[001] This application claims the benefit of priority to U.S. Provisional application serial No. 63/150469 filed February 17, 2021 , the disclosure of which is incorporated herein in its entirety as if fully set forth herein.

SUMMARY OF THE INVENTION

[002] In accordance with the invention there is provided an injection molding apparatus (10), comprising: a top clamp plate (800); a heatable manifold (40); a downstream channel (1040c, 1041c) having a gate (32, 34, 36) arranged to open into a cavity (30) of a mold (300); a valve pin (1040, 1041 , 1042) adapted to be driven in an upstream, downstream, or back forth path of travel (X), the valve pin having a proximal end (340) and a distal end, the distal end adapted to be driven downstream into a position where injection fluid flow through the gate (32, 34, 36) is stopped and upstream to one or more positions where the gate (32, 34, 36) is opened and injection fluid flow through the gate is enabled; an actuator (940, 941 , 942) mounted to one or the other or both of the top clamp plate and the heatable manifold, the actuator having: a pin driver (85, 940ld, 940r, 941 r, 942r) adapted to be driven reciprocally along a linear upstream, downstream, or back and forth path of travel (A, Y); and a drive device (940dr, 941 dr, 942dr) interconnected to the pin driver (85, 940ld, 940r, 941 r, 942r), the drive device (940dr, 941 dr, 942dr) adapted to drive the pin driver (85, 940ld, 940r, 941 r, 942r) and the valve pin (1040, 1041 , 1042); a pin coupler (80) removably interconnecting the pin driver (85, 940ld, 940r, 941 r, 942r) to the proximal end (340) of the valve pin (1040, 1041 , 1042); and a spring (74) disposed between the proximal end (340) of the valve pin and the pin driver (85, 940ld, 940r, 941 r, 942r), the spring (74) arranged to permit resilient relative motion (Z) between a spring compressed position (74c) and a less compressed or non compressed (74e) position.

[003] In such an apparatus, the drive device (940dr, 941 dr, 942dr) is typically housed within an actuator housing (940h, 941 h, 942h) and the spring (74) is typically disposed outside the actuator housing.

[004] The spring (74) is typically adapted to exert a spring force (L) between a surface (34a, 34b) of the proximal end (340) of the valve pin (1040, 1041, 1042) and the pin driver (85, 940ld, 940r, 941 r, 942r), the spring force (L) arranged to hold the valve pin (1040,

1041, 1042) in a stationary axial disposition when the valve pin is driven along the linear upstream, downstream, or back and forth path of valve pin travel (X).

[005] The spring (74) can be disposed between the proximal end (340) of the valve pin (1040, 1041, 1042) and the pin coupler (80), the spring (74) being arranged to exert a resilient spring force (L) between the proximal end (340) of the valve pin (1040, 1041 ,

1042) and the pin coupler (80).

[006] The pin coupler (80) can comprise: an actuator coupler (81 ); and a pin head adapter (70, 72, 78), wherein the actuator coupler (81) is rigidly interconnectable to the pin head adapter (70, 72, 78), and wherein the pin head adapter (70, 72, 78) is readily interconnectable to and readily disconnectable or removable from the actuator coupler (81).

[007] The spring (74) is typically engaged against a surface (78b) of the pin head adapter (70, 72, 78) and adapted to exert a spring force (L) on the proximal end (340) of the valve pin (1040, 1041, 1042)).

[008] The spring (74) can be engaged against a surface (81 b, 81c) of the actuator coupler (81 ) and adapted to exert a spring force (L) on the proximal end (340) of the valve pin (1040, 1041, 1042).

[009] The pin coupler (80) is typically adapted to receive the spring (74) and the proximal end (340) of the valve pin (1040, 1041, 1042) and the spring (74) is arranged to exert a spring force (L) on a surface (34a, 34b) of the proximal end (340) of the valve pin (1040, 1041, 1042), the spring force (L) arranged to hold the valve pin (1040, 1041, 1042) in a stationary axial disposition when the valve pin (1040, 1041, 1042) is driven along the linear upstream, downstream, or back and forth path of valve pin travel (X).

[0010] The pin driver (85, 940ld, 940r, 941 r, 942r) can be configured to travel along an upstream, downstream, or back and forth path of travel (Y) that is coaxial or non coaxial with the path of travel (X) of the valve pin (1040, 1041, 1042).

[0011] The drive device (940dr, 941 dr, 942dr) typically includes one or more of a rotary driver and a linear driver.

[0012] In another aspect of the invention there is provided a method of injection molding, comprising: providing an injection molding apparatus having a top clamp plate (80); heating a manifold (40); coupling at least one downstream channel (1040c, 1041c) of an injection molding apparatus (10) to a cavity of a mold, each downstream channel (1040c, 1041c) having a respective gate (32, 34, 36) that permits or restricts flow of an injection fluid into the cavity; directing an actuator (940, 941 , 942) mounted to one or the other or both of the top clamp plate and the heated manifold to drive a valve pin (1040, 1041, 1042), wherein the actuator includes a drive device (940dr, 941 dr, 942dr) interconnected to a pin driver (85, 940ld,

940r, 941 r, 942r), and wherein the valve pin has a proximal end (340) and a distal end, the distal end being drivable downstream into a position where injection fluid flow through the gate (32, 34, 36) is stopped and upstream to one or more positions where the gate (32, 34, 36) is opened and injection fluid flow through the gate is enabled; based on directing the actuator, driving the pin driver (85, 940ld, 940r, 941 r, 942r) reciprocally along a linear upstream, downstream, or back and forth path of travel (Y) and together driving the valve pin along an upstream, downstream, or back forth path of travel (X), wherein a pin coupler (80) removably interconnects the pin driver (85, 940ld, 940r,

941 r, 942r) to the proximal end (340) of the valve pin (1040, 1041, 1042); permitting, via a spring (74) disposed between the proximal end (340) of the valve pin and the pin driver (85, 940ld, 940r, 941 r, 942r), a resilient relative motion (Z) between a spring compressed position (74c) and a spring expanded (74e) position; and driving the valve pin (1040, 1041, 1042) in the upstream, downstream, or back forth path of travel (X).

[0013] Such a method can further comprise: disposing the spring (74) between the proximal end (340) of the valve pin and the pin coupler (80); and exerting, with the spring (74) a resilient spring force (L) between the proximal end (340) of the valve pin and the pin coupler (80).

[0014] Such a method typically further comprises: rigidly interconnecting an actuator coupler (81) to a pin head adapter (70, 72, 78); and adapting the pin head adapter (70, 72, 78) to be readily interconnectable to and readily disconnectable from the actuator coupler (81 ).

[0015] Such a method can further comprise: driving the pin driver (85, 940ld, 940r, 941 r, 942r) based on a rotational motion exerted on the drive device.

[0016] In another aspect of the invention there is provided an injection molding apparatus (10), comprising: a top clamp plate (800); a heatable manifold (40); a valve pin (1040, 1041, 1042) having a proximal end (340) and a distal end, the distal end adapted to be driven downstream into a position where injection fluid flow through a gate (32, 34, 36) is stopped and upstream to one or more positions where the gate (32, 34, 36) is opened and injection fluid flow through the gate is enabled; an actuator (940, 941 , 942) mounted to one or the other or both of the top clamp plate and the heatable manifold, the actuator having: a pin driver (85, 940ld, 940r, 941 r, 942r); and a drive device (940dr, 941 dr, 942dr) interconnected to the pin driver (85, 940ld, 940r, 941 r, 942r), the drive device (940dr, 941 dr, 942dr) adapted to drive the pin driver (85, 940ld,

940r, 941 r, 942r) and the valve pin (1040, 1041, 1042); a pin coupler (80) removably interconnecting the pin driver (85, 940ld, 940r, 941 r, 942r) to the proximal end (340) of the valve pin (1040, 1041, 1042); and, a resiliently compressible spring (74) disposed between the proximal end (340) of the valve pin and the pin driver (85, 940ld, 940r, 941 r, 942r), the spring (74) arranged to cushion axial force (L, 1, F2) exerted on the valve pin (1040, 1041, 1042) by permitting resilient relative motion (Z) between a spring compressed position (74c) and a less compressed or non compressed (74e) position.

[0017] In such an apparatus the drive device (940dr, 941 dr, 942dr) is typically housed within an actuator housing (940h, 941 h, 942h) and the resiliently compressible spring (74) is disposed outside the actuator housing.

[0018] The resiliently compressible spring (74) can be adapted to exert a spring force (L) between a surface (34a, 34b) of the proximal end (340) of the valve pin (1040, 1041 , 1042) and the pin driver (85, 940ld, 940r, 941 r, 942r).

[0019] The resiliently compressible spring (74) is typically disposed between the proximal end (340) of the valve pin and the pin coupler (80).

[0020] The pin driver (85, 940ld, 940r, 941 r, 942r) is typically configured to travel along an upstream, downstream, or back and forth path of travel (Y) that is coaxial or non coaxial with a path of travel (X) of the valve pin (1040, 1041 , 1042).

[0021] The drive device (940dr, 941 dr, 942dr) can comprise one or more of a rotary driver and a linear driver.

[0022] In another aspect of the invention there is provided an injection molding apparatus (10) comprising a top clamp plate (80), a heated manifold (40), an actuator (940, 941, 942) mounted to one or the other of the top clamp plate and the heated manifold, a downstream channel (1040c, 1041c) having a gate (32, 34, 36) that opens into a cavity (30) of a mold (300), the actuator including a rotary drive device (940r, 941 r, 942r) interconnected to a pin driver (85, 940ld, 940r, 941 r, 942r) adapted to drive a valve pin (1040, 1041, 1042), the pin driver being adapted to be driven by the rotary drive device (940rt, 941 rt, 942rt) reciprocally along a linear upstream, downstream or back and forth path of travel (Y) together with an upstream, downstream or back forth path of travel (X) of the valve pin, the valve pin having a distal end adapted to be driven downstream into a position where injection fluid flow through the gate (32, 34, 36) is stopped and upstream to one or more positions where the gate (32, 34, 36) is opened and injection fluid flow through the gate is enabled, the apparatus further comprising: a pin coupler (80) interconnected to the pin driver (85, 940ld, 940r, 941 r, 942r) in an arrangement such that the pin coupler (80) is driven in an upstream, downstream or back and forth path of travel in unison with the pin driver (85, 940ld, 940r, 941 r, 942r), the upstream end (340) of the valve pin (1040, 1041, 1042) being removably interconnected to the pin coupler (80) in an arrangement wherein the pin coupler (80) interconnects or couples the upstream end (340) of the valve pin to the pin driver (85,

940ld, 940r, 941 r, 942r), a spring (74) disposed between the upstream end (340) of the valve pin and the pin driver (85, 940ld, 940r, 941 r, 942r) such that the valve pin (1040, 1041, 1042) and the pin driver (85, 940ld, 940r, 941 r, 942r) are resiliently movable (Z) relative to each other between a spring compressed position (74c) and a less compressed or non compressed (74e) position while the pin coupler (80) is removably interconnected to the valve pin.

[0023] In such an apparatus the rotary drive device (940r, 941 r, 942r) is housed within an actuator housing (940h, 941 h, 942h) and the spring (74) is disposed outside the actuator housing.

[0024] In such an apparatus the spring (74) is adapted to exert a spring force (L) between a surface (34a, 34b) of the upstream end (340) of the valve pin (1040, 1041,

1042) and the driver (85, 940r, 941 r, 942r) such that the valve pin (1040, 1041, 1042) is held in a stationary axial disposition for driving the valve pin along the linear upstream, downstream or back and forth path of valve pin travel (X).

[0025] In such an apparatus the spring (74) is typically disposed between the upstream end (340) of the valve pin and the pin coupler (80) such that the spring (74) exerts a resilient spring force (L) between the upstream end (340) of the valve pin and the pin coupler (80). [0026] In such an apparatus, the pin coupler (80) can comprise an actuator coupler (81 ) and a pin head adapter (70, 72, 78), the actuator coupler (81 ) being rigidly interconnectable to the pin head adapter (70, 72, 78), the pin head adapter (70, 72, 78) being adapted to be readily interconnectable to and readily disconnectable or removable from the actuator coupler (81 ).

[0027] In such an apparatus the spring (74) can be arranged such that the spring (74) is engaged against a surface (70b, 78b) of the pin head adapter (70, 72, 78) to exert a spring force (L) on the upstream end (340) of the valve pin (1041 ).

[0028] In such an apparatus the spring (74) can be arranged such that spring (74) is engaged against a surface (81 b, 81 c) of the actuator coupler (81 ) to exert a spring force (L) on the upstream end (340) of the valve pin (1041).

[0029] In such an apparatus the pin coupler (80) is typically adapted to receive the spring (74) and the upstream end (340) of the valve pin in an arrangement wherein the spring (74) exerts a spring force (L) on a surface (34a, 34b) of the upstream end (340) of the valve pin (1040, 1041 , 1042) such that the valve pin is held in a stationary axial disposition for driving the valve pin along the linear upstream, downstream or back and forth path of valve pin travel (X).

[0030] In such an apparatus the pin driver (85, 940ld, 940r, 941 r, 942r) is configured to travel along an upstream, downstream or back and forth path of travel (Y) that is coaxial with the path of travel (X) of the valve pin.

[0031] In such an apparatus the pin driver (85, 940ld, 940r, 941 r, 942r) is configured to travel along an upstream, downstream or back and forth path of travel (Y) that is non coaxial with the path of travel (X) of the valve pin.

[0032] In another aspect of the invention there is provided a method for coupling a valve pin (1040, 1041 , 1042) to an actuator (940, 941 , 942) in an injection molding apparatus (10) comprising a top clamp plate (80), a heated manifold (40), an actuator (940, 941 , 942) mounted to one or the other of the top clamp plate and the heated manifold, a downstream channel (1040c, 1041c) having a gate (32, 34, 36) that opens into a cavity (30) of a mold (300), the actuator including a drive device (940rt, 941 rt, 942rt) interconnected to a pin driver (85, 940ld, 940r, 941 r, 942r) adapted to drive a valve pin (1040, 1041 , 1042), the pin driver being adapted to be driven reciprocally along a linear upstream, downstream or back and forth path of travel (Y) together with an upstream, downstream or back forth path of travel (X) of the valve pin, the valve pin having a distal end adapted to be driven downstream into a position where injection fluid flow through the gate (32, 34, 36) is stopped and upstream to one or more positions where the gate (32, 34, 36) is opened and injection fluid flow through the gate is enabled, the method comprising: interconnecting a pin coupler (80) to the pin driver (85, 940ld, 940r, 941 r, 942r) in an arrangement such that the pin coupler (80) is driven in an upstream, downstream or back and forth path of travel in unison with the pin driver (85, 940ld, 940r, 941 r, 942r), removably interconnecting the upstream end (340) of the valve pin (1040, 1041,

1042) to the pin coupler (80) in an arrangement wherein the pin coupler (80) interconnects or couples the upstream end (340) of the valve pin to the pin driver (85, 940ld, 940r, 941 r,

942r), disposing a spring (74) between the upstream end (340) of the valve pin and the pin driver (85, 940ld, 940r, 941 r, 942r) such that the valve pin (1040, 1041, 1042) and the pin driver (85, 940ld, 940r, 941 r, 942r) are resiliently movable (Z) relative to each other between a spring compressed position (74c) and a spring expanded (74e) position while the pin coupler (80) is removably interconnected to the valve pin.

[0033] Such a method typically includes adapting the spring (74) to exert a spring force (L) between a surface (34a, 34b) of the upstream end (340) of the valve pin (1040, 1041 ,

1042) and the driver (85, 940r, 941 r, 942r) such that the valve pin (1040, 1041, 1042) is held in a stationary axial disposition for driving the valve pin along the linear upstream, downstream or back and forth path of valve pin travel (X).

[0034] Such a method can include disposing the spring (74) between the upstream end (340) of the valve pin and the pin coupler (80) such that the spring (74) exerts a resilient spring force (L) between the upstream end (340) of the valve pin and the pin coupler (80).

[0035] Such a method can include adapting the actuator coupler (81 ) to be rigidly interconnectable to the pin head adapter (70, 72, 78) and adapting the pin head adapter (70, 72, 78) to be readily interconnectable to and readily disconnectable or removable from the actuator coupler (81 ). [0036] Such a method can include arranging the spring (74) such that the spring (74) is engaged against a surface (70b, 78b) of the pin head adapter (70, 72, 78) to exert a spring force (L) on the upstream end (340) of the valve pin (1041 ).

[0037] Such a method can include arranging the spring (74) such that spring (74) is engaged against a surface (81 b, 81 c) of the actuator coupler (81 ) to exert a spring force (L) on the upstream end (340) of the valve pin (1041).

[0038] Such a method can include adapting the pin coupler (80) to receive the spring (74) and the upstream end (340) of the valve pin in an arrangement wherein the spring (74) exerts a spring force (L) on a surface (34a, 34b) of the upstream end (340) of the valve pin (1040, 1041 , 1042) such that the valve pin is held in a stationary axial disposition for driving the valve pin along the linear upstream, downstream or back and forth path of valve pin travel (X).

[0039] Such a method can include configuring the pin driver (85, 940ld, 940r, 941 r, 942r) to travel along an upstream, downstream or back and forth path of travel (Y) that is coaxial with the path of travel (X) of the valve pin.

[0040] Such a method can include configureing the pin driver (85, 940ld, 940r, 941 r, 942r) to travel along an upstream, downstream or back and forth path of travel (Y) that is non coaxial with the path of travel (X) of the valve pin.

[0041] In another aspect of the invention there is provided an injection molding apparatus (10) comprising a top clamp plate (80), a heated manifold (40), an actuator (940, 941 , 942) mounted to one or the other of the top clamp plate and the heated manifold, a downstream channel (1040c, 1041c) having a gate (32, 34, 36) that opens into a cavity (30) of a mold (300), the actuator including a rotary drive device (940r, 941 r, 942r) interconnected to a pin driver (85, 940ld, 940r, 941 r, 942r) adapted to drive a valve pin (1040, 1041 , 1042), the pin driver (85, 940ld, 940r, 941 r, 942r) being adapted to be driven linearly by a driven rotor (940r, 941 r, 942r) of the rotary drive device (940rt, 941 rt, 942rt) and reciprocally along a linear upstream, downstream or back and forth path of travel (Y) together with or that follows an upstream, downstream or back forth path of travel (X) of the valve pin, the valve pin having a distal end (1041e) adapted to be driven downstream into a position where injection fluid flow through the gate (32, 34, 36) is stopped and upstream to one or more positions where the gate (32, 34, 36) is opened and injection fluid flow through the gate is enabled, the apparatus further comprising: the valve pin (1040, 1041, 1042) having an upstream end (340) that is interengaged with or interconnected to the pin driver (85, 940ld, 940r, 941 r, 942r), a spring (74) disposed between the upstream end (340) of the valve pin and the pin driver (85, 940ld, 940r, 941 r, 942r) such that the valve pin (1040, 1041, 1042) and the pin driver (85, 940ld, 940r, 941 r, 942r) are resiliently movable (Z) relative to each other between a spring compressed position (74c) and a less compressed or non compressed (74e) position while the upstream end of the valve pin is interengaged with or interconnected to the pin driver (85, 940ld, 940r, 941 r, 942r).

[0042] In such an apparatus the rotary drive device (940r, 941 r, 942r) is housed within an actuator housing (940h, 941 h, 942h) and the spring (74) is disposed outside the actuator housing.

[0043] In such an apparatus the spring (74) is adapted to exert a spring force (L) between a surface (34a, 34b) of the upstream end (340) of the valve pin (1040, 1041 , 1042) and the driver (85, 940r, 941 r, 942r) such that the valve pin (1040, 1041, 1042) is held in a stationary axial disposition for driving the valve pin along the linear upstream, downstream or back and forth path of valve pin travel (X).

[0044] In such an apparatus the spring (74) is typically disposed between the upstream end (340) of the valve pin and the pin coupler (80) such that the spring (74) exerts a resilient spring force (L) between the upstream end (340) of the valve pin and the pin coupler (80).

[0045] Such an apparatus can include a pin coupler (80) interconnected to the pin driver (85, 940ld, 940r, 941 r, 942r) in an arrangement such that the pin coupler (80) is driven in an upstream, downstream or back and forth path of travel in unison with or that follows the pin driver (85, 940ld, 940r, 941 r, 942r), the upstream end (340) of the valve pin (1040,

1041, 1042) being removably interconnected to the pin coupler (80) in an arrangement wherein the pin coupler (80) interconnects or couples the upstream end (340) of the valve pin to the pin driver (85, 940ld, 940r, 941 r, 942r)

[0046] In such an apparatus the pin coupler (80) can comprise an actuator coupler (81 ) and a pin head adapter (70, 72, 78), the actuator coupler (81) being rigidly interconnectable to the pin head adapter (70, 72, 78), the pin head adapter (70, 72, 78) being adapted to be readily interconnectable to and readily disconnectable or removable from the actuator coupler (81 ).

[0047] In such an apparatus the spring (74) can be arranged such that the spring (74) is engaged against a surface (70b, 78b) of the pin head adapter (70, 72, 78) to exert a spring force (L) on the upstream end (340) of the valve pin (1041 ).

[0048] In such an apparatus the spring (74) can be arranged such that spring (74) is engaged against a surface (81 b, 81 c) of the actuator coupler (81 ) to exert a spring force (L) on the upstream end (340) of the valve pin (1041).

[0049] In such an apparatus the pin coupler (80) is typically adapted to receive the spring (74) and the upstream end (340) of the valve pin in an arrangement wherein the spring (74) exerts a spring force (L) on a surface (34a, 34b) of the upstream end (340) of the valve pin (1040, 1041 , 1042) such that the valve pin is held in a stationary axial disposition for driving the valve pin along the linear upstream, downstream or back and forth path of valve pin travel (X).

[0050] In such an apparatus the pin driver (85, 940ld, 940r, 941 r, 942r) is configured to travel along an upstream, downstream or back and forth path of travel (Y) that is coaxial with the path of travel (X) of the valve pin.

[0051] In such an apparatus the pin driver (85, 940ld, 940r, 941 r, 942r) is configured to travel along an upstream, downstream or back and forth path of travel (Y) that is non coaxial with the path of travel (X) of the valve pin.

[0052] In another aspect of the invention there is provided a method of performing an injection molding cycle comprising operating any of the apparatuses described or depicted herein and performing an injection cycle in such operation.

[0053] In another aspect of the invention there is provided an injection molding apparatus (10) comprising a top clamp plate (800), a heated manifold (40), an actuator (940, 941 ,

942) mounted to one or the other of the top clamp plate and the heated manifold, a downstream channel (1040c, 1041c) having a gate (32, 34, 36) that opens into a cavity (30) of a mold (300), the actuator including a drive device (940dr, 941 dr, 942dr) interconnected to a pin driver (85, 940ld, 940r, 941 r, 942r) adapted to drive a valve pin (1040, 1041 , 1042), the pin driver (85, 940ld, 940r, 941 r, 942r) being adapted to be driven by the drive device (940dr, 941 dr, 942dr) reciprocally along a linear upstream, downstream or back and forth path of travel (A, Y) together with an upstream, downstream or back forth path of travel (X) of the valve pin, the valve pin having a distal end adapted to be driven downstream into a position where injection fluid flow through the gate (32, 34, 36) is stopped and upstream to one or more positions where the gate (32, 34, 36) is opened and injection fluid flow through the gate is enabled, the apparatus further comprising: a pin coupler (80) interconnected to the pin driver (85, 940ld, 940r, 941 r, 942r) in an arrangement such that the pin coupler (80) is driven in an upstream, downstream or back and forth path of travel in unison with the pin driver (85, 940ld, 940r, 941 r, 942r), the upstream end (340) of the valve pin (1040, 1041, 1042) being removably interconnected to the pin coupler (80) in an arrangement wherein the pin coupler (81) interconnects or couples the upstream end (340) of the valve pin to the pin driver (85,

940ld, 940r, 941 r, 942r), a spring (74) disposed between the upstream end (340) of the valve pin and the pin driver (85, 940ld, 940r, 941 r, 942r) such that the valve pin (1040, 1041, 1042) and the pin driver (85, 940ld, 940r, 941 r, 942r) are resiliently movable relative to each other (Z) between a spring compressed position (74c) and a less compressed or non compressed (74e) position while the pin coupler (80) is removably interconnected to the valve pin.

[0054] In such an apparatus the drive device (940dr, 941 dr, 942dr) is housed within an actuator housing (940h, 941 h, 942h) and the spring (74) is disposed outside the actuator housing.

[0055] The spring (74) is typically adapted to exert a spring force (L) between a surface (34a, 34b) of the upstream end (340) of the valve pin (1040, 1041, 1042) and the driver (85, 940ld, 940r, 941 r, 942r) such that the valve pin (1040, 1041, 1042) is held in a stationary axial disposition for driving the valve pin along the linear upstream, downstream or back and forth path of valve pin travel (X).

[0056] The spring (74) is typically disposed between the upstream end (340) of the valve pin and the pin coupler (80) such that the spring (74) exerts a resilient spring force (L) between the upstream end (340) of the valve pin and the pin coupler (80).

[0057] The pin coupler (80) can comprise an actuator coupler (81 ) and a pin head adapter (70, 72, 78), the actuator coupler (81) being rigidly interconnectable to the pin head adapter (70, 72, 78), the pin head adapter (70, 72, 78) being adapted to be readily interconnectable to and readily disconnectable or removable from the actuator coupler (81). [0058] The spring (74) can be arranged such that the spring (74) is engaged against a surface (78b) of the pin head adapter (70, 72, 78) to exert a spring force (L) on the upstream end (340) of the valve pin (1041).

[0059] The spring (74) is typically arranged such that spring (74) is engaged against a surface (81 b, 81c) of the actuator coupler (81 ) to exert a spring force (L) on the upstream end (340) of the valve pin (1041 ).

[0060] The pin coupler (80) can be adapted to receive the spring (74) and the upstream end (340) of the valve pin in an arrangement wherein the spring (74) exerts a spring force (L) on a surface (34a, 34b) of the upstream end (340) of the valve pin (1040, 1041, 1042) such that the valve pin is held in a stationary axial disposition for driving the valve pin along the linear upstream, downstream or back and forth path of valve pin travel (X).

[0061] The pin driver (85, 940ld, 940r, 941 r, 942r) is typically configured to travel along an upstream, downstream or back and forth path of travel (Y) that is coaxial or non coaxial with the path of travel (X) of the valve pin.

[0062] The drive device (940dr, 941 dr, 942dr) can comprise one or more of a rotary driver and a linear driver.

[0063] In another aspect of the invention there is provided, a method for coupling a valve pin (1040, 1041, 1042) to an actuator (940, 941, 942) in an injection molding apparatus (10) comprising a top clamp plate (80), a heated manifold (40), an actuator (940, 941, 942) mounted to one or the other of the top clamp plate and the heated manifold, a downstream channel (1040c, 1041c) having a gate (32, 34, 36) that opens into a cavity (30) of a mold (300), the actuator including a drive device (940dr, 941 dr, 942dr) interconnected to a pin driver (85, 940ld, 940r, 941 r, 942r) adapted to drive a valve pin (1040, 1041, 1042), the pin driver (85, 940ld, 940r, 941 r, 942r) being adapted to be driven reciprocally along a linear upstream, downstream or back and forth path of travel (Y) together with an upstream, downstream or back forth path of travel (X) of the valve pin, the valve pin having a distal end adapted to be driven downstream into a position where injection fluid flow through the gate (32, 34, 36) is stopped and upstream to one or more positions where the gate (32, 34, 36) is opened and injection fluid flow through the gate is enabled, the method comprising: interconnecting a pin coupler (80) to the pin driver (85, 940ld, 940r, 941 r, 942r) in an arrangement such that the pin coupler (80) is driven in a back and forth path of travel in unison with the pin driver (85, 940ld, 940r, 941 r, 942r), removably interconnecting the upstream end (340) of the valve pin (1040, 1041, 1042) to the pin coupler (80) in an arrangement wherein the pin coupler (80) interconnects or couples the upstream end (340) of the valve pin to the pin driver (85, 940ld, 940r, 941 r, 942r), disposing a spring (74) between the upstream end (340) of the valve pin and the pin driver (85, 940ld, 940r, 941 r, 942r) such that the valve pin (1040, 1041, 1042) and the pin driver (85, 940ld, 940r, 941 r, 942r) are resiliently movable relative to each other (Z) between a spring compressed position (74c) and a spring expanded (74e) position while the pin coupler (80) is removably interconnected to the valve pin.

[0064] Such a method typically further comprises disposing the spring (74) between the upstream end (340) of the valve pin and the pin coupler (80) such that the spring (74) exerts a resilient spring force (L) between the upstream end (340) of the valve pin and the pin coupler (80).

[0065] Such a method can further comprise adapting the actuator coupler (81 ) to be rigidly interconnectable to a pin head adapter (70, 72, 78) and adapting the pin head adapter (70, 72, 78) to be readily interconnectable to and readily disconnectable from the actuator coupler (81 ).

[0066] Such a method can further comprise configuring the drive device (940dr, 941 dr, 942dr) to comprise one or more of a rotary driver and a linear driver.

[0067] In another aspect of the invention there is provided a resiliently compressible spring (74) that cushions axial force (L, F1, F2) exerted on a valve pin (1040, 1041, 1042) in an injection molding apparatus (10) comprising a top clamp plate (800), a heated manifold (40), an actuator (940, 941 , 942) mounted to one or the other of the top clamp plate and the heated manifold, a downstream channel (1040c, 1041c) having a gate (32, 34, 36) that opens into a cavity (30) of a mold (300), the actuator including a drive device (940dr, 941 dr, 942dr) interconnected to a pin driver (85, 940ld, 940r, 941 r, 942r) adapted to drive a valve pin (1040, 1041, 1042), the pin driver (85, 940ld, 940r, 941 r, 942r) being adapted to be driven by the drive device (940dr, 941 dr, 942dr) reciprocally along a linear upstream, downstream or back and forth path of travel (A, Y) together with an upstream, downstream or back forth path of travel (X) of the valve pin, the valve pin having a distal end adapted to be driven downstream into a position where injection fluid flow through the gate (32, 34, 36) is stopped and upstream to one or more positions where the gate (32, 34, 36) is opened and injection fluid flow through the gate is enabled, wherein: a pin coupler (80) is interconnected to the pin driver (85, 940ld, 940r, 941 r, 942r) in an arrangement such that the pin coupler (80) is driven in an upstream, downstream or back and forth path of travel in unison with the pin driver (85, 940ld, 940r, 941 r, 942r), the upstream end (340) of the valve pin (1040, 1041, 1042) being removably interconnected to the pin coupler (80) in an arrangement wherein the pin coupler (81) interconnects or couples the upstream end (340) of the valve pin to the pin driver (85,

940ld, 940r, 941 r, 942r), and, wherein the resiliently compressible spring (74) is disposed between the upstream end (340) of the valve pin and the pin driver (85, 940ld, 940r, 941 r, 942r) such that the valve pin (1040, 1041, 1042) and the pin driver (85, 940ld, 940r, 941 r, 942r) are resiliently movable relative to each other (Z) between a spring compressed position (74c) and a less compressed or non compressed (74e) position while the pin coupler (80) is removably interconnected to the valve pin.

[0068] The drive device (940dr, 941 dr, 942dr) is typically housed within an actuator housing (940h, 941 h, 942h) and the resiliently compressible spring (74) is disposed outside the actuator housing.

[0069] The resiliently compressible spring (74) is typically adapted to exert a spring force (L) between a surface (34a, 34b) of the upstream end (340) of the valve pin (1040, 1041 , 1042) and the driver (85, 940ld, 940r, 941 r, 942r) such that the valve pin (1040, 1041,

1042) is held in a stationary axial disposition for driving the valve pin along the linear upstream, downstream or back and forth path of valve pin travel (X).

[0070] The resiliently compressible spring (74) is typically disposed between the upstream end (340) of the valve pin and the pin coupler (80) such that the spring (74) exerts a resilient spring force (L) between the upstream end (340) of the valve pin and the pin coupler (80). [0071] The pin coupler (80) can comprise an actuator coupler (81 ) and a pin head adapter (70, 72, 78), the actuator coupler (81) being rigidly interconnectable to the pin head adapter (70, 72, 78), the pin head adapter (70, 72, 78) being adapted to be readily interconnectable to and readily disconnectable or removable from the actuator coupler (81). [0072] The resiliently compressible spring (74) can be arranged such that the resiliently compressible spring (74) is engaged against a surface (78b) of the pin head adapter (70,

72, 78) to exert a spring force (L) on the upstream end (340) of the valve pin (1041 ).

BRIEF DESCRIPTION OF THE DRAWINGS

[0073] Fig. 1 is a schematic side sectional view of an injection molding apparatus using electric actuators in one embodiment according to the invention.

[0074] Fig. 2 is an example of a prior injection molding apparatus having an electric actuator fixedly interconnected to a valve pin.

[0075] Fig. 3 is a sectional view of the pin coupler and pin adapter components of the Fig. 2 prior apparatus showing a fixed, non resilient interconnection between the valve pin and the coupler that is interconnected to the linearly travelling driver of the actuator.

[0076] Fig. 4 is a sectional view of the pin coupler with a spring cushion component that couples or interconnects the valve pins of the Fig. 1 apparatus to the linearly travelling drive component of the electric motor actuators under a spring cushion, the spring shown in an expanded state or position.

[0077] Fig. 5 is a view similar to Fig. 4 showing the spring component in a compressed state or position.

[0078] Fig. 6 is a perspective top view of the actuator coupler and pin adapter components of the Figs. 1, 4, 5 apparatuses showing the components assembled and interconnected in operational form.

[0079] Fig. 7 is an exploded view of the components of the Fig. 6 assembly.

[0080] Fig. 8 is a schematic side sectional view of the armature and drive rod components of a linear drive proportional solenoid that can be substituted for the assembly of rotary motion enabling components of the rotary electric actuators described herein to enable direct linear actuation movement of the drive rod by the armature when energized with electricity. [0081] Fig. 9 is a schematic side sectional view of the armature and drive rod components of a linear motor that can be substituted for the assembly of rotary motion enabling components of the rotary electric actuators described herein to enable direct linear actuation movement of the drive rod by the armature when energized with electricity.

DETAILED DESCRIPTION

[0082] Fig. 1 shows an injection molding apparatus having a center valve with associated actuator (940) and two downstream valves with associated actuators (941 , 942) that are opened to a mold cavity 30 in a predetermined sequence as described herein after the center valve is first opened, the actuators (940, 941, 942) each comprising an electric motor having an electric drive (940d, 941 d, 942d). The electric drive (940d, 941d, 942d) can be housed within the same housing (940h, 941 h, 942h) as the driver components of the electric actuator (940, 941, 941), or the electric drive (940d,

941 d, 942d) can be housed within a physically separate thermally conductive housing (941 ds) such as shown in Fig. 1A that is readily attachable to and detachable from the housing (941 h) that houses the driver components (stator, armature) and rotor component of the electric actuator via conventional device such as bolts, screws, clamps, magnets or the like (941b).

[0083] As shown the electric drive (940d, 941 d, 942d) is mounted on or to the actuator housing (940h, 941 h, 942h) in some manner such that the drive components such as a Pulse Width Modulator (PWM) and associated electrical components are disposed in substantial heat communication or contact with the actuator housing (940h, 941 h, 942h) or the heated manifold (40).

[0084] As shown the injection cycle is a cascade process where injection is effected in a sequence from the center nozzle 22 first and at a later predetermined time from the lateral nozzles 20, 24. As shown in Fig. 13A the injection cycle is started by first opening the pin 1040 of the center nozzle 22 and allowing the fluid material 100 (typically polymer or plastic material) to flow up to a position 100a in the cavity just before 100b the distally disposed entrance into the cavity 34, 36 of the gates of the lateral nozzles 24, 20 as shown in Fig. 1. After an injection cycle is begun, the gate of the center injection nozzle 22 and pin 1040 is typically left open only for so long as to allow the fluid material 100b to travel to a position 100p just past the positions 34, 36. Once the fluid material has travelled just past the lateral gate positions 34, 36, the center gate 32 of the center nozzle 22 is typically closed by pin 1040. The lateral gates 34, 36 are then opened by upstream withdrawal of lateral nozzle pins 1041, 1042. The rate of upstream withdrawal or travel velocity of lateral pins 1041, 1042 can be controlled as described below. [0085] In alternative embodiments, the center gate 32 and associated actuator 940 and valve pin 1040 can remain open at, during and subsequent to the times that the lateral gates 34, 36 are opened such that fluid material flows into cavity 30 through both the center gate 32 and one or both of the lateral gates 34, 36 simultaneously.

[0086] When the lateral gates 34, 36 are opened and fluid material NM is allowed to first enter the mold cavity into the stream 102p that has been injected from center nozzle 22 past gates 34, 36, the two streams mix with each other. If the velocity of the fluid material is too high, such as often occurs when the flow velocity of injection fluid material through gates 34, 36 is at maximum, a visible line or defect in the mixing of the two streams will appear in the final cooled molded product at the areas where gates 34, 36 inject into the mold cavity. By injecting at a reduced flow rate for a relatively short period of time at the beginning when the gate 34, 36 is first opened and following the time when fluid first enters the flow stream, the appearance of a visible line or defect in the final molded product can be reduced or eliminated.

[0087] The rate or velocity of upstream withdrawal of pins 1041, 1042 starting from the closed position is controlled via controller 16 which controls the rate and direction of drive of the electric actuators 940, 941, 942.

[0088] The user programs controller 16 via data inputs on a user interface to instruct the electric actuators to drive pins 1041, 1042 at an upstream velocity of travel that is reduced relative to a maximum velocity that the actuators can drive the pins 1041 , 1042 to travel. Such reduced pin withdrawal rate or velocity is executed until a position sensor such as 951, 952 detects that an actuator 941, 952 or an associated valve pin (or another component), has reached a certain position A typical amount of time over which the pins are withdrawn at a reduced velocity is between about 0.01 and .10 second, the entire injection cycle time typically being between about 0.3 seconds and about 3 seconds, more typically between about 0.5 seconds and about 1.5 seconds.

[0089] Fig. 1 shows position sensors 950, 951 , 952 for sensing the position of the motors 940, 941 , 942 and their associated valve pins (such as 1040, 1041, 1042) and feed such position information to controller 16 for monitoring purposes. As shown, fluid material 18 is injected from an injection machine into a manifold runner 19 and further downstream into the bores 44, 46 of the lateral nozzles 24, 22 and ultimately downstream through the gates 32, 34, 36. When the pins 1041, 1042 are withdrawn upstream to a position where the tip end of the pins 1041 are in a fully upstream open position, the rate of flow of fluid material through the gates 34, 36 is at a maximum. However when the pins 1041, 1042 are initially withdrawn beginning from the closed gate position to intermediate upstream positions a gap that restricts the velocity of fluid material flow is formed between the outer surfaces of the tip end of the pins and the inner surfaces of the gate areas of the nozzles 24, 20.

The restricted flow gap remains small enough to restrict and reduce the rate of flow of fluid material through gates 34, 36 to a rate that is less than maximum flow velocity over a travel distance of the tip end of the pins 1041, 1042 going from closed to upstream.

[0090] The pins 1041 can be controllably withdrawn at one or more reduced velocities (less than maximum) for one or more periods of time over the entirety of the length of the path over which flow of mold material is restricted. Preferably the pins are withdrawn at a reduced velocity over more than about 50% of RP and most preferably over more than about 75% of the length RP. The pins 1041 can be withdrawn at a higher or maximum velocity at the end of a less than complete restricted mold material flow path.

[0091] The trace or visible lines that appear in the body of a part that is ultimately formed within the cavity of the mold on cooling above can be reduced or eliminated by reducing or controlling the velocity of the pin 1041, 1042 opening or upstream withdrawal from the gate closed position to a selected intermediate upstream gate open position that is preferably 75% or more of the length of RP. [0092] The restricted path can be about 1-8 mm in length and more typically about 2-6 mm, more typically 2-4 mm and even more typically 1-3 mm in length. According to the invention, the position of the electric actuators are adjusted in response to sensing of position of a suitable component such as the rotor of an actuator 941, 942 or associated valve pin to less than 100% open. Adjustment of the drive of an actuator 931, 942 thus reduces the velocity of upstream travel of the pins 1041, 1042 for the selected period of time. At the end of the travel or length of restricted flow path a position sensor signals the controller 16, the controller 16 determines that the end of the restricted flow path has been reached and the valve pin is driven at higher velocity, typically to its end of stroke (EOS) or its 100% open position to allow the actuator pistons and the valve pins 1041, 1042 to be driven at maximum upstream velocity in order to reduce the cycle time of the injection cycle.

[0093] Typically the user selects one or more reduced velocities that are less than about 90% of the maximum velocity (namely velocity when the valve is fully open), more typically less than about 75% of the maximum velocity and even more typically less than about 50% of the maximum velocity at which the pins 1041, 1042 are drivable by the electric actuator apparatus. The actual maximum velocity at which the actuators 941 , 942 and their associated pins 1041 , 1042 are driven is predetermined by selection of the size and configuration of the actuators 941 , 942. The maximum drive rate of the electric actuator apparatus is predetermined by the manufacturer and the user of the apparatus and is typically selected according to the application, size and nature of the mold and the injection molded part to be fabricated. [0094] Preferably, the valve pin and the gate are configured or adapted to cooperate with each other to restrict and vary the rate of flow of fluid material over the course of travel of the tip end of the valve pin through the restricted velocity path. Most typically the radial tip end surface of the end of pin 1041, 1042 is conical or tapered and the surface of the gate 1254 with which pin surface is intended to mate to close the gate 34 is complementary in conical or taper configuration.

[0095] In one embodiment, as the tip end of the pin 1041 continues to travel upstream from the gate closed GC position through the length of the restricted flow path (namely the path travelled for the predetermined amount of time), the rate of material fluid flow through restriction gap through the gate 34 into the cavity 30 continues to increase from 0 at gate closed GC position to a maximum flow rate when the tip end of the pin reaches a full open position where the pin is no longer restricting flow of injection mold material through the gate. In such an embodiment, at the expiration of the predetermined amount of time when the pin tip reaches the full open position the pin 1041 is immediately driven by at maximum velocity full open velocity. In alternative embodiments, when the predetermined time for driving the pin at reduced velocity has expired and the tip has reached the end of restricted flow path the tip may not necessarily be in a position where the fluid flow is not still being restricted. In such alternative embodiments, the fluid flow can still be restricted to less than maximum flow when the pin has reached the changeover position where the pin is driven at a higher, typically maximum, upstream velocity.

[0096] As shown the electrical drive (940d, 941 d, 942d) is incorporated into, housed within, or physically mounted onto or in direct heat communication with the actuator housing (940h, 941 h,

942h) of the actuator such that the electric drive (940d, 941 d, 942d) is in direct thermal communication or contact with the thermally conductive housing (940h, 941 h, 942h) of the actuator. [0097] The electrical drive (940d, 941 d, 942d) can be housed or mounted in a thermally conductive housing body (940ds) that is readily attachable to and detachable from the actuator housing (940h, 941 h, 942h) as shown in Figs. 1 , 4, 5, 7, such a readily attachable and detachable housing body (940ds) being attachable or mountable to the actuator housing (940h, 941 h, 942h) in an arrangement such that the electrical drive (940d, 941 d, 942d) is in direct thermally conductive contact or communication with the actuator housing (940h, 941 h, 942h).

[0098] As shown the housings (940h, 941 h, 942h) of each of the actuators (940, 941 , 942) is mounted on or to or in close physical proximity to or in direct thermal communication with a heated manifold (40).

[0099] The electric actuators 940, 941 , 942 typically comprise a driver 940dr, 941 dr, 942dr typically comprised of a stator and armature that are interconnected to a rotatably mounted rotor or shaft 940r, 941 r, 942r such that when the drivers 940dr, 941 dr, 942dr rotate on application and receipt of electrical energy or power, the shafts 940r, 941 r, 942r are simultaneously rotatably moved and driven.

[00100] In embodiment where the electric actuator uses a rotoer, the rotor (940r, 941 r, 942r) has a drive axis XX, The driver (940dr, 941 dr, 942dr) is interconnected to the rotor (940r,

941 r, 942r) and adapted to controllably drive the rotor rotatably around the drive axis XX. [00101] The drivers (940dr, 941 dr, 942dr) receives electrical energy or power from an electrical drive (940d, 941 d, 942d). The electrical drive (940d, 941 d, 942d) typically comprises an interface that receives electrical energy or power from a power source PS and controllably distributes the received electrical energy or power in controllably varied amounts during the course of an injection cycle to the drivers (940dr, 941 dr, 942dr).

[00102] The actuator includes a housing (940h, 941 h, 942h) that houses the rotor (940r,

941 r, 942r) and the driver (940dr, 941 dr, 942dr) and is adapted to support the rotor (940r,

941 r, 942r) such that the rotor is drivably rotatable 940rt, 941 rt, 942rt. The housing (940h, 941 h, 942h) is typically thermally or heat conductive such that the housing receives heat or thermal energy from devices such as the manifold (40) with which the housing (940h, 941 h, 942h) may be in thermally conductive communication or contact.

[00103] The electrical drive (940d, 941 d, 942d) is typically housed within or by the housing (940h, 941 h, 942h) or is physically mounted on or to the housing (940h, 941 h, 942h) in thermally conductive communication or contact therewith.

[00104] The housing (940h, 941 h, 942h) is typically mounted in a physical proximity or disposition relative to the heated manifold (40) or in a direct or indirect heat conductive contact with the heated manifold (40) such that one or the other or both of the housing (940h, 941 h, 942h) and the electrical drive (940d, 941 d, 942d) is or are in substantial heat or thermal communication or contact with the heated manifold (40).

[00105] The electrical drive (940d, 941 d, 942d) typically includes a PWM or pulse-width modulator that converts received electrical energy or power into sinusoidal voltage waveforms, each sinusoidal voltage waveform being adapted to drive a corresponding phase-coil of the actuator driver (940dr, 941 dr, 942dr).

[00106] The PWM or pulse-width modulator typically comprises an inverter or comparator. [00107] The PWM modulator typically comprises a three-phase PWM inverter that converts electrical energy or power received from the interface into three sinusoidal voltage waveforms, each one of the three sinusoidal voltage waveforms being adapted to drive a corresponding one of three phase-coils of the actuator driver.

[00108] As shown in Figs. 1, 4, 5, 6, 7 the head 340, 940I, 9411, 9421 of the pins 1040,

1041 , 1042 is fixedly and readily removably interconnected via a coupler 80 that is interconnected to a shaft 85 or drive member that is driven along a linear path of travel X the rotating rotor 940r, 941 r, 942r of an electric actuator 940, 941 , 942. Although in the embodiments shown, the path of travel of shaft 85 is arranged coaxially with the linear path of travel X of the valve pin 1041 , the shaft 85 can be arranged to travel in a linear path Y that is not coaxial with the path of travel X of the valve pin such as described in U.S patent no. 9,346,206 as described and shown in a Figs. 6, 7, 8 and in U.S patent no. 9937648 each showing a non coaxially arranged linear drive shaft that is linearly driven along a non coaxial path travel relative to the path of travel of the valve pin.

[00109] Figs. 2, 3 show a known prior art injection molding subassembly comprised of an electric actuator 42 having a rotor 40r and stator 40s that act as the drive device to drive a valve pin 50 between gate closed and gate open positions as described above. As shown the housing 20 encases the drive device 40r, 40s and includes bores 76, one in each corner of the housing, for receiving bolts 77 that removably couple the motor housing 20 to the lower clamp plate 1200. Four complementary tapped holes are provided in the upper surface of the lower mounting plate 1200 for receiving the bolts 77 and securing the motor housing 20 to the plate. This prevents rotational and other movement of the housing of the motor with respect to the mounting plates and manifold 60 and the injection molding apparatus generally. Extending downwardly from the motor housing 20 is a cylindrical projection 74 from which the cylindrical drive shaft 75 of the motor extends. Coupled to the downstream end of the drive shaft is the actuator pin coupler 80 and extending axially downstream from the coupler 80 is the valve stem or pin 50.

[00110] As shown in Fig. 2 the electrically powered actuator typically comprises a motor comprised of a rotor 40r that is controllably drivably rotatable R by controlled transmission of electrical energy to driver in the form of a stator and armature 40s via a controller (not shown). The rotatably driven R rotor 40r is interconnected via a rotary to linear conversion device (not shown) to a linear drive device 401 that is controllably drivable linearly upstream and downsteam along axis AA. As shown the linear drive device 401 is interconnected to the valve pin 80 via the pin coupler 80 and its associated components such that the valve pin 80 is controllably drivable linearly upstream and downstream by and together with the linearly driven drive device 401.

[00111] Fig. 2 shows the heated manifold 60 disposed between the mounting plates 1200 and mold plates 900. In use, the mounting plates and mold plates are fixedly secured together under high clamp pressure, so as to withstand high injection molding forces. A nozzle assembly 109 extends through a bore in the lower mold plate 900, and seats and unseats to form a gate 100 to the injection mold cavity 902. The actuator housing 20 is disposed in a chamber of the upper mounting plate 1200, with a radial clearance RC provided in at least one radial direction so as to facilitate the radial coupling and decoupling of the pin head adapter 94, 104 and actuator coupler 80. Assembly and disassembly of the actuator 42, pin head 50h, pin head adapter 94, 104 and coupler is described in U.S. patent no. 8,091,202 the disclosure of which is incorporated by reference in its entirety as if fully set forth herein.

[00112] The electric actuator 42 and associated components shown in Figs 2, 3 can be employed in conjunction with constructing an apparatus according to the invention as shown in the Figs. 4, 5, 6, 7, 8, 9 embodiments. In this embodiment, a cushion or spring 74 having opposing engagement surfaces 74us, 74bs can be mounted between the head 340 of the valve pin 1041 and the actuator drive members 40I, 40r in an arrangement such that any force exerted by the tip end 52 of the pin 50, 1041 on the surface area 107 of the gate 100 as a result of downstream force DF exerted by the drive members 40I, 40r during the initial valve pin positioning phase will be absorbed by the cushion device 500.

[00113] Embodiments of the invention can include a configuration employing an electric actuator having a drive member 85 that is driven linearly along a path of travel that is non coaxial with the path of travel X of the valve pin where the drive member 85 is interengaged with or interconnected to the upstream end 340 of the valve pin and travels back and forth or upstream downstream or follows the non coaxial path X of upstream downstream travel of the valve pin. Examples of such non coaxial electric actuator driver 85 and valve pin 1041 arrangements are set out in U.S. patent nos. 9937648 and 9492960, the disclosures of which are incorporated by reference herein in their entirety as if fully set forth herein.

[00114] With respect to the Figs. 4, 5, 6, 7 embodiment, typically at the beginning of an injection cycle the actuator 42 is controllably driven such that the drive members 40I, 40r exerted a downstream force DF on the coupler 80 which in turn exerts the downstream force DF on the valve pin 1041 which in turn exerts the downstream force DF on the gate surface 107 via engagement of the downstream driven tip end 52 of the valve pin 50 which is itself driven downstream under the downstream force DF via the interconnection of the valve pin 50 to the downstream driven coupler 80. The engagement of the tip end 52 with the gate surface 107 under the downstream force DF causes the valve pin 50 to transmit an opposing upstream force UF to the downstream surface 72b of the cushion or spring retaining member 72 which in turn causes the upstream surface 72u to engage and exert an upstream force F2, UF against downstream surface 74bs of the cushion or spring 74. As a result the upstream force F2, UF is transmitted to an upstream surface 74us of the cushion or spring 74 which in turn transmits the force F2, UF to the downstream surface 78b of a second retaining member 78 that in turn exerts an opposing downstream force on the upstream surface 74us of the cushion or spring 74 causing the cushion or spring 500 to compress a seleced compression distance Z depending on the degree of force.

[00115] As shown in Fig. 5, when the opposing forces LF and DF are exerted on the downstream 74bs and upstream 74us surfaces, the cushion or spring 74 can resiliently compress up to a selected maximum compression distance Z which simultaneously allows the valve pin 50 to travel along axis X upstream between zero and the maximum compression distance Z thus relieving the gate surface 107 of a selected degree of added or increased pressure or force that would otherwise be exerted by the tip end surface 52 of the valve pin 50 on the gate surface 107 as a result of the initial positioning of the tip end 52 of the valve pin 50, 1041 at the beginning of an injection cycle.

[00116] Apart from compression of the cushion or spring 74 at the beginning of an injection cycle, the cushion or spring 74 can be compressed and uncompressed at any time during the course of an injection cycle depending on the degree or extent of downstream force LF, DF exerted by the drive member 40, 40I, 40r on a valve pin 50, 1040 and on the gate surface 107 when the valve pin 50, 1040 is driven to a gate closed position. [00117] With reference to the embodiment shown in Figs. 4, 5, 6, 7, a pin couplier 80 is attached to or mounted on the actuator shaft 75. The coupler 80 coupling includes a radial recess 83, disposed laterally transverse to the elongated valve pin axis X. The recess 83 has a radial recess opening that allows a pin head adapter 70 to be radially inserted into and removed from the radial recess. The coupling 80 also includes a radial slot 84 through which the valve pin stem 50, 1040 can be readily radially inserted or translated within (or removed from) the slot 84 while the adapter 70 is simultaneously radially inserted or translated within (or removed from) the radial recess 83. The coupling 80 has walls 82 that form and act as a housing for the radial recess 83 and radial slot 84. As shown, the pin connector and the recess 83 and recess opening 84 are configured to have a complementary geometry, size, shape and configuration so as to enable the pin adaptor 70 to be received within the recess 83 and fully surrounded and contained within walls 91 and also to require that the pin adaptor 70 is receivable within and removable from the recess 83 only by movement of the pin adaptor 70 in a radial direction RD, Fig. 7, transverse to the axial path of travel X of the drive 40 and valve pin 50, 1040. The pin connector 94 is slidable by manual force along radial direction R into and out of the recess 83 and recess opening 84. As shown when the pin connector 94 is slid into and out of recess 83 and opening 84, the pin stem 31 is simultaneously slidable radially through slot opening 85 into slot 84. The walls 91 act to retain and couple the pin connector 94 and associated pin stem 50 to the shaft 75 when the connector 94 is received within recess 83 and stem 50 in slot 84.

[00118] In addition, the radial recess 83 is sized and configured to provide a radial clearance in all radial directions between the valve pin adapter 70 and the recess 83 when/while the adapter 70 is received and coupled within the recess 83 of the coupling 80. This radial clearance allows movement in any radial direction of the valve pin adapter 70 while it is mounted in the recess of the actuator coupling, so as to accommodate differences in thermal expansion between various components of the injection molding apparatus such as between the manifold 60 and the mounting or top clamp plates 800. As previously described, the valve stem 50 is mounted to a manifold 40 when the system is assembled, the manifold 40 being heated during the course of startup to a higher temperature than the relatively cold mounting plates 800 and cold actuator. During the time when the manifold 40 is being heated to a higher temperature than the mounting plates and actuator, it is desirable to provide a radial clearance as described to allow the valve pin 50 and adapter 70, which is mounted to the manifold by the bushing 28 and travels radially therewith and is also being heated via the manifold 40, to move radially together with the manifold 40 with respect to the mounting plate 800 and the axial path of travel X of the actuator so as to prevent the application of undesirable side bending forces on the valve pin 50, 1040 and assembly 70. Such side forces can bend or break the valve stem or otherwise interfere with proper alignment and operation of the valve pin assembly and actuator.

[00119] As shown in Fig. 7 a typical spring or cushion 74 can comprise a series of compressible washers that are sandwiched axially one on top of each other and mounted on and between a downstream mount 72 and an upstream cap 78, the mount 72 being insertable within a complementary receiving recess 70r of the pin head adapter 70, cap 78 being connectable via bolts to the adapter 70. Thus the cushion or spring 74 is readily insertable into and removable from the pin head coupler together with the adapter in a radial direction as described above.

[00120] As shown in Fig. 7, the cushion or spring 74 includes a downstream surface 74bs that engages against a complementary surface of the intermediate mount that is interconnected to or interengaged with the valve pin 50 via the adapter 70 in an arrangement that transmits upstream force UF that may be transmitted from the valve pin 50 as a result of engagement of the tip end 52 with the gate surface 107 to the downstream surface 74bs thus causing the spring assembly 500 to compress by a compression distance Z, Fig. 5 under influence of the upstream force UF.

[00121] An electrically driven linear actuator that effects direct linear drive movement of the drive element such as a rod 940I or plunger 940ld, Figs. 8, 9 can be used as an alternative to use of a rotary motion or rotor based actuator 940 as described with reference to the embodiments of Figs. 1 to 7.

[00122] One example of a linear actuator is a proportional solenoid as shown in Fig. 8 that effects analog positioning of a solenoid plunger or rod 940!d as a function of coil current contained in the armature or driver 94Gdr. As shown a solenoid, Fig. 8 or linear motor, Fig. 9, employs a flux carrying geometry that can produce a high starting force on the plunger or rod 940ld to cause the plunger or rod 940id to be controllably driven along the linear drive axis A. The resulting force (torque) profile as the solenoid progresses through its operational stroke is nearly flat or descends from a high to a lower value. The solenoid can be useful for positioning, stopping mid-stroke, or for low velocity linear actuation movement of the plunger or rod 940ld, especially in a closed loop control system. The proportional concept is more fully described in SAE publication 860759 (1986) the disclosure of which is incorporated by reference in its entirety as if full set forth herein. Another example of a linear actuator is a linear motor, Fig. 9, that instead of producing torque (rotation) produces a linear force along its drive axis A. A typical mode of operation is as a Lorentz-type actuator, in which applied force is linearly proportional to applied current and magnetic field. Thus a linear actuator 940 that effects linear driven movement of a rod, plunger or equivalent element 940ld can be employed as an alternative to a rotary driven electric motor for interconnection to a valve pin 50, 1040 to effect controllable driven linear movement of the valve pin 50, 1040 along its axis X of reciprocal movement as described hereinabove.

[00123] A linear actuator is particularly suited for use in a configuration where the drive axis of the actuator and the pin movement axis X are coaxially arranged such as in the embodiments described with reference to Figs. 4, 5, 6, 7 and the like. A linear actuator as described can be used to drive any drive member 940I as an alternative to the rotor based actuators described herein.