner, the actuation plate can continue to move while the piston remains stationary. The valve stem may also be protected from an over force situation such as if the valve stem encounters an obstruction as the actuation plate is moving toward the closed position.

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.

Disclosed is a system and a related method for regulating a temperature in a shooting pot associated with an injection molding machine. The structure includes, amongst other things, a cooling circuit and thermocouple proximate a plunger entry end of the shooting pot as well as a cooling adjustment unit for controlling an amount of cooling provided by the cooling fluid. In operation a controller coupled with the cooling adjustment unit and the thermocouple controls the cooling adjustment unit based on a temperature reading associated with the thermocouple.

Physical foaming a footwear component with a single-phase solution of a polymeric composition and a supercritical fluid is provided. The method include temperature conditioning a mold and then engaging the mold with a robot that conveys the mold to a press. At the press a gas counter pressure is applied to a cavity of the mold before injecting a single-phase solution of a polymeric composition and a supercritical fluid into the cavity of the mold. The process continues with releasing the gas counter pressure from the cavity of the mold and then removing the footwear component from the cavity of the mold. The parameters of the method are configured for the formation of the footwear component in an automated manner.

A system including an injector, a press, and a robotic conveyance is used to form a physically foamed article of footwear component from a single-phase solution of a polymeric composition and a supercritical fluid. The parameters and features of the system are configured for the formation of the footwear component in an automated manner with enhanced throughput by the system.

A method for predicting pressures in an injection molding system for molding plastic parts requires providing a mold that has at least one channel with each additional channel having a constant cross-sectional shape along its length and each channel having different thicknesses with a constant cross-sectional shape along its length. At least one first sensor configured to collect pressure data from each channel is provided. At least three second sensors configured to detect the presence of plastic located at known distances downstream of the at least one first sensor. Molten plastic is injected in each of the channels and sensor data is collected for the molten plastic flowing through each channel. A curve is fitted to progressive measured occurrences of pressure at the first sensor when plastic is first detected at each of the second sensors for each channel. Pressure can be predicted for a given flow rate, temperature, and channel thickness at, between, or beyond the measured occurrences.