Abstract: Methods and apparatus for processing materials employ two cylindrical members, one mounted within the other, defining an annular processing chamber. Preferably, the outer member is stationery (stator), while the inner rotates (rotor). The radial spacing between the stator inner surface and the rotor outer surface is equal to or less than the back-to-back radial thicknesses of the two laminar boundary layers formed on the two surfaces by the material being processed. The surfaces are made smooth, as by buffing to a finish of not more than 10 microinches. This structure inhibits formation of Taylor vortices in the processing passage, which cause unstable flow and consequent incomplete mixing. Preferably, the relative velocity between rotor and stator surfaces is at least 1.2 meters per second. The surfaces may be coated with catalysts. Transducers may be provided to apply processing energy, such as microwave, light or ultrasonic waves, through the stator wall.

Abstract: A unitized heat conductive assembly 32 formed of a one piece heat conductive conduit 40 which permits shaping the heat conductive assembly as a continuous unit. The heat conductive assembly 32 is press fit into the heater block 12 configured so that it provides a predetermined flow path 14 for the flowable molten plastic materials to be delivered to the injector nozzles. There is provided a heat flow path 28 that follows the flow path 14. The heat conductive carrying conduit 40 is formed with an opening 42. The conductive conduit 40 is formed from a tubular piece of conductive metal such as copper or brass by a swaging process which forms a tubular structure 40 in a continuous length. The outer contour of the tubular structure 40 can be round or oral and the preferred shape is either square or rectangular.

Abstract: This invention provides an improved heating apparatus for controlling the temperatures of the resin melt that is pressure fed to a molding cavity comprising a heating jacket 30 comprising the concentric tubular elements; a copper sheath 32 having an inside surface 34 and an outer surface 36, a retainer sleeve 40 and coiled heating element 42 sandwiched between the sheath 32 and the retainer sleeve 40. The inside surface of the sheath 32 is formed with at least one circumferential groove 38 which provides an insulating air gap so that a lesser amount of heat is conducted to the central portion of the heating jacket 30 thereby creating three distinct temperature zones. The sheath 32 is provided with a channel 46 extending longitudinally down its inside surface 36 between the heating coil 42 and the outside surface of the housing 22 for the hot runner conduit 24.

Abstract: This invention provides an improved heating apparatus for controlling the temperatures of the resin melt that is pressure fed to a molding cavity comprising a heating jacket 30 comprising the concentric tubular elements; a copper sheath 32 having an inside surface 34 and an outer surface 36, a retainer sleeve 40 and coiled heating element 42 sandwiched between the sheath 32 and the retainer sleeve 40. The inside surface of the sheath 32 is formed with at least one circumferential groove 38 which provides an insulating air gap so that a lesser amount of heat is conducted to the central portion of the heating jacket 30 thereby creating three distinct temperature zones. The outer surface 23 of the nozzle 22 is provided with a longitudinal groove 46 extending down its outside surface between the sheath 32 and the nozzle housing 22 for the hot runner conduit 24.

Abstract: A hot tip nozzle assembly for injection molding plastic components comprises a nozzle housing defining a hot runner passage and a nozzle tip section which is received in the hot runner passage. The nozzle tip section defines a hot runner tip passage in flow communication with the hot runner passage. The nozzle tip section slides freely within the hot runner passage during injection molding. A stop is provided on the nozzle tip section to limit downward movement relative to the cavity gate and automatically position the nozzle tip relative to the injection gate of the mold. In addition, axial thermal expansion of the nozzle housing is not imparted to the nozzle tip section. The nozzle tip section also has a restricted length that can axially thermally expand. Accordingly, the position of the nozzle tip is only minutely affected by even larger temperature changes in the nozzle assembly.

Abstract: A nozzle body is provided that is equipped with a runner, passages and orifices all communicating with one another to provide a fluid delivery system to mold cavities. The nozzle body is provided with a heat insulating cap equipped with peripheral projections at spaced positions around the outside wall of the cap so that the fluid injected into the mold at the gatewell will shear with a smooth cleavage after solidifying to provide a smooth separation surface on the molded part. Each gatewell is disposed in a peripheral projection in the cap and the peripheral projection is spaced of few thousandths from the mold. The cap serves to minimize the loss of heat from the nozzle body by aligning and centering the cap and the nozzle body relative to the gatewells leading to the mold.

Abstract: A nozzle has a runner for passing fluid through the nozzle. The fluid is heated as it passes through the runner. The temperature of the fluid may be regulated. The fluid flows from the runner into a well formed in a nozzle well insert which is disposed on the nozzle. A gate is disposed in the nozzle well insert in communication with the well. A tip having a raised portion and a reduced portion, each extending in a helical pattern, is disposed in the runner with the raised portion abutting the surface of the runner. The outlet end of the tip is disposed relative to the well in the nozzle well insert so that the fluid in the reduced portion of the tip flows in a swirling motion through the well to wipe the surface of the well and remove the fluid previously in the well. The surfaces of the raised and reduced portions of the tip may be coated with a material to prevent such surfaces from becoming deformed by the fluid flowing through the tip and the gate into the mold. In this way, a fluid of one color (e.g.

Abstract: A heating block made from a heat conductive material has a passage through which a fluid heated by the heater can flow. A groove preferably having a looped configuration extends into the block from a peripheral surface in the block. A heater made from an electrically conductive and heat conductive material is disposed in the groove, preferably in a looped configuration corresponding to the looped configuration of the groove. A heat conductive member disposed in the groove is provided with a hole to receive the heater in an enveloping relationship. The member may be defined by a pair of separable portions. The member is preferably disposed in the looped relationship in the groove. Localized deformation of the heating block holds the member and the heater in a fixed relationship with the block. The heater may deteriorate or become defective with extended usage and may have to be replaced. To accomplish this, the heater and the member may be removed as a unit from the block after removing the deformation.

Abstract: A nozzle has a runner for passing fluid through the nozzle. The fluid is heated as it passes through the runner. The temperature of the fluid may be regulated. The fluid flows from the runner into a well formed in a nozzle well insert which is disposed on the nozzle. A gate is disposed in the nozzle well insert in communication with the well. A tip having a raised portion and a reduced portion, each extending in a helical pattern, is disposed in the runner with the raised portion abutting the surface of the runner. The outlet end of the tip is disposed relative to the well in the nozzle well insert so that the fluid in the reduced portion of the tip flows in a swirling motion through the well to wipe the surface of the well and remove the fluid previously in the well. The surfaces of the raised and reduced portions of the tip may be coated with a material to prevent such surfaces from becoming deformed by the fluid flowing through the tip and the gate into the mold. In this way, a fluid of one color (e.g.

Abstract: A manifold is disposed within a pair of abutting pre-load mold plates in a pre-load relationship. Fluid flowing through the manifold is heated by a first heater. The fluid is then divided into a plurality of passages in the manifold. Pairs of passages have a back-to-back in-line relationship. A cylinder between each pair of the in-line passages holds a pair of pistons in the in-line relationship. Each piston in the pair has piston units in an interdigitated relationship with piston units on the other piston in the pair. Each pair of pistons is movable by pressurized fluid (e.g. air) between first and second positions. In the first position, each piston provides for the fluid (e.g. resin melt) flow through one of the passages to a pair of runners in the manifold. In the second position, each piston prevents the resin melt flow through the passages. A first heater heats the resin melt flowing through the passages. A second heater heats the resin melt flowing through the runners.

Abstract: A nozzle body has a runner, a passage and an orifice, all communicating with one another to provide for fluid flow into and through the body. The fluid is heated during its flow through the nozzle body by an electrical heater on such body and by a heat conductive plug (e.g. copper) extending through the nozzle. A cap made from a heat insulating material (e.g. titanium) and disposed in a tight fit on the nozzle body has a gate well for receiving the fluid in the orifice and for injecting such fluid into a mold. The cap is constructed so that fluid cannot leak into the area around the cap when heated fluid flows through the gate well. The cap is also constructed so that the article formed in the mold from the fluid injected into the article will shear to provide a smooth peripheral surface when the article is ejected from the mold after solidifying.