METHOD AND APPARATUS FOR BALANCING THE FILLING OF INJECTION MOLDS

Abstract: A method of balancing the flow of a molten polymer containing material in a multi-runner injection mold includes the step of providing a mold body having at least one mold cavity and at least two runners. The first runner (74) includes first and second ends and is connected to a source of molten material. The first runner (74) is connected to a second runner (76). The second runner (76) is connected to the at least one mold cavity. A stream of a molten polymer containing material flows through the first and second runners. The stream is repositioned in a circumferential direction as it flows from the first runner (74) through the second runner (76) while maintaining continuity between laminates of the stream of the molten material in a radial direction. In this way a balance is provided for the melt temperatures and material properties of the cross branching runners. An apparatus for producing molded products having balanced thermal, material and flow properties includes a device for repositioning a stream of the molten polymer containing material as it flows from a first runner (74) into at least a second downstream runner (76). If desired, the stream of the molten thermoplastic material can be repositioned by approximately 90 degrees.

Description: METHOD AND APPARATUS FOR BALANCING THE FILLING OF INJECTION MOLDS Background of Invention This application bases its priority on provisional application Serial No. 60/061,888 filed on October 14, 1997, on provisional application Serial No. 60/081,840 filed on April 15, 1998 and on provisional application Serial No. 60/100,516 filed on September 16, 1998. This invention relates to a method and apparatus for flowing a molten polymer containing material into a multi-runner injection mold. More specifically, the present invention pertains to a method and apparatus for minimizing the flow and thermal imbalances which occur in naturally or geometrically balanced runner systems typically used in injection molding. A conventional mold set for injection molding of polymer containing materials is constructed of high strength metals, usually tool steels having a very high co pressive yield strength. The mold cavity itself is defined by a mold set parting line which opens and closes with each mold cycle. On each side of the parting line is at least one part forming mold insert surface. Often, several spaced mold cavities are defined in the mold. These cavities are connected by runners . In multi-cavity molds, it is important that the melt is delivered to each cavity of the mold at the same time and with the same pressure and temperature. Any variations in these conditions will result in variations in the parts which are produced within these cavities. Such variations can include the size, shape or weight of the product as well as the mechanical properties and cosmetic appearance of the product. To help assure balanced conditions, the length and diameter of the runner feeding each cavity in a multi-cavity mold is preferably kept the same. This usually results in the runners being laid out in either a radial pattern, an "H" pattern, or some combination of a radial and an "H" pattern. With the radial pattern, the melt travels radially outwardly from the point of injection directly feeding a single cavity. Variations of this may branch the end of each runner and feed two or more cavities. With an "H" type pattern, the runner is continually split in two directions. When molding plastic parts using multi-cavity injection molds, it is important that each cavity in the multi-cavity mold produce substantially identical parts. This results in consistent part quality and maximum productivity. In order to provide such a mold, the cavity dimensions must be nearly identical for each of the several cavities and the cooling and delivery of melt to each cavity should be substantially the same. It is, therefore, standard practice in the design of multi-cavity injections molds to "naturally balance" the runner system in order to help provide the required mold filling consistency. In naturally balanced runners, the same cross sectional shape and length of runner feeds each cavity. The same concept of a natural or geometrically balanced runner system may also be applied to multiple runner branches which may be feeding a single part. Most multi-cavity injection molds are designed with a naturally balanced or geometrically balanced runner system in order to minimize variations in the molten thermoplastic flowing into the cavities during production. Despite the geometrical balance, it has often been observed that the filling of molds utilizing these naturally balanced runner designs results in imbalances. In most case, such imbalances do not occur until there are more than four cavities in the mold. However, the imbalance is actually dependent on the number of branches in the runner and can occur in molds with even a single multi-gated cavity, dependent on the layout of the system. It has been found that the parts formed in some of the cavities, usually those directly forward of the sprue, are commonly larger and heavier than are the parts formed in the other cavities. These flow imbalances have historically been attributed to variations in mold temperature and/or mold deflection. Applicant has discovered that there is a flow-induced cavity filling imbalance which exists in many of the most commonly used and accepted "naturally balanced" runner systems such as geometrically balanced "H" and modified "H" patterned runners, especially those with eight or more cavities. Flow imbalance can be created by a non-symmetrical shear distribution within the melt as it travels through the runner system. However, flow imbalance can also be created in a melt channel when a laminar flow material has a non- symmetrical temperature distribution. Both of these non-symmetrical conditions result in variations in the viscosity of the melt and, in some cases, in its structure. In most cases, during conventional molding of thermoplastic and thermosetting materials, this results in a hotter, lower viscosity material around the inner periphery of the flow channel surrounding a relatively cooler, higher viscosity material in the middle of the flow channel. When a branch in the runner occurs, the hotter material along the perimeter remains in its relative outer position while the inner material is split and is now positioned on the opposite side of the flow channel from the hotter material. This side to side variation will create a variation in an upcoming branch or a mold cavity, where the hotter material will flow to one side and the cooler material will flow to the other side. Attention in this regard is directed to the article by Beaumont and Young in the Journal of Injection Molding Technology. September 1997, Volume 1, No. 3 entitled "Mold Filling Imbalances in Geometrically Balanced Runner Systems" (pages 133-143) . This article is incorporated herein by reference in its entirety. The problem has become more evident in recent years as tolerances of plastic parts have become more demanding and attention to quality has increased. The trend toward the use of smaller diameter runners, which it was thought would improve the molding process, has compounded the problem. Attention is also directed to the article by Beaumont, Young and Jaworski entitled "Solving Mold Filling Imbalances in Multi-Cavity Injection Molds" found in the Journal of Injection Molding Technology. June 1998, Volume 2, No.2, pages 47- 58. This article is also incorporated herein by reference in its entirety. The imbalance found in the several mold cavities of a multi-cavity mold can be significant, resulting in mass-volume, flow-rate variations between the cavities of as high as 19-1 in extreme cases. The magnitude of the imbalance is material-dependent as is the sensitivity of the imbalance to process. A variety of different types of thermoplastics, including amorphous and semi-crystalline engineering resins, exhibit mold filling imbalances. While the majority of the description herein will refer to thermoplastic materials, it should be recognized that imbalanced melt conditions can occur in a multi-runner system in which a variety of types of fluid can flow. Such imbalances occur for any fluid exhibiting a) laminar flow and b) viscosity which is affected by shear rate (as with a non-Newtonian fluid) and/or by temperature. Both of these characteristics are typical of thermoplastics, thermosetting materials and many of today's powdered metal and powdered ceramic materials. A polymer carrier is often employed with powdered metals and powdered ceramics. It is the polymer which gives such powdered metal or powdered ceramic materials the same characteristics as plastic materials exhibit in regard to viscosity effects and laminar flow. The traditional methods of balancing flow by restricting high flow runner branches or gates, cannot be expected to provide both a pressure and a thermal balance in the mold. Even if a pressure balance can be achieved, a melt temperature variation between the several cavities remains. Flow diverters have been used to change the flow patterns in molten thermoplastic. One known device of this type is illustrated in U. S. patent No. 5,683,731 of Deardurff et al. This device contains a central flow channel and a plurality of diverters. The device is positioned in a melt stream. Melt from some portion of the inner laminates of the melt stream is fed into a central flow channel and melt from some portion of the outer laminates of the melt stream is fed into a plurality of diverters which are adjacent to the central flow channel. The melts from the two flow paths are later recombined such that the material from each of these flow regions is distributed equally between the plurality of flow channels. However, in Deardurff et al., the inner and outer laminates of the flow channel are separated and recombined. This results in a more complicated and expensive device than what is necessary. Moreover, Deardurff ' s device would not be practical in a runner system which solidifies and is ejected from the molding process during each cycle as the device would become molded into the runner and ejected from the mold. Therefore, Deardurff s device is limited to hot runner applications where the plastic in the runner is not ejected from the mold. In addition, Deardurff s device is relatively complex and requires consideration of the relative sizes and shapes of the central flow channel and the diverter. The sizes and shapes of these channels will dictate a) how much of the outer laminates will be repositioned relative to the central flow channel b) where they will be positioned and c) their distribution relative to each other. Also, any changes in material or process may alter the distribution of the melt between the central and diverter channels. Furthermore, Deardurff s device accomplishes its objective by selectively diverting some portion of the outer laminates and distributing them among a plurality of channels. The disadvantage of this design is its inability to provide a homogenous distribution of the melt stream as the variations in melt conditions are continuous across the melt stream. Achieving a homogenous distribution of melt is difficult with a device which selectively separates the laminates into only two regions, namely the inner and outer regions. Other known diverters are equally disadvantageous. None of these devices is capable of repositioning the laminates in a melt in a circumferential direction while maintaining continuity between the laminates in a radial direction. Additionally, the division of the flow channel into a multitude of flow channels, i.e. the central channel and the several diverter channels in the known devices creates a potentially significant pressure loss—as pressure drop is approximately a function of the radius of a round flow channel to its fourth power—due to the resultant smaller channels or the need to significantly increase the cross section of all the flow channels in order to alleviate the high pressure loss resulting from the smaller flow channels. Accordingly, it has been considered desirable to develop a new and improved process and apparatus for balancing the filling of mold cavities in injection molds which would overcome the foregoing difficulties and others while providing better and more advantageous overall results. Brief Summary of the Invention In accordance with the present invention, a new and improved method is provided for balancing the flow of a molten polymer containing material exhibiting laminar flow in a multi-cavity injection mold. More particularly in accordance with this method, a mold body is provided comprising at least one mold cavity and at least two runners wherein a first runner includes first and second ends and is connected to a source of molten material. The first runner is connected to a second runner. The second runner is connected to the at least one mold cavity. A stream of molten material flows through the first and second runners. The stream of molten material is repositioned in a circumferential direction as it flows from the first runner through the second runner while continuity is maintained between the laminates in a radial direction. In accordance with another embodiment of the present invention, an apparatus is provided for producing molded products having balanced thermal, material and flow properties. More particularly in accordance with this aspect of the invention, the apparatus comprises a mold body and at least one mold cavity defined in the mold body. A first runner is located in the mold body with the first runner having first and second ends wherein the first runner is connected to a source of molten polymer containing material. A second runner is located in the mold body, the second runner being connected to the first runner. The second runner is connected on its respective ends to first and second locations of the at least one mold cavity. A means is provided for rearranging variations in viscosity of a stream of molten polymer containing material as it flows from the first runner into the second and third runners. One advantage of the present invention is the provision of a new and improved method for minimizing mold filling imbalances in multi-runner injection molds. Another advantage of the present invention is the provision of a means for repositioning the laminates of a stream of a molten polymer containing material in a circumferential direction as it flows through a set of runners while maintaining continuity between the laminates in a radial direction to balance the thermal and flow properties of the molten material. Still another advantage of the present invention is the provision of a means for redirecting a molten polymer containing material as it flows through a cold runner in such a way as to align the hot and cold halves of the material travelling through the secondary runner branches with the top and bottom of a new runner branch rather than its left and right sides. Therefore, when the melt is again split at the next branch, the condition of the melt entering each of these branches is the same or nearly the same. At the same time, the runner can be easily removed from the mold after molding. Yet another advantage of the present invention is the provision of a mold construction in which at the end of the primary runner channel, the melt is diverted approximately normal or perpendicular to the plane or planes in which the primary and secondary runners lie. A further advantage of the present invention is the provision of a mold runner system which allows substantially equal filling of each mold cavity in a multi-cavity injection mold or each portion of a single mold cavity fed by a multi-branched runner system. A still further advantage of the present invention is the provision of a "melt flipper" which can be inserted into a runner in a hot runner system in a mold body. The melt flipper repositions the melt flowing in the runner in a circumferential direction by a desired amount (for example by approximately 90 degrees) as it flows through the runner while maintaining continuity between the laminates in a radial direction thereby strategically rearranging the shear or temperature induced variation across the melt. Though there is still a non-symmetrical melt distribution in the downstream runner, the non-symmetry is from top to bottom rather than from left to right. Therefore, when the melt splits left and right at a further runner or at gates into a mold cavity, the melt conditions entering each branch or each gate, will now be approximately the same. Thereby, flow to all the mold cavities or to a multi-gated single cavity will be approximately balanced. A yet further advantage of the present invention is the provision of a means for repositioning a flowing stream of molten polymer containing material which exhibits laminar flow in a circumferential direction as it flows from one runner to the next while maintaining continuity between the laminates in a radial direction. The repositioning means can be employed in both a hot runner system and a cold runner system. Still other benefits and advantages of the invention will become apparent to those skilled in the art upon a reading and understanding of the following detailed specification. Brief Description of the Drawings The invention may take physical form in certain parts and arrangement of parts, preferred embodiments of which will be described in detail in this specification and illustrated in the accompanying drawings which form a part hereof and wherein: Figure 1 is a schematic view of one type of multi- cavity injection mold which includes branching runners; Figure 2 is a schematic view of another type of a multi-cavity injection mold which includes an "H" pattern of runners; Figure 3 is a side elevational view in cross section of adjacent portions of a pair of connected runners showing a means for repositioning a flow of a molten polymer containing material according to a first preferred embodiment of the present invention; Figure 4 is a side elevational view in cross section of adjacent portions of a pair of connected runners according to a second preferred embodiment of the present invention; Figure 5 is a side elevational view in cross section of adjacent portions of a pair of connected runners according to a third preferred embodiment of the present invention; Figure 6 is a side elevational view in cross section of adjacent portions of a pair of connected runners according to a fourth preferred embodiment of the present invention; Figure 7 is a side elevational view in cross section of adjacent portions of a pair of adjacent runners according to a fifth preferred embodiment of the present invention; Figure 8 is a side elevational view in cross section of an intersection between a pair of adjacent runners according to a sixth preferred embodiment of the present invention; Figure 9 is a side elevational view in cross section of adjacent portions of a pair of runners according to a seventh preferred embodiment of the present invention; Figure 10 is a top plan view of a branching runner system employing an angle other than 90 degrees to the primary runner; Figure 11 is a perspective view of a cavity half of an injection mold according to another preferred embodiment of the present invention; Figure 12 is a perspective view of a core half of an injection mold which cooperates with the cavity half of Figure 1; Figure 13 is a top plan view of a pair of adjacent runners and a flow interrupter according to another preferred embodiment of the present invention; Figure 14 is a side elevational view in cross section of the embodiment of Figure 13 ; Figure 15 is a perspective view of a melt flipper according to another preferred embodiment of the present invention; Figure 16 is a front elevational view of the melt flipper of Figure 15 placed in a runner; Figure 17 is a perspective view of a portion of a branching runner thermal and flow balancer according to yet another embodiment of the present invention; Figure 18 is a top plan view of the runner section of Figure 17 ; Figure 19 is a front elevational view of the runner section of Figure 17; Figure 20 is a schematic view of one type of single cavity multi-gated injection mold in which a means for repositining the flow of a molten polymer containing material according to the present invention can be employed; Figure 21 is a schematic view of a two cavity, non- symmetrical mold in which a means for repositioning the flow of a molten polymer containing material according to the present invention can be employed; and, Figure 22 is a schematic top plan view of a pair of melt flippers positioned in a secondary runner according to another embodiment of the present invention. Detailed Description of the Preferred Embodiments While this invention is generally related to a means for rearranging the melt entering a mold cavity by repositioning the melt so as to reduce variations in melt temperature and flow rate, the means for rearranging a melt can also be employed to reduce variations in fill distribution or size as effected from flow through a runner and its branches in a mold. The runners can either be hot runners or cold runners. During injection molding, in a standard two plate eight or more cavity mold, a molten thermoplastic or other polymer containing material in a conventionally geometrically balanced H-type runner system in a mold will cause a separation of high shear melt and low shear melt. This has been described above. However, such variation can take place in runners which exhibit patterns other than the H pattern, such as, for example, a radial pattern or combinations of radial and H patterns . It is not always the case that the hotter material, which is normally near the outer laminates of the flow channel, ends up in cavities which are the closest to the point of injection. The final point of destination relative to the point of injection is dependent on runner layout. Figure l illustrates a four cavity layout where the normally hotter melt ends up in the outer two cavities and the normally cooler melt ends up in the inner two cavities. More specifically, in Figure 1, the molten thermoplastic material initially travels in a mold 10 along a primary runner 12. At the end of the primary runner, the material takes a 90 degree turn and splits in opposite directions as it flows into a secondary runner 14. At the first end of the secondary runner 14, the molten thermoplastic flows into a first tertiary runner 16 which feeds a first mold cavity 18 and a second mold cavity 20. At the second end of the secondary runner, the molten thermoplastic flows into a second tertiary runner 22 which feeds a third cavity 24 and a fourth cavity 26. The layout illustrated in Figure 1 is such that the hotter melt is expected to end up in cavities 18 and 26 which are further from the point of injection than are cavities 20 and 24. Another type of conventional mold is illustrated in Figure 2. This mold 30 includes a primary runner 32 which feeds a secondary runner 34. One end of the secondary runner feeds a first tertiary runner 36 which in turn feeds a pair of fourth order runners 38 and 40. The first fourth order runner 38 feeds first and second mold cavities 42 and 44. The second fourth order runner 40 feeds third and fourth mold cavities 46 and 48. At the other end of the secondary runner 34, it feeds a second tertiary runner 50 which in turn feeds another pair of fourth order runners 52 and 54. A third fourth order runner 52 feeds fifth and sixth mold cavities 56 and 58. A fourth fourth order runner 54 feeds seventh and eighth mold cavities 60 and 62. In each of these cases, the designer is striving to keep the runner lengths and diameters to each cavity substantially the same. The diameters of the runners may change along their lengths but the change needs to be consistent in each of the branches feeding the cavities. This construction provides a geometrical balance to the runner system. During laminar flow, the molten thermoplastic material flowing near the stationary runner walls experiences an increased shear versus that portion of the molten thermoplastic which is travelling in the midstream of the runner channel. During the thermoplastic injection molding process, frictional heating occurs just inside of a thin frozen layer formed as the plastic touches the cold runner surfaces. In ther osetting material, frictional heating occurs closer towards the runner surfaces as the temperature of the mold is generally hotter than the material introduced into the mold. This tends to compound the thermal variation that is created within these outer high friction laminates and the innermost laminates or portions of the molten thermoplastic material. The result of this frictional heating is a relatively high temperature layer which is created near the outermost perimeter of the runner channel. When the melt comes to the end of a runner branch, it is split in two directions. Due to the nature of the laminate flow, the hotter material travelling along the outer laminates will maintain its position to a significant extent along the outer region of the flow channel. This will result in the hotter material flowing along the inside half of the new runner branches. With the branch that goes to the right, the hotter outer laminate on the right side of the runner channel will flow along the wall of the right side of the new branch. The cooler center laminate will go to the opposite left side of the new right turning runner branch. The opposite will happen in the left branch of this runner where the hotter outer laminate of the left side of the runner channel will follow along the wall on the left side of the new branch. The cooler center laminate will flow to the opposite right edge of the new left turning runner channel. The result will be that one half of the runner will be hotter than will the other half. At the end of this runner section, if the runner is again split, i.e. as in Figure 2, the hotter material follows the branch on its side and the cooler material follows the branch on its side. The result is that the material travelling down each of these branches will be of a different temperature. This material may enter directly into the cavity or may continue to be split. Each time the flow is split at a new runner branch, the hotter material follows the inside edge of the new runner branch. The result is that the melt approaching and entering the centermost cavities of a mold with this type of runner system has a hotter melt temperature than the temperature of the material entering the outermost mold cavities. With reference now to Figure 2, mold cavities which would hold the relatively cooler temperature thermoplastic material would be mold cavities 42, 44, 46, 56, 58 and 60. The mold cavities which would hold the relatively hotter thermoplastic would be mold cavities 48 and 62. These mold cavities are in the path of high shear melt. Such variations in temperature will result in variations in the final molded product. In the conditions described above, it is assumed that frictional heating dominates over any cooling of the melt provided by the walls of the mold. The resulting variation in temperature is compounded by the shear thinning of these outer high friction regions due to the non-newtonian characteristics of plastic materials. Such non-newtonian characteristics will also affect viscosity of the melt across the channel. In some cases where frictional heating is not the dominating parameter, as might occur with large runner diameters and slow flow rates, the opposite condition could occur where the outer laminates are cooler than the inner laminates. In either case, there is a likelihood of a variation in melt temperatures, viscosity and/or the flow conditions across the runner channel. To provide a consistent melt to each of the cavities fed by branching runners such as is illustrated in Figures 1 and 2, the melt must be repositioned in a circumferential direction while maintaining continuity between the several laminates in a radial direction. The present invention repositions the fluid laminate in a flow channel in a direction perpendicular to the direction of flow. Such repositioning is relative to the approximate center of the melt stream without requiring the physical separation or repositioning of the relative positions of the laminates—i.e., the laminates from the central region do not move to the outer region of the cross section of the flow channel and vice versa. Instead, the present invention strategically repositions the locations of the laminates across the flow channel such that when they are split at a forward branch in the runner, the melt conditions between the branches are more homogenous. When so repositioned, the viscosity and thermal variation will not be from the left side to the right side of each runner channel, but rather will be from the top to the bottom of each runner channel. The amount of repositioning can vary dependent on the required positioning of the flow laminates to achieve the objective of balancing the melt conditions in a branching runner system or to strategically place the melt laminates within a mold cavity. Several embodiments of a means for repositioning the flow of a molten thermoplastic material according to the present invention will be disclosed hereinafter. With reference now to Figure 3 , a mold including a first mold half 70 and a second mold half 72 is there illustrated. Defined in the first mold half is a primary runner 74. Defined in a second mold half is a secondary runner 76 which overlays one end of the primary runner 74 and extends approximately normal thereto. In this embodiment, the molten thermoplastic travels along the primary runner 74. At the point at which the primary runner would branch, i.e. terminate into a secondary runner, the original channel is terminated. The branching or secondary runner is defined in the second mold half 72 and can either entirely or partially overlap the end of the first channel or runner. The melt is repositioned in the runner by diverting the flow of the melt in a direction approximately normal to the longitudinal axes of the primary and secondary runners. At the end of the primary runner channel 74, the melt is diverted upwardly, in a direction approximately normal or perpendicular to the mold's parting line. After travelling a short distance in this perpendicular direction, the melt enters the secondary runner 76. The secondary runner 76 extends in a direction approximately perpendicular to the primary runner. The flow geometry of Figure 3 will result in the hotter outer laminate being located adjacent the bottom of the secondary runner 76 and the cooler inner laminate being located adjacent the top of the secondary runner. Having the melt travel approximately normal or perpendicular to the plane of the mold parting line prior to entering the intersecting branching runner, effectively rolls the melt entering the secondary runner approximately 90 degrees relative to its previous position in the primary runner. However, in some cases, it may be desirable to reposition the melt by some other angle. This would include the cases where a mold's runner may include more than two branches in the melt delivery system. This could be accomplished in various ways. With reference now to Figure 4, at the end of a primary runner 80 in a first mold half 82, the channels could be angled at some other angle than perpendicular to the plane of the mold's parting line. To this end. Figure 4 shows an end wall 84 having an acute angle rather than a substantially perpendicular wall ending the channel. A secondary runner 86 is positioned in a second mold half 88 and overlies the end wall 84. Alternately, and with reference now to Figure 5, a primary runner 90 is illustrated as being positioned in a first mold half 92 and a secondary runner 94 is illustrated as being located in a second mold half 96. Figure 5 shows an embodiment in which the secondary runner partially overlaps the primary runner. With reference now to Figure 6, a primary runner 100 is illustrated as communicating with a diverter channel 102 which in turn communicates with a secondary runner 104. It is apparent from Figure 6 that an approximately 90 degree repositioning or flip of the molten thermoplastic material is accomplished because a ridge 106 separates the primary runner 100 from the secondary runner 104. Flow of the molten thermoplastic through the diverter channel 102 , which is displaced from the plane of the primary and secondary runners, causes about a 90 degree repositioning of the molten thermoplastic material. In this embodiment, both the primary and secondary runners 100 and 104 are located in the same mold half. With reference now to Figure 7 , an embodiment is disclosed in which there is less than a 90 degree repositioning. In this embodiment, a primary runner 110 communicates with a diverter channel 112 which in turn communicates with a secondary runner 114. However, in this embodiment, a ridge 116 which is defined in the material of the mold half between the primary runner 112 and the secondary runner 114 does not completely separate these two runners. Rather, the ridge 116 is only of approximately half height. This construction results in a less than 90 degree repositioning of the flowing molten plastic. With reference now to Figure 8, an embodiment of the invention is shown in which a primary runner 120 is defined in a bottom half 122 of the mold and a diverter channel 124 is defined in a top half 125 of the mold. A secondary runner 126 is defined in the bottom half mold 122 separated from the primary runner by a ridge 128. Unlike the embodiment of Figure 6, the ridge 128 in Figure 8 has curved shoulders to smooth the flow of the thermoplastic. In addition, the walls of the diverter channel 124 are also curved, unlike the straight line walls in the diverter channel 102 in Figure 6. The flow of the molten thermoplastic is illustrated by the arrows. The repositioning of the stream of molten thermoplastic is by approximately 90 degrees . With reference now to Figure 9 , another embodiment of the present invention is there illustrated. In this embodiment, a primary runner 130 is defined partially in a bottom mold half 132 and partially in a top mold half 134. A diverter channel 135 is defined only in the top mold half 134. A secondary runner 136 is defined only in the bottom mold half 132. The construction is such that only a reduced height ridge 138 is defined between the primary runner 130 and the secondary runner 136. An approximately 90 degree repositioning of the stream of molten thermoplastic material is accomplished as is illustrated by the arrows in Figure 9. By progressively removing material from the hatched surfaces 128 and 138 in Figures 8 and 9 , one can reduce the degree of repositioning of the melt. While in the previous embodiments, the secondary runners are all shown as being disposed approximately perpendicular to the primary runner, this need not always be the case. Figure 10 illustrates a mold 140 in which a primary runner 142 communicates with a pair of branching runners 144 and 146 that are disposed at an angle other than a 90 degree angle. With reference now to Figure 11, a cavity half 150 according to a preferred embodiment of the present invention is there illustrated. Partially defined in this cavity half is a primary runner 152. The primary runner communicates with a secondary runner 154 that is also partially defined in the cavity half 150. Figure 12 illustrates a core half 156 which is adapted to be mounted on the cavity half. Defined in the core half is another portion 158 of the primary runner and another portion 160 of the secondary runner. Also defined in the core half is a protrusion 162 which fits into an indented section 164 of the primary runner 152 defined in the cavity half 150. In this way, a somewhat arching primary runner channel is defined by the core half and the cavity half. The flow of molten thermoplastic will be such that the molten thermoplastic will flow in an arc along the primary runner and approach the secondary runner from below and in a direction approximately normal to both the longitudinal axis of the secondary runner and to the longitudinal axis of the beginning of the primary runner. With reference now to Figure 13 , another preferred embodiment of the present invention is there illustrated. In this embodiment, a primary runner 170 is shown as communicating with the secondary runner 172. The longitudinal axis of the secondary runner is oriented approximately normal to the longitudinal axis of the primary runner. Located at the intersection of the runners is a flow diverter in the form of a pin 174. As is illustrated in Figure 14, the pin does not extend the entire height of the secondary runner. Moreover, the diameter of the pin is smaller than is the diameter of either the primary runner or the secondary runner. The height of the pin and the diameter of the pin are suitably controlled to adjust the flow of the molten thermoplastic around the pin in such a way as to change the direction of the flow path. While a pin 174 is illustrated as the flow diverter, it should be appreciated that flow diverters having other shapes than a pin could also be employed. For example, flow diverters having the shape of an arrowhead or a hexagon could also be employed. Also, flow diverters with varying cross sections can be employed. In other words, a means is provided for diverting the flow of the molten thermoplastic material through the use of an insert or pin which can be placed at the intersection of a pair of runners where it is desirable to reposition the melt. This allows for a repositioning to occur in a typical runner configuration in which the runners are all located in the same plane. As is evident from Figure 14, one mold half 176 of the mold body contains both the primary runner 170 and the secondary runner 172. The pin 174 can be detachably mounted to the mold half 176 at the intersection of the primary and secondary runners. In this way, when a different type of thermoplastic is flowing through the runners, a pin with a different height, a different diameter or a different cross section may be used. The present invention is advantageous even in a situation where there are four cavities such as illustrated in Figure 1, or even less. In each instance, the melt delivered to each cavity will still be balanced even though there may be thermal variations within the melt entering each cavity. What is important to recognize is that the thermal variations in the melt will exist within each cavity and not between the several cavities. If it is desirable that the material entering a cavity be the same from side to side, the melt could be repositioned as it is split in the runner immediately prior to approaching a particular cavity. The imbalance of the flow is most dramatic with many plastic materials that are used for high precision products. As a result, many companies requiring high precision plastic products must limit themselves to a maximum of four cavity molds, or even less. However, with the balanced system illustrated herein, a mold with a larger number of cavities can be used and higher yields can thus be obtained. Therefore, the present invention significantly reduces product costs in the molding process. With reference now to Figure 15, another form a flow diverter or melt flipper 179 is there illustrated. This flow diverter is ribbon-like and includes a first side 180, a second side 182, a first side edge 184 and a second side edge 186. The flow diverter is positioned in a runner 190 as illustrated in Figure 16. The flow diverter has a leading edge 192 and forms a pair of curved surfaces 194 and 196 over which the molten thermpolastic flows. The flow diverter also has a trailing edge 198. With the flow diverter of Figure 15, there is a 90 degree repositioning of a slug of molten thermoplastic material. The flow diverter of Figures 15 and 16 is particularly useful in a hot runner type system in which the molten thermoplastic material in the runner does not solidify between cycles and is not ejected between cycles of molding. The flow diverter 179 would normally be used in a runner after a branch, e.g. from a primary runner to a secondary runner. The flow diverter 179 is made from a relatively thin flat blade (of a conventional metal, for example) which is bent and placed in the melt flow channel such that it divides the flow into two halves. The trailing edge 198, or exit end of the flow diverter is twisted by about 90 degrees in relation to the leading edge. The melt approaching the blade will be split into two "D" shaped flow paths. The twisted blade will cause the melt to be moved. The divided "D" shaped flows are recombined at the trailing edge 198 of the blade. The relative positions of the laminates to each other will remain the same. Only their position along the circumference of the flow channel will have been changed. In the disclosed embodiment, the two halves of the melt are repositioned by approximately 90 degrees. However, for the hot runner system, the flow diverter or melt flipper can reposition the melt by less than 90 degrees, such as, e.g., 70 degrees or more than 90 degrees, such as, e.g., 110 degrees or even 150 degrees, if that is desired. The flow diverter 179 can be employed at an intersection between two runners. However, it would normally be positioned downstream from a branch where the non-desirable melt variations have been created. With reference now to Figure 17, a cold runner type embodiment of a set of flow channels is there illustrated. In this embodiment, a primary runner 200 splits into first and second secondary runners 202 and 204. The geometry of the flow path is such, however, that the substantially circular diameter of the primary runner leads to non-circular beginning portions of the secondary runners. The non-circular flow paths at the outset of the secondary runners causes a repositioning of the molten thermoplastic material which flows from the primary runner to each of the secondary runners. The flowing molten thermoplastic is repositioned by about 90 degrees. It is apparent that in this embodiment, the runners 200, 202 and 204 are defined by mating channel halves in a pair of mold cavity halves 210 and 212. It is also apparent from Figure 17 that a vertically extending wall 214 defines the end of the primary runner 200 and splits the flow of molten thermoplastic into the pair of secondary runners 202 and 204. The non-circular shape of the beginning of the secondary runners 202 and 204 causes a repositioning of the melt in a circumferential direction while maintaining continuity between the laminates of the melt in a radial direction. This creates a similar repositioning as in the hot runner of Figure 16 but in a cold runner system. While the inlets to the secondary runners 202 and 204 are non-circular, once the repositioning has taken place, the secondary runners assume a circular cross section which can then be maintained. It should be apparent that the instant invention is useful not only in situations where there is a multi- cavity mold, but also in situations where there is a many branched runner system which feeds a single central mold cavity. With reference now to Figure 20, another type of conventional mold is there illustrated. This mold 230 is a single cavity multi-runner mold for manufacturing a circular object such as, e.g., a golf ball. The mold includes a primary runner 232, a secondary runner 234 and a pair of tertiary runners 236 and 238 which lead to several gates of a mold cavity 240. Figure 20 also illustrates the path of a high shear melt 246 and a low shear melt 248 which flow into the mold cavity 240. Without the presence of a means for repositioning the molten thermoplastic as it flows through the several runners—such as the means disclosed herein—the circular object being molded will have differing properties depending upon which half, roughly, of the product is examined. In other words, there will be flow resistance in the upper half of the mold and imbalances in the product which is being molded. The magnitude of the flow imbalance is dependent upon which type of thermoplastic material is being molded and the process. Engineering resins, such as PMMA, 33% glass filled PA6/6, PBT and ABS showed the greatest sensitivity to flow imbalance. Polyolefins proved to be the least susceptible to flow imbalances of the materials tested. With reference now also to Figure 21, a two cavity mold 250 is there illustrated with a simple runner system. In this embodiment, flow imbalances in the mold occur because of the non-symmetrical parts which are being molded in the two mold cavities 252 and 254. As a result of the non-symmetrical mold cavities, molten thermoplastic would be subject to differential filling of the two mold cavities 252 and 254 as it flows from a primary runner 256 into a secondary runner 258. Thus, in the absence of a means for repositioning the flowing molten thermoplastic, a first high shear layer 260 is outwardly oriented in the first mold cavity and a second high shear layer 262 is outwardly oriented in a second mold cavity. Lower shear layers 264 and 266 face each other in the two mold cavities. Finally, with reference now to Figure 22, two melt flippers 280 and 282, such as those illustrated, e.g. in Figures 15 and 16, can be positioned in a secondary runner 284 in a hot runner arrangement downstream from a primary runner 286 thereof. In this way, the molten thermoplastic which flows in opposite directions in the secondary runner 284 is rotated by the two melt flippers as it flows either directly into one or more mold cavities or into respective tertiary runners. One can employ more than the pair of melt flippers 280 and 282 illustrated in Figure 22. More specifically, the construction illustrated in Figure 22 would be used in connection with an eight cavity mold, such as is illustrated in Figure 2. The two melt flippers would be employed in the secondary runner 34 on either side of its intersection with the primary runner 32. However, in a sixteen cavity mold, in addition to the two melt flippers mentioned, four more melt flippers are needed. These would be used at the intersections of the next branches. Thus, the number of melt flippers needed is dependent on the number of mold cavities provided in the mold body. The invention has been described with reference to several preferred embodiments. Obviously, modifications and alterations will occur to others upon the reading and understanding of the preceding specification. It is intended that the invention be construed as including all such alterations and modifications insofar as they come within the scope of the appended claims or the equivalents thereof.

Claims: What is claimed: 1. A method of balancing the flow of a molten polymer containing material exhibiting laminar flow in a multi-runner injection mold, comprising the steps of: providing a mold body comprising at least one mold cavity and at least two runners, wherein a first runner includes first and second ends and is connected to a source of a molten material, said first runner being connected to a second runner with said second runner being connected to said at least one mold cavity; flowing a stream of molten material through said first and second runners; and, repositioning the stream of the molten material in a circumferential direction as it flows from the said first runner through said second runner while maintaining continuity between laminates of the stream of the molten material in a radial direction. 2. The method of claim 1 wherein said step of repositioning the molten material comprises the subsidiary step of controlling the degree of repositioning of the molten material. 3. The method of claim 2 wherein the molten material is repositioned by approximately 90 degrees. 4. The method of claim 1 wherein said step of repositioning the molten material comprises the subsidiary step of placing a first flow turning device in one of said first and second runners. 5. The method of claim 4 further comprising the step of providing a third runner which is connected to said first runner and wherein said step of repositioning the molten material comprises the subsidiary step of placing a second flow turning device in one of said second and third runners. 6. The method of claim 1 wherein said step of repositioning the molten material comprises the subsidiary step of moving the molten material away from a longitudinal axis of at least one of said first and second runners. 7. An apparatus for producing molded products having balanced thermal, material and flow properties, the apparatus comprising: a mold body; at least one mold cavity defined in said mold body; a first runner located in said mold body, said first runner having first and second ends, wherein said first runner is connected to a source of molten polymer containing material; a second runner located in said mold body, said second runner being connected to said first runner, said second runner being connected on its respective ends to first and second locations in said at least one mold cavity; and, a means for rearranging variations in viscosity of a stream of molten polymer containing material as it flows from said first runner through said second runner. 8. The apparatus of claim 7 wherein said means for rearranging comprises a first flow turning device located in one of said first and second runners. 9. The apparatus of claim 8 wherein said means for rearranging further comprises a second flow turning device positioned in another of said first and second runners . 10. The apparatus of claim 8 wherein said first flow turning device comprises a body having a diameter which is smaller than a diameter of the runner in which it is placed. 11. The apparatus of claim 10 wherein said body is shorter in height than is a height of the runner in which said pin is placed. 12. The apparatus of claim 8 wherein said flow turning device comprises a planar member including a first edge and a second edge which is oriented at an angle to said first edge, said planar member being positioned in one of said first and second runners such that said first and second edges contact spaced portions of a wall of the runner in which said flow turning device is placed. 13. The apparatus of claim 7 wherein said first runner is located in a first plane and said second runner is located in a second plane which is spaced from said first plane. 14. The apparatus of claim 13 further comprising a third runner and wherein said third runner is located in said first plane and is separated from said first runner by a ridge. 15. A redistributing device for use with melt flows exhibiting a first region having a comparatively high viscosity and a second region having a comparatively low viscosity, the device comprising: a body including a melt flow inlet end and a melt flow outlet end, said body engaging a melt flow channel in an associated mold, the melt flow channel comprising a secondary runner which is positioned downstream from a primary runner; a first wall section of said body for repositioning a first portion of the melt flow and a second wall section of said body for repositioning a second portion of the melt flow; wherein said body defines a separator for separating the melt flow into said first and second portions, wherein the material flowing adjacent said first wall section meets the material flowing adjacent said second wall section when the material emerges from the redistributing device. 16. The device of claim 15 wherein said body together with the melt flow channel defines a somewhat D-shaped first flow channel for the first portion of the melt. 17. The device of claim 16 wherein said body together with the melt flow channel defines a somewhat D-shaped second flow channel for the second portion of the melt. 18. The device of claim 15 wherein peripheral edges of the device contact said melt flow channel to prevent the device from being swept along the melt flow channel as the melt flows. 19. The device of claim 15 wherein two such devices are positioned in a spaced manner in the secondary runner, with both devices being located downstream from an intersection of the primary runner with the secondary runner. 20. The device of claim 15 wherein said first and second wall sections are curved. 21. The device of claim 15 wherein said body is made of a planar sheet of a material resistant to the melt.

Inventors: BEAUMONT JOHN D, BEAUMONT, JOHN, D.
Applicants: PENN STATE RES FOUND, THE PENN STATE RESEARCH FOUNDATION
Application year: 1998
Main classification: B29C45
IPC codes: B29C45