Cooled electric actuator controlled injection

文档序号：1966553 发布日期：2021-12-14 浏览：22次中文

阅读说明：本技术 冷却式电致动器控制的注射 (Cooled electric actuator controlled injection ) 是由 D·汉森 J·赖特 V·加拉蒂 P·萨瓦于 2020-02-25 设计创作，主要内容包括：注塑成型系统(1000)包括：致动器(5),具有由径向壁(20r、20ri、20ro、20roa、20rob、20roc、20rod)和轴向壁(20a、20ai、20aue、20ade)组成的壳体(20),这些壁形成容纳导热腔室流体(CF)的封闭腔室(45)；转子和驱动器,由电能驱动并且通过径向壁和轴向壁被支撑在腔室内,其中径向壁和轴向壁中的一个或多个包括导热材料,并具有布置成与容纳在封闭腔室内的导热流体(CF)导热接触的内表面；致动器管或通道(25),布置在径向壁和轴向壁中的一个或多个内；吸热流体(25f)的源(260),可密封地互连到致动器管或通道(25)。(An injection molding system (1000) includes: an actuator (5) having a housing (20) consisting of radial walls (20r, 20ri, 20ro, 20roa, 20rob, 20roc, 20rod) and axial walls (20a, 20ai, 20aue, 20ade) which form a closed chamber (45) containing a heat conducting Chamber Fluid (CF); a rotor and a driver driven by electrical energy and supported within the chamber by a radial wall and an axial wall, wherein one or more of the radial wall and the axial wall comprises a thermally conductive material and has an inner surface arranged in thermally conductive contact with a thermally Conductive Fluid (CF) contained within the enclosed chamber; an actuator tube or channel (25) disposed within one or more of the radial wall and the axial wall; a source (260) of heat absorbing fluid (25f) sealably interconnected to the actuator tube or channel (25).)

1. An injection molding system (1000) comprising an injection molding machine (500) that injects a flow of injection fluid (400) into a heated manifold (300) that distributes the injection fluid (400) to flow channels that deliver the injection fluid to gates (70) of mold cavities (80), the injection molding system (1000) comprising:

an actuator (5) comprising a rotor (250) having a drive axis (Y) and a driver (100, 200) interconnected to the rotor (250), the driver being adapted to drive the rotor around the drive axis, the driver (100, 200) receiving electrical energy or power generating drive Heat (HT),

the actuator has a housing (20) comprising a radial wall (20r, 20ri, 20ro, 20roa, 20rob, 20roc, 20rod) and an axial wall (20a, 20ai, 20aue, 20ade) forming an enclosed chamber (45) containing a heat transfer Chamber Fluid (CF), the rotor and drive (250, 100, 200) being mounted within the chamber (45) in intimate heat transfer contact with the heat transfer fluid,

the rotor and driver being supported within the chamber (45) by radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade), arranged to drivably rotate the rotor (250) and driver (100, 200) within the chamber (45),

wherein one or more of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) comprise a thermally conductive material and have an inner surface disposed in thermally conductive contact with a thermally Conductive Fluid (CF) contained in the enclosed chamber,

one or more radial or axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) absorb heat from a heat transfer fluid (CF) contained within the chamber (45),

an actuating tube or channel (25) surrounded by and in intimate thermally conductive contact with the thermally conductive material of one or more of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade),

a source (260) of heat absorbing fluid (25f) sealably interconnected to the tube or channel (25), arranged such that the heat absorbing fluid (25f) is directed through the tube or channel (25) in a flow that absorbs heat from one or more thermally conductive walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade),

a valve pin (800) having a pin axis (X) interconnected to the rotor (250) such that the valve pin is controllably drivable along the pin axis (X) and along a linear path of travel (XX).

2. The system of claim 1 wherein the radial walls 20r, 20ri, 20rit, 20ro, 20roa, 20rob, 20roc, 20rod and the axial walls 20a, 20ai, 20aue, 20ade are interconnected to each other to form a separate housing body 20 attachable to and detachable from a housing 120 of a linear travel converter or transmission (15) mounted to the manifold and adapted to convert rotational movement of the rotor (250) about the rotor axis (Y) into linear movement of the valve pin along axis (X, XX).

3. The system of claim 2, wherein the independent housing body (20) is mounted to the manifold (300) by mounting the linear travel converter (15) to the manifold.

4. The system according to all of the preceding claims, wherein the linear travel converter or transmission (15) comprises a rotary to linear or linear to linear conversion or transmission (15), comprising one or more gears, racks, screws or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970), and adapted to convert the rotary motion of the rotor (250) about the rotor axis (Y) into linear motion of the valve pin along an axis (X, XX) that is not coaxial to the rotor axis (Y).

5. The system according to all of the preceding claims, wherein the linearly traveling transducer or actuator housing (120) comprises one or more transducer or actuator walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) composed of a thermally conductive material.

6. The system according to all of the preceding claims, wherein the converter or transmission walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) are mounted to the heating manifold (300), arranged such that manifold heat (300) is transferred to the converter or walls (120r, 120rb, 120rc, 120ri, 120ro, 120 a).

7. System according to all the previous claims, wherein the actuator housing body (20) surrounds or houses the tube or channel (25) independently from the converter or transmission wall (120r, 120rb, 120rc, 120ri, 120ro, 120 a).

8. The system according to all of the preceding claims, wherein the housing (20) of the actuator is mounted in heat conducting communication with the heating manifold (300) such that one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing absorb or transfer manifold heat, the heat absorbing fluid (25f) absorbing manifold heat absorbed or transferred by one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing.

9. System according to all the previous claims, wherein one or more radial or axial walls of the actuator housing:

comprising a first body (20r, 20ri, 20a), said first body (20r, 20ri, 20a) being made of a heat-conducting material, having an inner surface (20ris, 20ais) in intimate heat-conducting contact with a fluid (CF) contained in a chamber,

comprising a second entity (20ro, 20ao), said second entity (20ro, 20ao) being constituted by a heat conductive material, having an inner surface (20rois, 20aois) in intimate heat conductive contact or communication with the heat exchanging surface (20rihcs, 20aihcs) of the first entity (20ri, 20ai), or comprising an intermediate entity, constituted by a heat conductive material, having a second inner surface (20riis, 20aiis) arranged in intimate heat conductive contact or communication with a fluid (CF) contained in the chamber (45).

10. System according to all the previous claims, wherein said first entity (20, 20a0) is constituted by a thermally insulating or non-thermally conductive material and said second entity (20ro, 20ao) is constituted by a highly thermally conductive material.

11. The system of all of the preceding claims further comprising a linear travel converter (15) interconnected between the rotor (250) and the valve pin (800) arranged to convert rotational movement of the rotor into linear movement (XX) of the valve pin (800),

wherein the heating manifold (300) generates manifold heat,

the linearly traveling converter (15) comprising a converter housing (120) comprising one or more converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) of a thermally conductive material, the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) being mounted to the heating manifold (300) arranged such that manifold heat is transferred to the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a),

a converter tube or channel (125) surrounded by and in intimate thermally conductive contact with the thermally conductive material of one or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a),

a source (125F) of heat absorbing fluid sealably interconnected to the converter tube or channel (125), arranged such that the heat absorbing fluid (125F) is directed through the converter tube or channel (125) in a stream that absorbs manifold heat that is transferred to the converter walls.

12. The system of claim 11, wherein one or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) have an outer surface (120aos, 120ros) arranged in heat conducting communication with a heat conducting surface (20aos) of one or more of the radial and axial walls (20r, 20ro, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the actuator (5).

13. The system of claim 11 or 12, wherein one or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) has an inner surface (120ris, 120ais) arranged in heat conducting communication with a linear travel device (127) interconnected between the rotor (250) and the valve pin to convert rotational movement of the rotor into linear movement (XX) of the valve pin (800).

14. The system of claims 11-13, wherein one or more of the converter walls comprises a unitary body (120ro) of thermally conductive material having an inner surface (120rois) in thermally conductive contact with a heat exchange surface (120rihcs) of an intermediate unitary body (120ri) of thermally conductive material having a second inner surface (20riis) disposed in thermally conductive communication with a linear travel means (127) interconnected between the rotor (250) and the valve pin to convert rotational movement of the rotor into linear movement (XX) of the valve pin (800).

15. The system of claims 2-14 wherein the linear travel converter (15) is interconnected between the rotor (250) and the valve pin (800) arranged to convert rotational movement of the rotor (250) into linear movement (XX) of the valve pin (800),

the linear travel converter (15) is mounted in a closed chamber (45) in fluid contact with the heat transfer Chamber (CF)

The actuator housing (20) is mounted in conductive thermal communication with the heating manifold (300) such that manifold heat is absorbed or transferred by one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing,

the heat absorbing fluid (25f) absorbs manifold heat absorbed or transferred by one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing.

16. The system of all of the preceding claims wherein the rotor (250) has a rotor axis (Y) and the valve pin (800) has a travel axis (X, XX), the rotor axis (Y) and the travel axis (X, XX) being coaxial.

17. System according to claims 2-16, wherein the rotor (250) has a rotor axis (Y) and the system comprises a transmission comprising:

one or more gears, racks, screws or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970) adapted to convert rotational movement of the rotor (250) about the rotor axis (Y) into linear movement of the valve pin along an axis (X, XX) that is not coaxial with the rotor axis (Y),

one or more transmission walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) forming an enclosed chamber (55) enclosing one or more of the gears, racks, screws or nuts (16A, 16B, 72, 190, 191, 195, 950, 960, 970),

the one or more transfer device walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) are constructed of a thermally conductive material,

a converter tube or channel (125) surrounded by and in intimate thermally conductive contact with the thermally conductive material of one or more of the actuator walls (120r, 120ro, 120ri, 120a, 120ao, 120ai),

a source (125F) of heat absorbing fluid sealably interconnected to the converter tube or channel (125), arranged such that the heat absorbing fluid (125F) is routed through the converter tube or channel (125) in a flow that absorbs heat absorbed or transferred by one or more transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120 ai).

18. The system according to all of the preceding claims, wherein the actuator housing (20) is removably attached to a top clamp or mounting plate (1002) mounted upstream of the manifold and interconnected to the mold.

19. The system of claims 2-18 wherein the linear travel converter (15) is removably attached to a top clamp or mounting plate (1002) mounted upstream of the manifold and interconnected to the mold.

20. An injection molding system (1000) comprising an injection molding machine (500) that injects a flow of injection fluid (400) into a heated manifold (300) that distributes the injection fluid (400) to flow channels that deliver the injection fluid to gates (70) of mold cavities (80), the injection molding system (1000) further comprising:

an actuator (5) comprising a rotor (250) having a drive axis (Y) and a drive (100, 200) interconnected to the rotor (250), the drive being adapted to drive the rotor around the drive axis (Y),

a linear travel converter (15) interconnected between the rotor (250) and the valve pin (800) arranged to convert rotational movement of the rotor into linear movement (XX) of the valve pin (800),

a heating manifold (300) that generates manifold heat,

converter tubes or channels (125) surrounded by and in intimate thermally conductive contact with the thermally conductive material of one or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a),

21. The system of claim 20, wherein one or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) has an inner surface (120ris, 120ais) disposed in thermally conductive communication with a linear travel device (127) interconnected between the rotor (250) and the valve pin to convert rotational motion of the rotor into linear motion (XX) of the valve pin (800).

22. The system of claims 20-21, wherein one or more of the converter walls comprises a unitary body (120ro) of thermally conductive material having an inner surface (120rois) in thermally conductive contact with a heat exchanging surface (120rihcs) of a central unitary body (120ri) of thermally conductive material having a second inner surface (20riis) disposed in thermally conductive communication with a linear travel means (127) interconnected between the rotor (250) and the valve pin to convert rotational movement of the rotor into linear movement (XX) of the valve pin (800).

23. System according to claims 20-22, wherein the actuator has a housing (20) comprising radial walls (20r, 20ri, 20ro, 20roa, 20rob, 20roc, 20rod) and axial walls (20a, 20ai, 20aue, 20ade) forming a closed chamber (45) containing a heat conducting Chamber Fluid (CF), the rotor and driver (250, 100, 200) being mounted within a chamber (45) in close heat conducting contact with the heat conducting fluid,

said rotor and driver being supported within said chamber by radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade), arranged such that said rotor (250) and driver (100, 200) are drivably rotated within said chamber (45),

wherein one or more of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) comprise a thermally conductive material and have an inner surface arranged in thermally conductive contact with a thermally Conductive Fluid (CF) contained in the closed chamber,

one or more radial or axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) absorb the heat of the heat-Conducting Fluid (CF) contained in said chamber (45),

an actuator tube or channel (25) surrounded by and in intimate thermally conductive contact with the thermally conductive material of one or more of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade),

a source (260) of heat absorbing fluid (25f) sealably interconnected to the tube or channel (25), arranged such that the heat absorbing fluid (25f) is routed through the tube or channel (25) in a flow that absorbs heat from one or more thermally conductive walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20 ade).

24. The system of claims 20-23, wherein one or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) have an outer surface (120aos, 120ros) arranged in heat conducting communication with a heat conducting surface (20ros, 20aos) of one or more of a radial wall and an axial wall (20r, 20ro, 20roa, 20rob, 20roc, 20rod, 20a, 20aue, 20ade) of the actuator (5).

25. The system of claims 20-24 further comprising a transmission comprising one or more gears, racks, screws or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970) adapted to convert rotational motion of the rotor (250) about the rotor axis (Y) into linear motion of the valve pin along an axis (X, XX) that is not coaxial with the rotor axis (Y),

one or more transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) forming an enclosed chamber (55) enclosing one or more of said gears, racks, screws or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970),

one or more actuator walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) are constructed of a thermally conductive material,

a source (125F) of heat absorbing fluid sealably interconnected to the converter tube or channel (125), arranged such that the heat absorbing fluid (125F) is directed through the converter tube or channel (125) in a flow that absorbs heat absorbed or transferred by one or more transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120 ai).

26. The system of claims 20-25 wherein the rotor (250) has a rotor axis (Y) and the valve pin (800) has a travel axis (X, XX), the rotor axis (Y) and the travel axis (X, XX) being coaxial.

27. The system of claims 20-26, wherein the actuator housing (20) is removably attached to a top clamp or mounting plate (1002) mounted upstream of the manifold and interconnected to the mold.

28. The system of claims 20-27 wherein the linear travel converter (15) is removably attached to a top clamp or mounting plate (1002) mounted upstream of the manifold and interconnected to the mold.

29. An injection molding system (1000) comprising an injection molding machine (500) that injects a flow of injection fluid (400) into a heated manifold (300) that distributes the injection fluid (400) to flow channels that deliver the injection fluid to gates (70) of mold cavities (80), the injection molding system (1000) further comprising:

an actuator (5) comprising a rotor (250) having a drive axis (Y) and a drive (100, 200) interconnected to the rotor (250), the drive being adapted to drive the rotor around the drive axis (Y),

-a transmission comprising one or more gears, racks, screws or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970) adapted to convert rotational motion of the rotor (250) about the drive axis (Y) into linear motion of the valve pin along an axis (X, XX) that is not coaxial with the drive axis (Y),

one or more actuator walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) are constructed of a thermally conductive material,

a source (125F) of heat absorbing fluid sealably interconnected to the converter tube or channel (125), arranged such that the heat absorbing fluid (125F) is directed through the converter tube or channel (125) in a flow that absorbs heat absorbed or transferred by one or more transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120 ai).

30. The system of claim 29, wherein one or more of the transmission walls comprises an integral body (120ro) of thermally conductive material having an inner surface (120rois) in thermally conductive contact with a heat exchanging surface (120rihcs) of an intermediate integral body (120ri) of thermally conductive material having a second inner surface (120riis) disposed in thermally conductive communication with the chamber (55).

31. The system of claims 29-30 wherein the actuator has a housing (20) comprising radial walls (20r, 20ri, 20ro, 20roa, 20rob, 20roc, 20rod) and axial walls (20a, 20ai, 20aue, 20ade) forming an enclosed chamber (45) containing a thermally conductive Chamber Fluid (CF), the rotor and driver (250, 100, 200) being mounted within a chamber (45) in intimate thermally conductive contact with the thermally conductive chamber fluid,

wherein one or more of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) comprise a thermally conductive material and have an inner surface arranged in thermally conductive contact with a thermally Conductive Fluid (CF) contained in the closed chamber,

one or more radial or axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) absorb the heat of the heat-Conducting Fluid (CF) contained in said chamber (45),

32. The system of claims 29-31, wherein one or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) have an outer surface (120aos, 120ros) arranged in heat conducting communication with a heat conducting surface (20ros, 20aos) of one or more of a radial wall and an axial wall (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20aue, 20ade) of the actuator (5).

33. The system of claims 29-32 wherein the transmission comprises one or more gears, racks, screws or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970) adapted to convert rotational movement of the rotor (250) about the rotor axis (Y) into linear movement of the valve pin along an axis (X, XX) that is not coaxial with the rotor axis (Y),

one or more of the transfer walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) are constructed of a thermally conductive material,

34. The system of claims 29-33 wherein the rotor (250) has a rotor axis (Y) and the valve pin (800) has a travel axis (X, XX), the rotor axis (Y) and the travel axis (X, XX) being coaxial.

35. The system of claims 29-34 wherein the actuator housing (20) is removably attached to a top clamp or mounting plate (1002) mounted upstream of the manifold and interconnected to the mold.

36. The system of claims 29-35 wherein the linear travel converter (15) is removably attached to a top clamp or mounting plate (1002) mounted upstream of the manifold and interconnected to the mold.

37. An injection molding system (1000) comprising an injection molding machine that injects a flow of injection fluid into a heated manifold that distributes the injection fluid to flow channels that deliver the injection fluid to gates of cavities contained in a mold, the injection molding system comprising:

an actuator comprising an electric drive interconnected with a rotor, the electric drive adapted to receive electrical energy, rotatably drive the rotor about a drive axis and generate electric drive heat, the rotor being interconnected with a valve pin having a pin axis arranged to be driven along the pin axis along a linear path of travel,

the actuator comprising a thermally conductive wall forming a housing removably mounted to one or the other of the manifold and the top clamp plate (1002), the housing mounting the electric drive within an enclosed chamber formed in whole or in part by one or more of the thermally conductive walls, the thermally conductive wall having an inner surface in thermally conductive contact with electrically driven heat generated by the electric drive within the enclosed chamber such that the electrically driven heat is received by the thermally conductive wall,

a cooler comprising a tube or channel formed or contained within or in intimate contact with one or more thermally conductive walls, the tube or channel containing a cooling fluid, the tube or channel being adapted to receive electrically driven heat from the one or more thermally conductive walls and to transfer or conduct the electrically driven heat to the cooling fluid contained within the tube or channel.

38. The system of claim 37, wherein the actuator housing is mounted to and in thermally conductive communication with one or more actuator mounts mounted downstream from or in thermally conductive communication with the heating manifold, the housing having a housing axis and mounted to one or more actuator mounts.

39. The system of claims 37-38, wherein the actuator is mounted in thermal communication with the manifold such that heat generated by the heating manifold is received by a housing of the actuator, the tube or channel being formed or housed within or in contact with one or more thermally conductive walls, the manifold heat received by the one or more thermally conductive walls being arranged to be transferred or conducted to a cooling fluid.

40. The system of claims 37-39, wherein the actuator mount is arranged such that the actuator housing is axially or radially spaced from the manifold.

41. The system of claims 37-40, wherein the cooling fluid is pumped through the tube or channel from a reservoir of cooling fluid where the cooling fluid remains cool relative to an operating temperature of the housing of the actuator.

42. The system of claims 37-41, wherein the housing comprises one or more thermally conductive walls that do not contain a fluid, the thermally conductive walls being mounted in thermally conductive contact with one or more thermally conductive walls in which the tube or channel is formed or contained or in contact with.

43. The system of claims 37-42, wherein the rotor is interconnected with a rotary to linear converter housed within the chamber or disposed outside or outside the chamber.

44. The system of claims 37-43 wherein a downstream end of the rotary to linear transducer is interconnected to an upstream end of a valve pin.

45. The system of claims 37-43 wherein a downstream end of the rotary to linear transducer is interconnected to an upstream end of a linear to linear transducer, the linear to linear transducer having a downstream end that is in turn interconnected to an upstream end of a valve pin.

46. The system of claims 37-45, wherein one or the other of the actuator, the rotary-to-linear converter, and the linear-to-linear converter is removably mounted to the heating manifold.

47. The system of any one of claims 37-46, wherein one or the other of the actuator, the rotary-to-linear converter, and the linear-to-linear converter is removably mounted to a top clamping plate (1002) mounted upstream of the manifold and interconnected to the mold.

48. The system of claims 37-47, further comprising a transmission having a drive shaft driveably rotatable about a transmission axis, the rotor and the drive shaft driveably interconnected and arranged such that the drive axis and the transmission axis are non-coaxially mounted or disposed relative to one another and such that driven rotation of the rotor about the drive axis rotatably drives the drive shaft about the transmission axis.

49. The system of claim 48, wherein the drive shaft is interconnected to an upstream end of a rotary to linear transducer and the valve pin is interconnectable to a downstream end of the rotary to linear transducer,

the interconnection between the rotary to linear converter and the drive shaft is adapted to convert rotation of the drive shaft into linear travel of the travel shaft along a linear travel axis,

the downstream end of the travel shaft is interconnected to the upstream end of the valve pin, arranged such that linear movement of the travel shaft back and forth causes corresponding upstream and downstream movement of the valve pin.

50. The system of claim 49 wherein the downstream end of the travel shaft is interconnected to an upstream end of a linear-to-linear transducer and the downstream end of the linear-to-linear transducer is interconnectable to an upstream end of the valve pin. Alternatively, the downstream end of the travel shaft may be directly interconnected to the upstream end of the valve pin.

51. The system of claims 48-50, wherein the drive shaft and the pin axis are coaxial or non-coaxial.

52. An injection molding system including an injection molding machine that injects a flow of injection fluid to a heated manifold that distributes the injection fluid to flow channels that deliver the injection fluid to gates of mold cavities, the injection molding system comprising:

an actuator comprising an electric motor housed in an actuator housing constructed of an actuator thermally conductive material, the electric motor having a rotor with a drive axis about which the rotor is driven for rotation by electrical energy or power, the rotor being interconnected to a valve pin having a pin axis arranged to be driven along a linear path of travel along the pin axis,

wherein the actuator comprises a transmission comprising a transmission shaft driveably rotatable about a transmission axis,

the rotor and the drive shaft being drivably interconnected and arranged such that the drive axis and the transmission axis are non-coaxially mounted or disposed relative to each other and such that driven rotation of the rotor about the drive axis rotatably drives the transmission shaft about the transmission axis,

the actuator housing is mounted in thermal communication with the electric motor such that, when the rotor is rotatably driven by electrical energy or electricity, the actuator housing receives heat from the electric motor,

the system includes a cooler comprising a tube or housing of relatively cool thermally conductive material adapted to fluid-tightly contain a cooling fluid, the tube or housing being arranged for mounting to the actuator housing, the tube or housing being arranged in thermal communication with the actuator housing or rotor, the cooling fluid receiving heat transferred to the tube or housing by the actuator housing or rotor.

53. An injection molding system (1000) comprising an injection molding machine (500) that injects a flow of injection fluid (400) into a heated manifold (300) that distributes the injection fluid (400) to flow channels that deliver the injection fluid to gates (70) of mold cavities (80), the injection molding system (1000) comprising:

an actuator (5) comprising a rotor (250) having a drive axis (Y) and a driver (100, 200) interconnected to the rotor (250), the driver being adapted to drive the rotor about the drive axis, the driver (100, 200) receiving electrical energy or power to drive the driver (100, 200),

the actuator having a housing (20) comprising radial walls (20r, 20ri, 20ro, 20roa, 20rob, 20roc, 20rod) and axial walls (20a, 20ai, 20aue, 20ade) forming an enclosed chamber (45), the rotor and driver being supported by radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) within an interior space (45s) of the chamber (45), arranged such that the rotor (250) and driver (100, 200) are drivably rotatable within the chamber (45),

wherein one or more of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) comprise a thermally conductive material in thermally conductive contact or heat transfer with heat generated by the manifold (300) or within the closed chamber (45),

a valve pin (800) having a pin axis (X) interconnected to the rotor (250) such that the valve pin is controllably drivable along the pin axis (X) along a linear path of travel (XX).

54. The system of claim 53, wherein one or more radial or axial walls of the actuator housing:

comprising a first body (20r, 20a, 20ri, 20ai) consisting of a heat-conducting material, having an inner surface (20ris, 20ai, 20riis, 20aiis) arranged in close heat-conducting contact with an inner space (45s) of the chamber, and

comprising a second entity (20ro, 20ao) constituted by a heat conductive material, having an inner surface (20rois, 20aois) in close heat conductive contact or communication with the heat exchanging surface (20rihcs, 20aihcs) of the first entity (20ri, 20ai), or constituted by one or more intermediate entities constituted by a heat conductive material, having a second inner surface (20riis, 20aiis) arranged in close heat conductive contact or communication with the inner space (45s) of the chamber (45).

55. System according to claim 54, wherein said actuator tube or channel (25) is provided within said second entity (20ro, 20 ao).

56. System according to claim 54, wherein said first entity (20r, 20a, 20ri, 20ai) is constituted by a heat insulating material and said second entity (20ro, 20a) is constituted by a highly heat conductive material.

57. System according to claim 55, wherein said first entity (20r, 20a, 20ri, 20ai) is constituted by a heat insulating material and said second entity (20ro, 20ao) is constituted by a highly heat conductive material.

58. An injection molding system (1000) comprising an injection molding machine (500) that injects a flow of injection fluid (400) into a heated manifold (300) that distributes the injection fluid (400) to flow channels that deliver the injection fluid to gates (70) of mold cavities (80), the injection molding system (1000) further comprising:

an actuator (5) comprising a rotor (250) having a drive axis (Y) and a drive (100, 200) interconnected to the rotor (250), the drive being adapted to drive the rotor around the drive axis (Y),

a linear travel converter (15) interconnected between the rotor (250) and the valve pin (800) arranged to convert rotational movement of the rotor into linear movement (XX) of the valve pin (800),

a heating manifold (300) that generates manifold heat,

linear-motion transducer (15) comprising a transducer housing (120) comprising one or more transducer walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) forming a transducer chamber (145) comprising:

a first monolithic converter body (120r, 120a, 120ri, 120ai) composed of a thermally conductive material, having an inner surface (120ris, 120ai, 120riis, 120aiis) arranged in close thermally conductive contact with an inner space (145s) of the converter chamber (145), and

comprising a second monolithic converter body (20ro, 20ao) consisting of a thermally conductive material having an inner surface (120rois, 120aois) in close thermally conductive contact or communication with a heat exchanging surface (120rihcs, 120aihcs) of the first monolithic converter body (120ri, 120ai), or comprising one or more intermediate monolithic converter bodies consisting of a thermally conductive material.

59. The system of claim 58, wherein the actuator tube or channel (125) is disposed within the second entirety (120ro, 120 ao).

60. The system of claim 58, wherein the first unitary converter body (120r, 120a, 120ri, 120ai) is constructed of a thermally insulating material and the second unitary converter body (120ro, 120ao) is constructed of a highly thermally conductive material.

61. A method of performing an injection molding cycle comprising operating the system of any of claims 1-60.

Background

Injection molding systems have been developed for performing injection molding cycles controlled by electric motor actuators. The motor actuator is not actively cooled but only passively.

Disclosure of Invention

According to the present invention, there is provided an injection molding system (1000) comprising an injection molding machine (500) that injects a flow of injection fluid (400) to a heated manifold (300) that distributes the injection fluid (400) to flow channels that deliver the injection fluid to gates (70) of a mold cavity (80), the injection molding system (1000) comprising:

an actuator (5) comprising a rotor (250) having a drive axis (Y), and a driver (100, 200) interconnected to the rotor (250) adapted to drive the rotor about the drive axis, the driver (100, 200) receiving electrical energy or power for driving the driver (100, 200),

the actuator has a housing (20) comprising radial walls (20r, 20ri, 20ro, 20roa, 20rob, 20roc, 20rod) and axial walls (20a, 20ai, 20aue, 20ade) forming a closed chamber (45), by means of which radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) the rotor and the driver are supported in an inner space (45s) of the chamber (45), in such a way that the rotor (250) and the driver (100, 200) can be driven in rotation in the chamber (45),

wherein one or more of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) comprise a thermally conductive material in thermally conductive contact or communication with heat generated by the manifold (300) or within the enclosed chamber (45),

a source (260) of endothermic fluid (25f) is arranged sealably interconnected to the tube or channel (25) such that a stream of endothermic fluid (25f) is directed through the tube or channel (25), the stream having one or more thermally conductive walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) absorbing heat,

a valve pin (800) having a pin axis (X) interconnected to the rotor (250) such that the valve pin is controllably drivable along the pin axis (X) along a linear path of travel (XX).

In such a system, one or more of the radial wall or the axial wall of the actuator housing (20) can:

comprising a first body (20, 20a, 20r, 20a) made of a heat-conducting material, having an inner surface (20ris, 20ais, 20riis, 20ais) arranged in close heat-conducting contact with an inner space (45s) of the chamber, and,

comprising a second entity (20ro, 20ao) of a heat conducting material having an inner surface (20rois, 20aos) in close heat conducting contact or communication with the heat exchanging surface (20rihcs, 20aihcs) of the first entity (20ri, 20ai), or comprising one or more intermediate entities of a heat conducting material having a second inner surface (20riis, 20aiis) arranged in close heat conducting contact or communication with the inner space (45s) of the chamber (45).

In such systems, the actuator tube or channel (25) is typically disposed within the second entity (20ro, 20 ao).

In such a system, the first entity (20, 20a, 20ri, 20ai) is generally constituted by a heat insulating material, while the second entity (20ro, 20ao) is generally constituted by a highly heat conductive material.

an actuator (5) comprising a rotor (250) having a drive axis (Y) and a driver (100, 200) interconnected with the rotor (250) adapted to drive the rotor about the drive axis, the driver receiving electrical energy or power producing drive heat,

the actuator has a housing (20) comprising radial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod) and axial walls (20a, 20ai, 20aue, 20ade) forming an enclosed chamber (45) containing a heat conducting Chamber Fluid (CF), the rotor and driver (250, 100, 200) being mounted within the chamber (45) in intimate heat conducting contact with said heat conducting fluid,

the rotor and the driver being supported within the chamber by radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade), arranged such that the rotor (250) and the driver (100, 200) can drivingly rotate within the chamber (45),

one or more radial or axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) absorb heat from a heat transfer fluid (CF) contained in the chamber (45),

a source (260) of endothermic fluid (25f) is arranged sealably interconnected to the tube or channel (25) such that the endothermic fluid (25f) is conducted through the tube or channel (25) in the form of a flow that absorbs heat from one or more thermally conductive walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade),

a valve pin (800) having a pin axis (X) interconnected to the rotor (250) such that the valve pin is controllably driven along the pin axis (X) along a linear path of travel (XX).

The radial walls 20r, 20ri, 20rit, 20ro, 20roa, 20rob, 20roc, 20rod and the axial walls 20a, 20ai, 20aue, 20ade are typically interconnected to each other to form a separate housing body 20 that is attachable to and detachable from the housing 120 of a linear travel converter or transmission 15 mounted to the manifold and adapted to convert rotational movement of the rotor (250) about the rotor axis (Y) into linear movement of the valve pins along the axis (X, XX). The independent housing body 20is mounted to the manifold via mounting the linear travel converter 15 to the manifold. The linear travel converter or transmission 15 generally comprises a rotary to linear or linear to linear conversion or transmission 15 comprising one or more gears, racks, screws or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970) adapted to convert rotary motion of the rotor (250) about the rotor axis (Y) into linear motion of the valve pin along an axis (X, XX) that is not coaxial with the rotor axis (Y). The housing 120 of the linearly traveling transducer or actuator generally includes one or more transducer or actuator walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) constructed of a thermally conductive material. The converter or transmission walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) are typically mounted to a heating manifold (300), arranged such that manifold heat 300 is transferred to the converter or walls (120r, 120rb, 120rc, 120ri, 120ro, 120 a).

The actuator housing body 20 generally surrounds or houses a tube or channel (25) that is independent of the transducer or actuator walls 120r, 120rb, 120rc, 120ri, 120ro, 120 a.

Such a system may further include a heating manifold (300) generating manifold heat, the housing (20) of the actuator being mounted in conductive thermal communication with the heating manifold (300) such that one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing absorb or transfer the manifold heat.

One or more radial or axial walls of the actuator housing may:

comprising a first body (20r, 20ri, 20a,) made of a heat-conducting material, having an inner surface (20ris, 20ais) arranged in close heat-conducting contact with a fluid (CF) contained in the chamber, or,

comprising a second entity (20ro, 20ao) made of a heat-conducting material having an inner surface (20rois, 20aois) in close heat-conducting contact or communication with the heat exchange surface (20rihcs, 20aihcs) of the first entity (20ri, 20ai), or an intermediate entity made of a heat-conducting material having a second inner surface (20riis, 20aiis) arranged in close heat-conducting contact or communication with the fluid (CF) contained in the chamber (45).

In such a system, the first entity (20ro, 20a0) is generally constructed of a thermally or thermally non-conductive material, while the second entity (20ro, 20ao) is generally constructed of a highly thermally conductive material.

The system may further comprise a linear travel converter (15) interconnected between the rotor (250) and the valve pin (800), arranged to convert rotational movement of the rotor into linear movement (XX) of the valve pin (800),

a heating manifold (300) that generates manifold heat,

the linearly traveling converter (15) comprises a converter housing (120) comprising one or more converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) composed of a thermally conductive material, which converter walls are mounted to a heating manifold (300), arranged such that the manifold heat is transferred to the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a),

a source (125F) of heat absorbing fluid is sealably interconnected to the converter tube or channel (125), arranged such that the heat absorbing fluid (125F) is directed in a stream through the converter tube or channel (125) to absorb manifold heat transferred to the converter walls.

In such a system, one or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) typically have an outer surface (120aos, 120ros) arranged in heat conducting communication with the heat conducting surface (20aos) of one or more of the radial and axial walls (20r, 20ro, 20roa, 20rob, 20roc, 20rod, 20a, 20aue, 20ade) of the actuator (5).

In such a system, one or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) may have an inner surface (120ris, 120ais) disposed in thermally conductive communication with a linear travel device (127) interconnected between the rotor (250) and the valve pin to convert rotational movement of the rotor into linear movement (XX) of the valve pin (800)

One or more of the converter walls may comprise an integral body (120ro) of thermally conductive material having an inner surface (120rois) in thermally conductive contact with a heat exchanging surface (120rihcs) of an intermediate integral body (120ri) of thermally conductive material having a second inner surface (120riis) arranged in thermally conductive communication with a linear travel means (127) interconnected between the rotor (250) and the valve pin to convert the rotational movement of the rotor into a linear movement (XX) of the valve pin (800).

The system may further comprise a linear travel converter (15) interconnected between the rotor (250) and the valve pin (800) arranged to convert rotational movement of the rotor (250) into linear movement (XX) of the valve pin (800),

the linear travel transducer (15) is mounted within the enclosed chamber (45) in fluid (CF) contact with the heat conducting chamber

The housing (20) of the actuator is mounted in conductive thermal communication with the heating manifold (300) such that one or more radial and axial walls (20r, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing absorb or transfer manifold heat,

the heat absorbing fluid (25f) absorbs manifold heat absorbed or transferred by one or more of the radial and axial walls (20r, 20ro, 20r, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing.

In such a system, the rotor 250 has a rotor axis (Y) and the valve pin (800) has a travel axis (X, XX), the rotor axis (Y) and the travel axis (X, XX) may be coaxial.

In such a system, the rotor (250) has a rotor axis (Y), and the system may comprise a transmission comprising:

one or more transmission walls (120r, 120a, 120ao, 120ai) forming an enclosed chamber (55) enclosing one or more of the gears, racks, screws or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970),

one or more actuator walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) are constructed of a thermally conductive material,

a source (125F) of endothermic fluid is sealably interconnected to the converter tube or passage (125) arranged such that the endothermic fluid (125F) is directed through the converter tube or passage (125) in a flow manner to absorb heat absorbed or transferred by the one or more transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120 ai).

The actuator housing (20) is typically removably attached to a mounting plate (1002) mounted upstream of the manifold and interconnected to the mold top clamp or mounting plate.

A linear travel converter (15) is removably attached to a mounting plate (1002) mounted upstream of the manifold and interconnected to the mold top clamp or mounting plate.

In another aspect of the invention, an injection molding system (1000) is provided, the injection molding system comprising an injection molding machine (500) that injects a flow of injection fluid into a heated manifold (300) that distributes the injection fluid (400) to flow channels that deliver the injection fluid to gates (70) of mold cavities (80), the injection molding system (1000) further comprising:

an actuator (5) comprising a rotor (250) having a drive axis (Y), and a driver (100, 200) interconnected with the rotor (250) and adapted to drive the rotor about the drive axis (Y),

a linear travel converter (15) interconnected between the rotor (250) and the valve pin (800) arranged to convert rotational movement of the rotor into linear movement (XX) of the valve pin (800),

a heating manifold (300) that generates manifold heat,

linear travel converter (15) comprising a converter housing (120) comprising one or more converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) of a thermally conductive material, the converter walls being mounted to a heated manifold (300), arranged such that manifold heat is transferred to the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a),

In such a system, one or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) may have an inner surface (120ris, 120ais) disposed in thermally conductive communication with a linear travel device (127) interconnected between the rotor (250) and the valve pin to convert rotational motion of the rotor into linear motion (XX) of the valve pin (800).

In such a system, one or more of the converter walls may comprise an integral body (120ro) of thermally conductive material having an inner surface (120ros) in thermally conductive contact with a heat exchanging surface (120rihcs) of an intermediate integral body (120ri), the intermediate integral body (120ri) being of thermally conductive material and having a second inner surface (20riis) arranged in thermally conductive communication with a linear travel device (127) interconnected between the rotor (250) and the valve pin to convert rotational movement of the rotor into linear movement (XX) of the valve pin (800).

In such a system, the actuator may have a housing (20) comprising radial walls (20r, 20ri, 20ro, 20roa, 20rob, 20roc, 20rod) and axial walls (20a, 20ai, 20aue, 20ade) forming a closed chamber (45) containing a heat conducting Chamber Fluid (CF), the rotor and driver (250, 100, 200) being mounted within the chamber (45) in intimate heat conducting contact with the heat conducting fluid,

one or more radial or axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) absorb heat from a heat transfer fluid (CF) contained within the chamber (45),

a source (260) of endothermic fluid (25f) is sealably interconnected to the tube or channel (25), arranged such that the endothermic fluid (25f) is directed through the tube or channel (25) in a flow that absorbs heat from one or more thermally conductive walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20 ade).

In such a system, one or more of the translator walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) may have an outer surface (120aos, 120ros) arranged in heat conducting communication with a heat conducting surface (20ros, 20aos) of one or more of the radial and axial walls (20r, 20ro, 20roa, 20rob, 20roc, 20rod, 20a, 20aue, 20ade) of the actuator (5).

Such a system may further comprise a transmission comprising

One or more gears, racks, screws or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970) adapted to convert rotational movement of the rotor (250) about the rotor axis (Y) into linear movement of the valve pin along an axis (X, XX) that is not coaxial with the rotor axis (Y),

one or more transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) forming an enclosed chamber (55) enclosing one or more of the gears, racks, screws or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970),

one or more actuator walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) are constructed of a thermally conductive material,

a source (125F) of endothermic fluid is sealably interconnected to the converter tube or channel (125), arranged such that a flow of endothermic fluid (125F) is directed through the converter tube or channel (125), which flow absorbs heat absorbed or transferred by one or more of the transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120 ai).

In such a system, the rotor (250) has a rotor axis (Y) and the valve pin (800) has a travel axis (X, XX), the rotor axis (Y) and the travel axis (X, XX) may be coaxial.

An actuator housing (20) is removably attached to a top clamp or mounting plate (1002) mounted upstream of the manifold and interconnected to the mold.

The linear travel converter (15) is removably attached to a top clamp or mounting plate (1002) mounted upstream of the manifold and interconnected with the mold.

In another aspect of the invention, an injection molding system (1000) is provided, the injection molding system comprising an injection molding machine (500) that injects a flow of injection fluid (400) into a heated manifold (300) that distributes the injection fluid (400) to flow channels that deliver the injection fluid to gates (70) of mold cavities (80), the injection molding system (1000) further comprising:

an actuator (5) comprising a rotor (250) having a drive axis (Y), and a driver (100, 200) interconnected with the rotor (250) and adapted to drive the rotor about the drive axis (Y),

transmission means comprising one or more gears, racks, screws or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970) adapted to convert rotary motion of the rotor (250) about the drive axis (Y) into linear motion of the valve pin along a shaft (X, XX) that is not coaxial with the drive axis (Y),

one or more transmission walls (120r, 120a, 120ao, 120ai) forming an enclosed chamber (55) enclosing one or more of the gears, racks, screws or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970),

one or more actuator walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) are constructed of a thermally conductive material,

a source (125F) of endothermic fluid is sealably interconnected to the converter tube or passage (125), arranged such that the endothermic fluid (125F) is directed through the converter tube or passage (125) in a flow that absorbs heat absorbed or transferred by the one or more transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120 ai).

In such a system, one or more of the transmission walls may include an integral body (120ro) of thermally conductive material having an inner surface (120rois) in thermally conductive contact with a heat exchange surface (120rihcs) of an intermediate integral body (120ri) of thermally conductive material having a second inner surface (120riis) disposed in thermally conductive communication with the chamber (55).

In such a system, the actuator may have a housing (20) consisting of radial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod) and axial walls (20a, 20ai, 20aue, 20ade) forming a closed chamber (45) containing a heat conducting Chamber Fluid (CF), the rotor and driver (250, 100, 200) being mounted within the chamber (45) in intimate heat conducting contact with the heat conducting fluid,

one or more radial or axial walls (20r, 20ro, 20r1, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) absorb heat from a heat transfer fluid (CF) contained within the chamber (45),

In such a system, one or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) may have an outer surface (120aos, 120ros) arranged in heat conducting communication with the heat conducting and exchanging surface (20ros, 20aos) of one or more of the radial and axial walls (20r, 20ro, 20roa, 20rob, 20roc, 20rod, 20a, 20aue, 20ade) of the actuator (5).

Such a system may further comprise a transmission comprising one or more gears, racks, screws or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970) adapted to convert rotational movement of the rotor (250) about the rotor axis (Y) into linear movement of the valve pin along an axis (X, XX) that is not coaxial with the rotor axis (Y),

one or more transmission walls (120r, 120a, 120ao, 120ai) forming an enclosed chamber (55) enclosing one or more of the gears, racks, screws or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970),

one or more actuator walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) are constructed of a thermally conductive material,

The rotor (250) has a rotor axis (Y) and the valve pin (800) has a travel axis (X, XX), which may be coaxial with the travel axis (X, XX).

An actuator housing (20) is removably attached to a top clamp or mounting plate (1002) mounted upstream of the manifold and interconnected to the mold.

The linear travel converter (15) is removably attached to a top clamp or mounting plate (1002) mounted upstream of the manifold and interconnected with the mold.

In another aspect of the present invention, there is provided an injection molding system including an injection molding machine that injects a flow of injection fluid to a heated manifold that distributes the injection fluid to flow channels that deliver the injection fluid to gates of cavities contained in a mold, the injection molding system comprising:

an actuator comprising an electric drive interconnected to a rotor, the electric drive adapted to receive electrical energy, drive the rotor to rotate about a drive axis and generate electric drive heat, the rotor arranged to be interconnected to a valve pin having a pin axis, wherein the valve pin is driven along a linear path of travel along the pin axis,

the actuator includes a thermally conductive wall forming a housing removably mounted to one or the other of the manifold and the top clamping plate (1002), the housing mounting the electric drive within an enclosed chamber formed by all or one or more of the thermally conductive wall, the thermally conductive wall having an inner surface in thermal contact with an electrically driven thermal conductor generated by the electric drive within the enclosed chamber such that the electrically driven thermal conductor is received by the thermally conductive wall,

In such systems, the actuator housing is typically mounted to and in conductive thermal communication with one or more actuator mounts mounted downstream of or in conductive thermal communication with a heating manifold, the housing having a housing shaft and being mounted to the one or more actuator mounts such that

The actuator may be mounted in thermal communication with the manifold such that heat generated by the heating manifold is received by a housing of the actuator, the tube or channel being arranged to be formed or housed within or in contact with the one or more thermally conductive walls, wherein manifold heat received by the one or more thermally conductive walls is transferred or conducted to the cooling fluid.

The actuator is typically mounted in an arrangement in which the actuator housings are axially or radially spaced apart

Cooling fluid is typically pumped through the tubes or channels from a reservoir of cooling fluid, wherein the cooling fluid remains cool relative to the operating temperature of the housing of the actuator.

The housing may comprise one or more fluid-free thermally conductive walls mounted in thermally conductive contact with the one or more thermally conductive walls, the tube or channel being formed in or received in or in contact with the thermally conductive walls.

The rotor may be interconnected to a rotary to linear converter that may be housed within the chamber or disposed outside or outside the chamber.

The downstream end of the rotary to linear transducer may be interconnected with the upstream end of the valve pin. Alternatively, the downstream end of the rotary to linear transducer may be interconnected with an upstream end of a linear to linear transducer having a downstream end which in turn is interconnected with an upstream end of the valve pin.

One or the other of the actuator, the rotary-to-linear converter, and the linear-to-linear converter is removably mounted to the heating manifold.

One or the other of the actuator, the rotary-to-linear converter, and the linear-to-linear converter is removably mounted to a top clamping plate (1002) that is mounted upstream of the manifold and interconnected with the mold.

The system may comprise a transmission comprising a drive shaft drivingly rotatable about a transmission axis, the rotor and the drive shaft being drivably interconnected and arranged such that the drive axis and the transmission axis are non-coaxially mounted or disposed relative to one another and such that driven rotation of the rotor about the drive axis drives rotation of the drive shaft about the transmission axis.

The drive shaft may be interconnected to an upstream end of the rotary-to-linear converter, and the valve pin may be interconnected to a downstream end of the rotary-to-linear converter,

the interconnection between the rotary to linear converter and the drive shaft is adapted to convert rotation of the drive shaft into linear travel of the travel shaft along a linear travel axis,

the downstream end of the travel shaft is interconnected with the upstream end of the valve pin and is arranged such that forward and rearward linear movement of the travel shaft results in corresponding upstream and downstream movement of the valve pin.

A downstream end of the travel shaft may be interconnected with an upstream end of the linear-to-linear transducer, and a downstream end of the linear-to-linear transducer may be interconnected with an upstream end of the valve pin. Alternatively, the downstream end of the travel shaft may be directly interconnected with the upstream end of the valve pin.

The transmission axis and pin axis may be coaxial or non-coaxial.

In another aspect of the present invention, there is provided an injection molding system including an injection molding machine that injects a flow of injection fluid to a heated manifold that distributes the injection fluid to flow channels that deliver the injection fluid to gates of mold cavities, the injection molding system comprising:

an actuator comprising an electric motor housed in an actuator housing constructed of a thermally conductive material of the actuator, the electric motor having a rotor with a drive axis, the rotor being driven about the drive axis by electrical energy or power, the rotor being arranged to be interconnected to a valve pin having a pin axis, wherein the valve pin is driven along a linear path of travel of the pin axis,

wherein the actuator comprises a transmission comprising a transmission shaft driveably rotatable about a transmission axis,

the rotor and the drive shaft are drivably interconnected and arranged such that the drive axis and the transmission axis are non-coaxially mounted or disposed relative to each other, and such that driven rotation of the rotor about the drive axis drives rotation of the drive shaft about the transmission axis,

the system includes a cooler comprising a tube or housing constructed of a cooler thermally conductive material adapted to fluid-tightly contain a cooling fluid, the tube or housing mounted to the actuator housing and arranged with the tube or housing in thermal communication with the actuator housing or rotor, the cooling fluid receiving heat transferred to the tube or housing through the actuator housing or rotor.

In another aspect of the invention, an injection molding system (1000) is provided, the injection molding system comprising an injection molding machine (500) that injects a flow of injection fluid (400) into a heated manifold (300) that distributes the injection fluid (400) to flow channels that deliver the injection fluid to gates (70) of mold cavities (80), the injection molding system (1000) further comprising:

an actuator (5) comprising a rotor (250) having a drive axis (Y), and a driver (100, 200) interconnected with the rotor (250) adapted to drive the rotor about the drive axis (Y),

a linear travel converter (15) interconnected between the rotor (250) and the valve pin (800) arranged to convert rotational movement of the rotor into linear movement (XX) of the valve pin (800),

a heating manifold (300) that generates manifold heat,

linear-motion transducer (15) comprising a transducer housing (120) comprising one or more transducer walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) forming a transducer chamber (145) comprising:

the first monolithic converter body (120r, 120a, 120ri, 120ai) is constructed of a thermally conductive material, has an inner surface (120ris, 120ais, 120riis, 120aiis) arranged in close thermally conductive contact with an inner space (145s) of the converter chamber (145), and,

and a second unitary converter body (20ro, 20ao) constructed of a thermally conductive material having an inner surface (120rois, 120aois) in intimate thermally conductive contact or communication with the heat exchange surfaces (120rihcs, 120aihcs) of the first unitary converter body (120ri, 120ai) or one or more intermediate unitary converter bodies constructed of a thermally conductive material.

In such a system, the actuator tube or channel (125) is preferably disposed within the second entity (120ro, 120 ao).

In such a system, the first unitary converter body (120r, 120a, 120ri, 120ai) is preferably constructed of a thermally insulating material, while the second unitary converter body (120ro, 120ao) is preferably constructed of a highly thermally conductive material.

In another aspect of the present invention, a method of performing an injection molding cycle is provided that includes operating a system according to any of the systems described or disclosed herein.

Drawings

FIG. 1 is an upper left perspective view of an injection molding system showing an electrical actuator having a distal housing component with active cooling channels incorporated into the body of the housing component, where the housing component is in thermal contact with an enclosed interior drive chamber of the actuator.

Fig. 2 is a side sectional view of the system of fig. 1.

FIG. 3 is a top rear left perspective view of an injection molding system similar to the system of FIG. 1, showing a specific configuration of a distal end housing a cooling component, wherein the specific configuration of the active cooling channels are incorporated into the body of the component.

FIG. 4 is a cross-sectional end view of the system of FIG. 3 taken along line 4-4 showing details of the distal cooling housing component.

FIG. 5 is a side cross-sectional view of the injection molding system of FIG. 3 showing details of the rotor and driver, stator and armature, components, and their mounting within the actuator housing.

FIG. 6 is an upper left rear perspective view of an injection molding system similar to the system of FIGS. 1 and 3, except that a housing cooling component is provided and extends along a bottom radial wall of the housing, with actively-cooled cooling channels disposed within the radial wall.

Fig. 7 is a side sectional view of the system of fig. 6 taken along line 7-7 of fig. 6.

FIG. 8 is a top left rear perspective view of an injection molding system similar to the system of FIGS. 1 and 3, except that a housing cooling component is provided and extends along a pair of opposite side radial walls of the housing, with actively-cooled cooling channels provided in the side radial walls.

Fig. 9 is a cross-sectional view taken along line 9-9 of fig. 8.

Fig. 10 is a cross-sectional view taken along line 10-10 of fig. 8.

Fig. 11 is a top front perspective view of an injection molding system similar to the system of fig. 1,3, except that a housing cooling component is provided and extends along a bottom radial wall member that extends along a bottom radial wall of a rotary to linear translator device that is interconnected to an electric actuator element, the bottom radial wall containing actively cooled cooling channels.

Fig. 12 is a side sectional view taken along line 12-12 of fig. 11.

FIG. 13 is a view similar to FIG. 12 showing a cross-section of another portion of the cooling gallery contained in the radial bottom wall.

FIG. 14 is a top rear perspective view of an injection molding system similar to the system of FIGS. 1 and 3, except that a housing cooling component is provided and extends along opposite radial side walls and radial bottom and top walls of the actuator housing, with all of the walls containing actively-cooled cooling channels.

FIG. 15 is an exploded perspective view of an actuator housing of the system of FIG. 14.

Fig. 16 is a side cross-sectional view of the system of fig. 14.

FIG. 17 is an assembled perspective view of the actuator housing of the system of FIG. 14.

FIG. 18 is a top rear perspective view of an alternative integral actuator housing similar to the removable actuator housing of the system of FIG. 14.

FIG. 19 is a top rear perspective view of another alternative one-piece actuator housing similar to the removable actuator housing of the system of FIG. 14.

FIG. 20is a top rear perspective view of an injection molding system having an actuator housing wall including a top radial plate member that is not actively cooled and an integral housing member including an axial wall and a lateral radial wall that are actively cooled.

Fig. 21 is an end view of the apparatus of fig. 20.

Fig. 22 is an exploded perspective view of the system of fig. 20.

FIG. 23 is a top rear perspective view of an injection molding system with actuator housing walls comprised of top and bottom radial plate members that are not actively cooled and a housing comprised of assembled and removable axial and lateral walls that are actively cooled.

Fig. 24 is an end view of the apparatus of fig. 23.

Fig. 25 is an exploded perspective view of the system of fig. 23.

FIG. 26 is a rear exploded perspective view of an injection molding system having an actuator including an electric motor housed within a housing including a unitary housing member forming a top radial wall, a bottom radial wall, and opposing side radial walls and front and rear axial walls removably assembled with the unitary member, all of the walls containing actively-cooled cooling channels.

Fig. 27 is a side cross-sectional view of the system of fig. 26.

Fig. 28 is a sectional view taken along line 28-28 of fig. 27.

FIG. 29 is a front right perspective view of an injection molding system showing a motor actuator mounted to a rotary to linear converter having a converter housing with opposing left and right radial side walls containing actively cooled cooling channels, the side walls being assemblable with top and bottom axial wall plates that are not actively cooled.

Fig. 30 is a cross-sectional view taken along line 30-30 of fig. 29.

Fig. 31 is a top front perspective view of a driver and rotor component subassembly of an electrical actuator that may be used in other described embodiments of the systems described herein.

FIG. 32 is a view similar to FIG. 31 showing the opposing permanent magnet components of the stator used as a subassembly of the motor components.

FIG. 33 is a view similar to FIG. 31 showing an alternative motor drive and rotor arrangement.

Fig. 34 is a view similar to fig. 31 showing the copper wire windings of the motor drive arranged and mounted with respect to the permanent magnets to serve as the armature components of the motor.

Fig. 35 is a view similar to fig. 34 showing the copper wire armature in a driven rotational position when current is applied through the wire.

FIG. 36 is a side cross-sectional view of a subassembly of a motor actuator and rotary-to-linear converter in which a gear assembly interconnects the motor rotor and the rotary-to-linear converter, the subassembly of components having interconnecting housings in thermal communication with each other, and rotor and drive gear components that are non-coaxial with respect to each other.

Fig. 37 is a side cross-sectional view of a downstream interconnecting component of the linear transducer of fig. 36.

Fig. 38 is a front perspective view of an electric actuator contained in a housing, wherein a rotor of the electric motor is interconnected with a rotary-to-linear gear arrangement that drives a valve pin in a path that is non-coaxial with respect to an axis of the rotor of the actuator, wherein the housing of the rotary-to-linear converter includes actively cooled sidewalls.

Fig. 39 is a side cross-sectional view of another embodiment of an electric actuator contained in a housing, wherein a rotor of the electric motor is interconnected with a rotary-to-linear gear arrangement that drives a valve pin in a path that is not coaxial with respect to an axis of the rotor of the actuator, wherein the housing of the rotary-to-linear converter includes actively cooled sidewalls.

Fig. 40 is a view similar to fig. 39 showing a housing including an electric actuator with actively cooled radial sidewalls.

FIG. 41 is a view similar to FIG. 40, showing the housing of the rotary to linear converter including actively cooled radial sidewalls.

Fig. 42 is a cross-sectional view of a system including an electric actuator in which both the driver and the gear assembly are housed within a housing of the actuator, the housing having a radial sidewall into which the active cooling channel is incorporated, and the axis of the rotor is coaxial with the axis of the valve pin.

Fig. 43 is a schematic diagram showing an actuator similar to that of fig. 42, with active cooling channels incorporated into an end wall of the actuator's housing, and the actuator additionally removably mounted to a top clamp plate that itself is cooled or actively cooled relative to the heating manifold.

FIG. 44 is an exploded view of a harmonic gear rotational speed reduction device with eccentric pin drive connections that may be interconnected to the rotor of an electric motor used in embodiments of the present invention.

FIG. 45 is a side cross-sectional view of the device of FIG. 44 with the components of the device assembled in an operative condition.

Fig. 46 is a schematic cross-sectional side view of an electrical actuator having an end wall containing active cooling channels, the actuator being interconnected with a rotational speed reduction device as shown in fig. 44, wherein the end wall 120ro of the housing of the reduction device contains active cooling channels.

FIG. 47 is a side schematic view of a system having an electric actuator with an end wall having an active cooling channel mounted away from the rotary speed reducer shown in FIG. 44 and interconnected to the rotary speed reducer shown in FIG. 44 via an extended drive shaft, the axis of the rotor and the axis of the valve pin being arranged in a non-coaxial relationship with respect to each other.

Fig. 48 is a side cross-sectional view of a linear to non-coaxial linear motion converter that may be interconnected to an electric actuator, wherein the housing wall 120ro of the converter includes active cooling channels.

Fig. 49 is an exploded view of the linear to non-coaxial linear motion converter assembly of fig. 48 showing the housing wall 120ro of the converter incorporating active cooling channels.

Detailed Description

Fig. 1,2, 3, 4, 5, 6, 7,8, 9 show an injection molding system (1000) including an injection molding machine (500) that injects a stream of injection fluid (400) into a heated manifold (300) that distributes injection fluid (400) to flow channels 302 of manifold 300 that deliver injection fluid to gates (70) of mold cavities (80).

The system comprises an actuator (5) comprising a rotor (250) having a drive axis (Y) and a driver (100, 200) interconnected with the rotor (250), the driver being adapted to drive the rotor about the drive axis, the driver (100, 200, fig. 1, 4) receiving electrical energy or power producing drive heat.

The actuator (5) has a housing (20) comprising radial walls (20r, 20ri, 20rit, 20ro, 20roa, 20rob, 20roc, 20rod) and axial walls (20a, 20ai, 20aue, 20ade) which form an enclosed chamber (45) containing a thermally conductive Chamber Fluid (CF), the rotor and driver (250, 100, 200) being mounted within the chamber (45) in intimate thermally conductive contact with the thermally conductive fluid. The radial walls 20r, 20ri, 20ro, 20roa, 20rob, 20roc, 20rod are disposed at substantially radial positions or locations relative to the axis Y of the rotor 250. And, the axial wall is generally disposed at an axial position or location relative to the axis Y of the rotor 250.

The radial 20r, 20ri, 20rit, 20ro, 20roa, 20rob, 20roc, 20rod wall and the axial wall 20a, 20ai, 20aue, 20ade are interconnected to form a separate housing body 20 that is typically removably attached to, and preferably easily detachable from, the housing 120 of the linear travel converter or transmission 15. The housing 120 of the linearly traveling transducer or actuator generally includes one or more transducer or actuator walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) constructed of a thermally conductive material. The converter or transmission walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) are typically mounted to the heated manifold (300) in an arrangement such that the manifold heat 300 is communicated to the converter or walls (120r, 120rb, 120rc, 120ri, 120ro, 120 a).

As shown in fig. 3, 4, 5, 6, 7, 11, 12, 13, one or more of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) are disposed in thermal contact or communication with heat generated by the manifold (300) or thermal conduction generated within the enclosed chamber (45). One or more of the radial or axial walls of the actuator housing comprise a first entity (20r, 20a, 20ri, 20ai) consisting of a heat-conductive material, having an inner surface (20ris, 20ai, 20riis, 20ai) arranged in close heat-conductive contact with the inner space (45s) of the chamber. One or more of the radial or axial walls comprise a second entity (20ro, 20ao) constituted by a heat conductive material, having an inner surface (20rois, 20aois) in close heat conductive contact or communication with the heat exchanging surface (20rihcs, 20aihcs) of the first entity (20ri, 20ai), or one or more intermediate entities (not shown) constituted by a heat conductive material, having a second inner surface (20riis, 20aiis) arranged in close heat conductive contact or communication with the inner space (45s) of the chamber (45).

An actuator tube or channel (25) is provided within the second body (20ro, 20 ao). The first entity (20r, 20a, 20ri, 20ai) is generally constituted by a heat insulating material, while the second entity (20ro, 20ao) is generally constituted by a highly heat conductive material.

In embodiments where the actuator or converter housing wall comprises two or more integral wall bodies, e.g. a first inner wall body (20r, 20a, 20ri, 20ai, 120r, 120a, 120r, 120ai) and a second outer body (20ro, 20ao, 120ro, 120ao), the outer wall body is attached to the inner wall body, preferably in a compressed surface-to-surface contact manner, such that the attached two or more integral wall bodies serve as a single wall body for heat absorption and dissipation purposes, and active cooling channels in the outer wall body serve to receive and dissipate heat from the one or more inner wall bodies to which the outer wall body is attached, as if the cooling channels were provided within the inner wall body.

When power is supplied to drive the rotor 250, the drive components 100, 200 of the motor heat up, and in turn heat up the gas or fluid CF residing, or contained or enclosed, within the motor chamber 45 in contact with the drive components 100, 200. The drive components 100, 200 typically include conventional motor stator and armature copper or other conductive wires or coils, as shown in fig. 45-47. Thus, as the coils or wires 100, 200 heat up, the gas CF within the chamber 45 is heated and the heated gas CF in turn heats the housing walls 20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade in contact with the hot gas CF. The rotor 250 and the drivers 100, 200 are rotatably supported within the chamber by radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20 ade).

The drives 100, 200 may be controllably driven by a controller 2000 that includes a program that can be programmed to controllably position the axial or linear position of one or more valve pins driven by associated actuator motors that may be housed within any injection molding system 1000.

One or more of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) are constructed of a thermally conductive material, such as steel, aluminum, or the like. One or more of the walls has an inner surface 20is, 20ais arranged in heat conducting contact with a heat Conducting Fluid (CF) contained within the enclosed chamber 45. One or more radial or axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) absorb heat from the heat transfer fluid (CF) contained within the chamber (45).

The actuator tube or channel (25) is typically embedded, drilled or formed within the body of solid material of a selected one of the radial or axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) such that the tube or channel surrounds its circumference, is surrounded by, and remains in intimate thermally conductive contact or communication with, the thermally conductive material comprising the radial or axial wall.

A source (260) of endothermic fluid (25f), typically actively cooled, is sealingly interconnected to the tube or channel (25) such that the fluid is actively pumped or directed through the tube or channel (25) in the form of a flow that typically absorbs and delivers heat from one or more actuator heat conductive walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) to a larger source of active cooling fluid. The cooling fluid 25f typically comprises water, antifreeze, or similar inert fluid, which can be easily pumped through the cooling channel or conduit 25. Where a tube (as opposed to an aperture in the wall material) is used as a medium for the flow of cooling fluid, the tube 25 is typically constructed of a highly heat absorbing or conductive material (e.g., copper or the like). In the case of a tube, the tube is embedded within the body of the wall material such that the outer periphery of the wall of the tube is in intimate, thermally conductive contact with the wall material.

As shown, the valve pin (800) has a pin axis (X) and is interconnected to the rotor (250) such that the valve pin is oriented or disposed along a linear path of travel (XX) that is generally coaxial with the pin axis (X).

The system 1000 includes a heating manifold (300) that generates manifold heat. The housing (20) of the actuator 5 is typically mounted in conductive thermal communication with the heating manifold (300) such that manifold heat is absorbed by or transferred to one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing to one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing.

One or more of the radial walls or axial walls may comprise a unitary body (20r, 20ro, 20a) of thermally conductive material. The monolithic wall body has an inner surface (20ris, 20ais) that may be directly arranged in intimate thermally conductive contact with a fluid (CF) contained within the chamber.

Alternatively, the radial or axial wall of the actuator 5 may comprise a first outer whole mounted or attached to a second inner or intermediate monolithic wall body (20ri, 20 ai). In such an embodiment, the outer monolith has an inner surface (20rois, 20aois) arranged in intimate thermally conductive contact with the intermediate thermal communication surface (20rihcs, 20aihcs) of the inner or intermediate monolith (20ri, 20 ai). In such an embodiment, the inner or intermediate wall body is constructed of a thermally conductive material and has a second inner surface (20riis, 20aiis) arranged in direct intimate thermally conductive contact with a fluid (CF) contained within the chamber (45).

In embodiments where one or more of the radial or axial walls includes a first outer unitary body (20ro, 20a0) and a second inner or intermediate unitary body (20ri, 20ai), the first or outer unitary body is typically constructed of a first thermally conductive material that is a thermally insulating or low thermally conductive material such as titanium. Also, the second outer or intermediate monolithic wall body is typically constructed of a highly thermally conductive material such as copper, aluminum, or the like.

The system may also include a linear travel converter (15) interconnected between the rotor (250) and the valve pin (800) in an arrangement that converts rotor and rotational motion to linear motion (XX) of the valve pin (800). The linearly traveling transducer (15) generally includes a transducer housing (120) including one or more transducer walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) comprising a thermally conductive material. The converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) may be mounted to the heating manifold (300) arranged such that manifold heat is transferred to the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120 a).

The converter tubes or channels (125) are typically embedded or drilled within the body of a selected one of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) such that the tubes or channels 125 are surrounded by and disposed in intimate thermally conductive contact with the thermally conductive material of one or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120 a).

The source of endothermic fluid (125f) as described above is typically arranged to be sealingly interconnected to the converter tube or channel (125) such that the endothermic fluid (125f) is actively pumped or directed through the converter tube or channel (125) in the form of a stream that absorbs manifold heat transferred to the converter walls.

One or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) may have an outer surface (120aos, 120ros) arranged in heat conducting communication with or in contact with a heat conducting surface (20aos) of one or more of the radial and axial walls (20r, 20ro, 20roa, 20rob, 20roc, 20rod, 20a, 20aue, 20ade) of the actuator (5), such that heat absorbed by or contained in the converter wall is conducted to or away from the actuator wall.

One or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) may have an inner surface (120ris, 120ais) disposed in thermally conductive communication with a linear travel device (127) interconnected between the rotor (250) and the valve pin to convert rotational movement of the rotor into linear movement (XX) of the valve pin (800). In such embodiments, the transducer walls are arranged to form a housing or chamber 55, 127c in fig. 7, 50, with the linear travel device 127 mounted or disposed within the housing or chamber 55, 127 c. The inner surface (120ris, 120ais) of the converter wall is typically in thermally conductive contact or communication with the linear travel device 127.

One or more of the converter walls may comprise a unitary body (120r, 120a, 120ro, 120ao) of thermally conductive material having an inner surface 120ris, 120ais in direct thermally conductive or communicative contact with the chamber 127c or the linear travel device 127 itself.

In an alternative embodiment, one or more of the converter walls may comprise a first outer entirety (120ro, 120ao) of thermally conductive material and a second intermediate or inner entirety (120ri) to which the first outer entirety is attached. In this embodiment, the outer or first entity 120ro, 120ao has an inner surface (120rois) in heat conducting contact with the heat transfer surface (120rihcs) of the inner or intermediate entity (120 ri). The inner or middle body is constructed of a thermally conductive material and has a second inner surface (120riis) disposed in thermally conductive contact or communication with the air or gas contained within the linear travel device 127 or chambers 55, 127 c.

In another alternative embodiment of fig. 42, the linear travel transducer (15) may be mounted within the same enclosed chamber 45 as the drives 100, 200, in contact with the thermally conductive Chamber Fluid (CF). In such embodiments, the actuator housing (20) is typically mounted in conductive thermal communication with the heating manifold (300) such that manifold heat is absorbed by or transferred to one or more of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing body 20. The heat absorbing fluid (25f) is directed in a flow such that the manifold heat is absorbed by or transferred to one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing. In such embodiments, the rotor axis Y and the travel axis X, XX of the valve pin are adapted to be generally coaxial.

The system according to the invention may comprise a transmission, typically comprising one or more of a gear, rack, screw or nut (16a, 16b, 72, 190, 191, 195, 950, 960, 970) adapted to convert rotational movement of the rotor (250) about the rotor axis Y into linear movement of the valve pin along an axis (X, XX) that is not coaxial with the rotor axis (Y). In such embodiments, one or more of the transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) form an enclosed chamber 55 that houses or encloses one or more of a gear, rack, screw, or nut (16A, 16b, 72, 190, 191, 195, 950, 960, 970). The one or more transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) are typically constructed of a thermally conductive material. The converter tube or channel (125) is embedded within or surrounded by a thermally conductive material and in intimate thermally conductive contact therewith, and one or more of the driving walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) are included within the thermally conductive material. As described above with reference to the actuator housing wall, the source (125F) of heat absorbing fluid is arranged to be sealably interconnected to the converter tube or channel (125) such that the heat absorbing fluid (125F) is pumped or directed through the converter tube or channel (125) in a flow that absorbs heat absorbed or transferred by the one or more transfer walls (120r, 120ro, 120ri, 120a, 120ao, 120 ai).

In an alternative embodiment, as shown for example in fig. 40, 41, 43, the actuator housing 20 may be removably mounted and attached to a top clamp or mounting plate 1002 that is mounted upstream of the manifold 300 and interconnected with the mold. The clamp or mounting plate 1002 is typically maintained in a cooled state relative to the heated manifold by mounting it in spaced relation to the heated manifold 300, or by active cooling using fluid channels or tubes supplied with a cooling fluid, which channels or tubes are embedded within the clamp plate 2002 in intimate contact with the body of the clamp plate 1002.

For example, in another alternative embodiment as shown in fig. 41, the housing 120 of the linear travel converter 15 may be mounted and removably attached to a top clamp or mounting plate 1002, the top clamp or mounting plate 1002 being mounted upstream of the manifold and interconnected with the mold. Also, the clamp or mounting plate 1002 is typically maintained in a cooled state relative to the heated manifold by being mounted in spaced relation to the heated manifold 300, or by active cooling using fluid passages or tubes supplied with a cooling fluid, which passages or tubes are embedded within the clamp plate 2002 in intimate contact with the body of the clamp plate 1002.

Typically, one or the other or both of the linear travel converter 15 and the actuator 20 are mounted to the heating manifold 300

The actuator generally has a housing (20) consisting of radial walls (20r, 20ri, 20ro, 20roa, 20rob, 20roc, 20rod) and axial walls (20a, 20ai, 20aue, 20ade) forming a closed chamber (45) containing a heat conducting Chamber Fluid (CF), the rotor and driver (250, 100, 200) being mounted within the chamber (45) in intimate heat conducting contact with the heat conducting fluid. The rotor and driver are generally supported within the chamber by radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade), arranged such that the rotor (250) and driver (100, 200) are drivably rotatable within the chamber (45).

One or more of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) typically comprise a thermally conductive material and have an inner surface disposed in thermally conductive contact with a thermally Conductive Fluid (CF) contained within the enclosed chamber. One or more radial or axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) absorb heat from a thermally Conductive Fluid (CF) contained within the chamber (45) and have an actuator tube or channel (25) surrounded by and in intimate thermally conductive contact with the thermally conductive material of a first one of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20 ade). A source (260) of endothermic fluid (25f) is sealably interconnected to the tube or channel (25), arranged such that the endothermic fluid (25f) is directed through the tube or channel (25) in a flow that absorbs heat from one or more thermally conductive walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20 ade).

In some embodiments shown in fig. 21-25, at least one of the radial walls may comprise a non-actively cooled monolith (20rot) having an inner surface (20rotis) in intimate thermally conductive contact with an outer surface (20roos) of a first one of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20 ade).

At least one of the radial walls comprising the non-actively cooled monolith may further comprise an intermediate monolith (20ri) having a thermally conductive surface (20rihcs) in intimate thermally conductive contact with the inner surface (20rotis) of the non-actively cooled monolith (20 rot). The intermediate body is generally formed of a thermally conductive material and has a second inner surface (20ris, 20aiis) arranged in intimate thermally conductive contact with a fluid (CF) contained within the chamber (45).

A first one of the radial or axial walls may comprise a whole (20r, 20a) made of a heat-conducting material having an inner surface (20ris, 20ais) arranged in close heat-conducting contact with the fluid (CF) contained in the chamber, or may comprise a whole (20ro, 20ao) made of a heat-conducting material having an inner surface (20rois, 20aois) in close heat-conducting contact with a heat exchanging surface (20rihcs, 20aihcs) of an intermediate whole (20ri, 20ai) made of a heat-conducting material having a second inner surface (20riis, 20aiis) arranged in close heat-conducting contact with the fluid (CF) contained in the chamber (45).

The apparatus includes a heating manifold (300) generating manifold heat, a housing (20) of the actuator mounted in conductive thermal communication with the heating manifold (300) such that the manifold heat is absorbed by or transferred to one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing, and a heat absorbing fluid (25f) absorbs the manifold heat absorbed or transferred by the one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing.

In some embodiments, such as shown in fig. 29, 36, 37, the apparatus can further include a linear travel converter (15) interconnected between the rotor (250) and the valve pin (800) to convert the rotational motion of the rotor to linear motion (XX) of the valve pin (800). The linearly traveling converter (15) generally includes a converter housing (120) including one or more converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) comprising a thermally conductive material, the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) being mounted to a heating manifold (300) arranged such that manifold heat is transferred to the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120 a). The converter walls include converter tubes or channels (125) surrounded by, and in intimate thermally conductive contact with, the thermally conductive material of one or more of the converter walls (120r, 120rb, 120rc, 120ri, 120ro, 120 a). A source (125F) of heat absorbing fluid is arranged sealably interconnected to the converter tube or channel (125) such that the heat absorbing fluid (125F) is directed in a stream through the converter tube or channel (125) to absorb manifold heat transferred to the converter walls.

In such embodiments, one or more of the translator walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) may have an outer surface (120aos, 120ros) disposed in thermally conductive communication with the thermally conductive surface (20aos) of one or more of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the actuator (5). One or more of the translator walls (120r, 120rb, 120rc, 120ri, 120ro, 120a) may have an inner surface (120ris, 120ais) arranged in thermally conductive communication with a linear travel device (127), the linear travel device (127) being interconnected between the rotor (250) and the valve pin to translate rotational movement of the rotor into linear movement (XX) of the valve pin (800).

In such embodiments, one or more of the converter walls typically comprises a unitary body (120ro) of thermally conductive material having an inner surface (120rois) in thermally conductive contact with a thermally communicating surface (120rihcs) of an intermediate unitary body (120ri), the intermediate unitary body (120ri) being of thermally conductive material and having a second inner surface (120riis) disposed in thermally conductive communication with a linear travel means (127) interconnected between the rotor (250) and the valve pin to convert rotational movement of the rotor into linear movement (XX) of the valve pin (800).

Such embodiments may also include a linear travel converter (15) interconnected between the rotor (250) and the valve pin (800) to convert rotational movement of the rotor (250) into linear movement (XX) of the valve pin (800). The linear travel transducer (15) is mounted within the enclosed chamber (45) in fluid contact with the thermally conductive Chamber (CF). The housing (20) of the actuator is mounted in conductive thermal communication with the heating manifold (300) such that manifold heat is absorbed or transferred by one or more radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing. The heat absorbing fluid (25f) absorbs manifold heat absorbed or transferred by one or more of the radial and axial walls (20r, 20ro, 20ri, 20roa, 20rob, 20roc, 20rod, 20a, 20ai, 20aue, 20ade) of the housing.

The rotor (250) has a rotor axis (Y) and the valve pin (800) has a travel axis (X, XX), the rotor axis (Y) and the travel axis (X, XX) may be coaxial as in the embodiment shown in fig. 42, 43.

In some embodiments, such as shown in fig. 1-41, the rotor (250) has a rotor axis (Y), and the system may include a transmission comprised of one or more gears, racks, screws or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970) adapted to convert rotational motion of the rotor (250) about the rotor axis (Y) to linear motion of the valve pin along the axis (X, XX), wherein the axis (X, XX) is not coaxial with the rotor axis (Y). In such embodiments, the one or more actuator walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) form an enclosed chamber (55) enclosing one or more of the gears, racks, screws, or nuts (16a, 16b, 72, 190, 191, 195, 950, 960, 970), the one or more actuator walls (120r, 120ro, 120ri, 120a, 120ao, 120ai) being comprised of a thermally conductive material.

In some embodiments, the converter tube or channel (125) is surrounded by, and in intimate thermally conductive contact with, thermally conductive material of one or more of the actuator walls (120r, 120ro, 120ri, 120a, 120ao, 120 ai). A source (125F) of heat absorbing fluid is arranged sealably interconnected to the converter tube or channel (125) such that the heat absorbing fluid (125F) is directed in a stream through the converter tube or channel (125) to absorb heat absorbed or transferred by the one or more transmission walls (120r, 120ro, 120ri, 120a, 120ao, 120 ai).

In some embodiments, the actuator housing (20) is removably attached to a top clamp or mounting plate (1002) that is mounted upstream of the manifold and interconnected with the mold.

In some embodiments, the linear travel converter (15) is removably attached to a top clamp or mounting plate (1002), the top clamp or mounting plate (1002) being mounted upstream of the manifold and interconnected with the mold.

In another aspect of the invention, a method of performing an injection molding cycle is provided that includes operating an injection molding system as described above.

In certain embodiments, the shaft 250 of the motor may be interconnected at a downstream end to a rotation reduction mechanism, such as the harmonic speed reduction mechanism 15h of fig. 44-47. In such an embodiment, the rotational speed of the rotor 250 is reduced so that the degree of torque force of the motor may be increased. In such embodiments, the downstream rotating device 500 components of the rotation reducing mechanism 15h rotate at a lower rotational speed and higher torque, and are typically attached to an eccentrically mounted cam device 600 that drives the slide plate 43 along a linear travel path X, XX that is not coaxial with the axis of rotation of the rotor 250. The cam device 600 in combination with the slide mechanism 43 thus acts as a linear travel converter 15 that converts rotational motion to linear X, XX motion.

The transducer 15 may include a mounting or alignment support 40a and a sled or slide 43 to which the valve pin 100 is interconnected to the sled or slide 43. The alignment support 40a has a guide surface 40 as. When the slide plate 43 is reciprocally driven along the linear path a by the eccentric drive means comprising the cam member 47, the complementary surface 43s of the slide plate or slide 43 slides against the guide surface 40as, as shown in fig. 1. As shown in the embodiment of fig. 8, the sled 43 has freely rotatable wheels 43r that facilitate the sled's sliding up and down stream along the surface 40 as. In an alternative embodiment, the wheel 43r is not necessary, and the side surface 43s may be adapted to slide directly against the surface 40as without the wheel. As shown in the embodiment of fig. 1, alignment support 40a is attached to rotation reducer 42. The converter 40 may be fixedly mounted to the top clamp plate 1002 or the heating manifold 300.

The converter 15 comprises a drive or mounting wheel or disc 500 having a centre of rotation 500c to which the rotatable drive shaft 250 of the actuator 5 is axially attached or interconnected with the centre of rotation 500c, either directly or indirectly via a rotatably interconnected elongate shaft 20, 20f or a connector shaft such as a splined shaft 42 s. Referring to fig. 5-9, the electric rotatable drive rotor or drive shaft 12 of the motor is rotatably interconnected to the center 500c of the drive wheel or disc 500 of the rotary to linear converter 40 mechanism. An eccentrically mounted cam member 600 (typically a freely rotatable disc or wheel) is mounted to the rotatable driven disc or wheel 500 and an eccentric distance ED from the center of rotation 500c of the drive wheel or disc 500 is selected.

The electric drive of motor rotor 250 drivably rotates R3 drive wheel 500 at a controllably selectable speed and direction. As shown, the drive wheel 500 of the converter 15 is rotatably driven and the eccentrically mounted cam member 600 rotates R3 about the center 500c of the drive wheel 500. As shown, the transducer 15 comprises a slider or slide plate 43 provided with a cam groove 43sl arranged to be attached to the support 40a such that an outer circumferential surface 600cs of the cam member 600 engages a complementary inner cam surface 43ss of the slider or slide plate 43 member. The cam surface 43ss of the slider 43 is configured and adapted relative to the diameter D and eccentric distance ED of the cam member 600 so that the outer surface 600cs of the cam member 600 can forcibly engage the inner surface 43ss of the slider 43 and thus cause the slider 43 to be forcibly driven up and down in a linear direction or to and fro in or along the linear direction or axis a as the cam member 600 is eccentrically drivable in rotation R3 about the center of the driven disc or wheel member 500. As shown, valve pin 800 is arranged to be fixedly attached to the driven slide or sled member 43 such that valve pin 800 is driven linearly with the linear movement of slide 43.

Due to the eccentric mounting of the cam member 600, during a constant rotational speed R3, the linear or axial velocities a31, a32, a33 of the valve pin 800 and sled 43 along the linear path a change a31, a32, a33 depending on the rotational or angular position of the cam member 600. When the cam member 600 is in the ninety degree rotational position, the linear or axial velocity A32 is at a maximum, and when the cam member 600 is in the 45 degree position and the 135 degree rotational position, the linear or axial velocity A32 is at a lower velocity. Similar to the eccentric cam embodiment, linear or axial velocity a32 of valve pin 800 is at a maximum when eccentric or eccentric configuration cam surface 600cs of disk 500 is at a ninety degree position, and linear velocities a31 and a33 are less than maximum when eccentric cam surface 600cs is at 0 and 45 degree positions.

Conversely, due to the eccentric mounting of the cam member 600, the torque forces T31, T32, T33 exerted by the eccentric cam 600 on the valve pin 800 and slide plate 43 along the linear path a vary T31, T32, T33 depending on the rotational or angular position of the cam member 600, wherein the rotational speed R3 is constant. The torque force is minimal when the cam member 600 is disposed in the ninety degree rotational position, and is higher when the cam member 600 is in the 45 degree position and the 135 degree rotational position. Similar to the eccentric cam embodiment, torque force T32 exerted on valve pin 100 by cam surface 600cs is at a minimum when eccentric or eccentric configuration cam surface 600cs of disk 500 is in the ninety degree position, while torque forces T31, T33 are greater than a minimum when eccentric cam surface 600cs is in the 0 degree (at maximum torque force) and 45 degree positions.

Thus, the linear travel converter 15 is a device that converts linear motion or rotational motion to linear motion along an axis X, XX that is not coaxial with the axis Y of the motor.

The rotational speed reduction devices shown in fig. 44-47 include a strain wave gear having a rotatable elliptical or other non-circular shape (e.g., a triple node comprising a disk or ring shape) that produces a reduced rotational speed output relative to the rotational speed of the input rotor. Strain wave gears typically include three basic components: wave generator, flexible wheel and rigid wheel. The wave generator is typically constructed of an elliptical or other non-circular shape (e.g., three nodes comprising a disk or ring, which are referred to as a wave generator plug and an outer ball bearing), the outer bearing also having an elliptical or other non-circular shape (e.g., a shape comprising three nodes). The flexspline is generally shaped like a shallow cup. The circumferential side wall of the wheel is very thin, but the bottom is relatively rigid. This results in the wall at the open end being significantly flexible due to the thin wall and being fairly rigid on the closed side and capable of being tightly fixed to the output shaft. The teeth are positioned radially around the outside of the flexspline. The flexspline fits snugly on the wave generator so that when the wave generator plug is rotated, the flexspline deforms to a rotational elliptical or other non-circular shape (e.g., the three nodes comprising the shape) and does not slide over the outer elliptical or other non-circular shape (e.g., the three nodes comprising the annular shape of the ball bearing). The ball bearings rotate the flexspline independently of the shaft of the wave generator. A rigid wheel is a rigid circular ring with teeth inside. The flexspline and the wave generator are placed inside the rigid spline so as to mesh with the teeth of the flexspline and the rigid spline. Because the flexspline is deformed into an elliptical or other non-circular shape (e.g., three nodes comprising a shape), its teeth actually mesh with the teeth of the rigid spline only in two regions on opposite sides of the flexspline (located on the major axis of the elliptical or other non-circular shape, e.g., three nodes comprising a shape).

As the wave generator plug rotates, the flex spline teeth, which engage those of the rigid spline, change position. Because the major axis of the elliptical or other non-circular shape of the flexspline (such as the three nodes comprising the shape) rotates with the wave generator, the point at which the teeth mesh rotates about a central point at the same rate as the axis of the wave generator. The design key of strain wave gears is that there are fewer teeth (typically two less, for example) on the flexspline than on the rigid spline. This means that for each full rotation of the wave generator, a minor amount of backward rotation of the flex spline relative to the rigid spline (two teeth in this example) will be required. Thus, the rotational action of the wave generator results in a much slower rotation of the flexspline in the opposite direction. For strain wave gearings, the gearing reduction ratio can be calculated from the number of teeth on each gear.

In the embodiment shown in fig. 44-47, the strain wave gear 400 includes a wave generator or thin-walled bearing 460 mounted within and against the inner circumferential wall of the flexspline 430, which in turn is mounted within the inner wheel circumference of the rigid circular spline 448, as shown. An inner bearing race 464 having or taking a shape complementary to the cam or elliptical or other non-circular shape (e.g., the three nodes comprising the surface of the hub 472) is pressed against the elliptical or other non-circular shape (e.g., the three nodes comprising the surface of the hub 472) and transmits force 470 through ball bearings 466 to the complementary shaped outer race 462 (which is also generally elliptical or other non-circular shape, e.g., the three nodes comprising the shape) and the flexspline teeth 444, forcing them into engagement with the ring gear teeth 446 as the cam rotates on the shaft 12. The flexible gear teeth 444a are shown aligned with a reference point P on the ring gear.

The input shaft includes a motor shaft 250 that rotates about the shaft axis Y, the outer surface of which is in compression fit with the inner circumferential surface 480 of the shaft receiving bore 474 of the hub of the gear. In the illustrated embodiment, the output shaft or disc is the inner race 414 of the output bearing 410, and the interface surface 420 of the inner race 414 is attached to the complementary end surface 432 of the flexspline 430. The strain wave gear as shown comprises a housing 400 with a slew ring bearing mounted at the forward end of the housing. The outer race 412 of the bearing is bolted to the housing and the inner race 414 is part of an armature 418 supported by rollers 416. The slew ring bearing provides better stability against any forward to aft movement of the armature as it rotates in the housing. The front end or face 422 of the armature has a bolt pattern 424, and the drive disc 500 is fastened to this bolt pattern 424 by screws 428 passing through the bolt pattern 502. The cam member 600 is bolted to the armature 418 through one of the holes in the bolt pattern 502 of the drive disk 500 and rotates about the output rotational axis R3a eccentric distance ED. Shoulder bolts 602 clamp boss 604 to disk 500, which is drivably rotated about gear reducer rotation axis R3a, as shown in fig. 10, 11. The bosses form an inner race for the roller bearing 606. Outer race 608 has an outer surface 600cs of up-down drive sled 43. At the back end 420 of the armature there is a bolt pattern 426 to which the flexspline 430 is bolted. The flexspline is cup-shaped. The front end 432 is closed and has a bolt pattern 436 for securing the end of the flexspline to the armature by a clamping plate 436 and bolts 438. The side walls 440 of the flexspline are thin to be flexible and to maintain good torsional strength. The rear end of the cup 442 is open to receive the wave generator 460. The outer surface of the rim has gear teeth 444 that selectively engage teeth 446 on ring gear 448 as the wave generator rotates. The wave generator is mounted on the motor drive shaft 12 by a hub 472. Hub 472 has an aperture 474 that lines compressible wedge sleeve 480. When the screws 478 are tightened, they force the clamping ring 476 to compress the sleeve rearwardly and self-center and clamp the hub to the shaft 12 for smoother operation without the use of Allen set screws (Allen set screws) or keyways. The wave generator 460 includes an oval cam mounted by press-fit formed on the hub 472, and a ball bearing assembly having a flexible inner race press-fit on the cam portion of the hub 472. The lobe 482 on the hub forms the inner race 464 as a cam with two lobes 468 spaced 180 degrees apart in an oval shape. Outer race 462 may be rigid, oval or other non-circular shape, such as three nodes comprising a shape complementary to the oval shape, or other non-circular shape, such as three nodes comprising the shape of hub 472 and inner race 464, or may be thin and flexible so that it may conform to the shape of the cam such that it projects outwardly (arrow 470) with ball bearing 466 as shaft 12 rotates to force gear teeth 444, 446 into engagement at location 450. After the lobe has passed, the teeth 444 at location 452 flex inward to allow clearance so that one or more of the teeth 444 clear the ring gear teeth 446 and allow the flexspline 430 to rotate relative to the ring gear 448, as determined by the gear ratio and number of teeth.

The nature of the nested arrangement of the operating components (wave generator, flexspline, rigid spline) of the strain wave gears 46, 400 provides a physical device depth GD, diameter DIA or physical dimension that is suitable for being compact and space efficient, sufficient or sufficient to enable the device to be mounted to the housing of the rotary-to-linear converter 40, and readily mounted to and removable from either or the other of the top clamping plate and heated manifold, either alone or with the rotary-to-linear converter.

Alternatively, the means to reduce speed and increase torque may comprise an assembly, such as a worm gear assembly, spur gear assembly, planetary gear assembly, wherein the rotor 250 of the motor 200 is connected to and rotates the highest speed gear or gear teeth of the component containing the assembly, while the intermediate shaft is connected to and rotated by the highest speed gear or gear teeth of the component containing the assembly, to effectively reduce the rotational speed of the rotor 250 and increase its torque output, which is transmitted to the output shaft 160o, which is driven at a reduced speed R3 and higher torque R3 s. Other assemblies, such as helical gear assemblies, or belt and pulley arrangements and assemblies may be used to effect such speed changes and torque changes.

Fig. 48-49 illustrate one embodiment of linear-to-linear motion converter 15, which includes a sliding body 507 fixedly interconnected to linear driven shaft 15l by actuator 5. A lower surface of sliding body 507 is slidably mounted on mounting surface 505bs of bottom wall 505b of subassembly body housing 505 such that sliding body 507 is controllably driven along a first linear drive axis L1 by controlled driving of actuator 1000 with controller 176. Sliding body 507 is formed to include a bore or slot 509 in body 507 that is configured and adapted to allow valve pin 80 to be driven along axis L2 at one or more selected speeds that are related to the drive speed CV of actuator 5. The upstream end 80h of the valve pin 800 is fixedly connected to the follower pin 520 about which one or more wheels 520w are typically mounted, which are typically rotatably mounted on the follower pin 520. The housing 505, the follower pin 520, the valve pin and the manifold are assembled such that the guide groove 509 receives the follower pin 520 and the wheel 520w and is thereby arranged to engage against the guide surface 509s of the groove 509 at the outer surface of the wheel 520 w. As sliding body 507 moves along axis L1, slot 509 moves along axis L1 and driven pin 520 is forced to move along non-coaxial axis L2 by engagement against moving slot surface 509, whereupon the valve pin moves along axis L2 while sliding body 507 moves along axis L1. The moving speed V of the valve pin 80 depends on the profile or contour of the surface 509s of the guide groove 509 and on the moving speed CV of the linear driving member 150 of the actuator 5.

In the embodiment of fig. 48-49, the groove 509 has a linear or straight configuration such that the rate of movement of the valve pin 80 varies directly or linearly with the rate of movement CV of the linear drive member 150. When the surface 509s of the groove 509 is straight, the pin speed V remains constant as the linear drive member speed CV is constant.

Fig. 31-35 show conventional motor components in various arrangements from which the electric actuator component of the apparatus according to the invention is typically constructed. As shown, a typical motor includes an armature 200 and a stator 100, the armature 200 and the stator 100 being electrically conductive and interacting with each other through electromagnetic fields generated by such currents, the angular orientation settings of which are determined by the geometry, mounting and arrangement of the copper coils or permanent magnets 100pm that make up the armature 200 and the stator 100. The electromagnetic field emitted by the conductive coil shown is generated by applying a current (AC or DC) through the conductive coil, or by a field inherently generated by the permanent magnet 100 pm. Application of an electrical current through one or more of the coils 200, 100 generates heat HT which heats the gaseous medium 45 contained within the actuator housing body 20. The heated gaseous medium in turn contacts and heats the inner surfaces 20ais, 20is, 120ais, 120is, 20is, 120is of the walls of the actuator housing. Thus, in addition to being heated by heat from the heating manifold, the wall of the electric actuator housing body 20is also heated by the coils of the electric motor. Thus, the heat of this generated by the electric motor is dissipated by the active cooling mechanisms described herein.

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